US20050104698A1 - Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device - Google Patents
Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device Download PDFInfo
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- US20050104698A1 US20050104698A1 US11/009,152 US915204A US2005104698A1 US 20050104698 A1 US20050104698 A1 US 20050104698A1 US 915204 A US915204 A US 915204A US 2005104698 A1 US2005104698 A1 US 2005104698A1
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- C12N15/1006—Extracting or separating nucleic acids from biological samples, e.g. pure separation or isolation methods; Conditions, buffers or apparatuses therefor by means of a solid support carrier, e.g. particles, polymers
- C12N15/101—Extracting or separating nucleic acids from biological samples, e.g. pure separation or isolation methods; Conditions, buffers or apparatuses therefor by means of a solid support carrier, e.g. particles, polymers by chromatography, e.g. electrophoresis, ion-exchange, reverse phase
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- C—CHEMISTRY; METALLURGY
- C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
- C12Q—MEASURING OR TESTING PROCESSES INVOLVING ENZYMES, NUCLEIC ACIDS OR MICROORGANISMS; COMPOSITIONS OR TEST PAPERS THEREFOR; PROCESSES OF PREPARING SUCH COMPOSITIONS; CONDITION-RESPONSIVE CONTROL IN MICROBIOLOGICAL OR ENZYMOLOGICAL PROCESSES
- C12Q1/00—Measuring or testing processes involving enzymes, nucleic acids or microorganisms; Compositions therefor; Processes of preparing such compositions
- C12Q1/68—Measuring or testing processes involving enzymes, nucleic acids or microorganisms; Compositions therefor; Processes of preparing such compositions involving nucleic acids
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- C12Q1/6827—Hybridisation assays for detection of mutation or polymorphism
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F30/00—Fixed transformers not covered by group H01F19/00
- H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F38/00—Adaptations of transformers or inductances for specific applications or functions
- H01F38/08—High-leakage transformers or inductances
- H01F38/10—Ballasts, e.g. for discharge lamps
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/082—Devices for guiding or positioning the winding material on the former
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B41/00—Circuit arrangements or apparatus for igniting or operating discharge lamps
- H05B41/02—Details
- H05B41/04—Starting switches
- H05B41/042—Starting switches using semiconductor devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
- H01F2017/046—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2823—Wires
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Definitions
- the present invention relates to an electromagnetic device, a high-voltage generating device, and a method for making the electromagnetic device.
- the high-voltage generating device is generally provided in the form of ant electromagnetic device such as a pulse transformer for converting a low-voltage input to a high-voltage output of pulsed waveform (as disclosed in, for example, Japanese Patent Laid-open Publications 11-16752 and 11-74132).
- a coil bobbin 60 is made of an insulating material such as synthetic resin having substantially a cylindrical shape which comprises two outer flanges 61 at both ends and a partition flange 62 between the two outer flanges 61 .
- a primary winding 63 at the low voltage side is wound between one of the two outer flanges 61 and the partition flange 62 while a secondary winding 64 at the high voltage side is wound between the other outer flange 61 and the partition flange 62 .
- the secondary winding 64 is fabricated by winding a long, flat rectangular foil conductor with its wider sides facing each other (in the form of, so-called, edge-wise winding) for improving both the edge side insulation and the contact area of windings.
- a couple of U-shaped magnetic cores 65 made of Mn—Zn ferrite are inserted and joined to both ends of the coil bobbin 60 with the primary winding 63 and the secondary winding 64 , hence forming an electromagnetic device (a pulse transformer).
- FIG. 69 a is a perspective view of another conventional electromagnetic device and FIG. 69 b is a cross sectional view taken along the line A-A′ of FIG. 69 a .
- the another conventional electromagnetic device comprises a bar-like magnetic core 3PA and a coil winding 2 wound as the secondary winding on a coil bobbin 60 thereof mounted on the magnetic core 3PA.
- a recess 31PA is provided in each end of the magnetic core 3PA to determine its position along the axial direction.
- a process of fabricating the bar-like magnetic core 3PA having the recess in each end thereof will be explained referring to FIG. 70 .
- the process of fabricating the magnetic core 3PA employs a pair of rods K, each having a projection K1′ for shaping the recess 31PA and a swage die U having a through hole U1 provided therein for insertion of the rods K.
- the process starts with shaping the magnetic core 3PA using the die U and the rods K.
- the lower rod K is lifted up to the upper end of the die U as shown in FIG. 70 b to remove the magnetic core 3PA from the die U in the direction denoted by the arrow for increasing the efficiency.
- the magnetic core 3PA may however be injured at the edge R1 of the recess 31PA upon being removed from the die U as shown in FIG. 71 .
- FIG. 72 is a perspective view of a further conventional electromagnetic device.
- the electromagnetic device shown is a pulse transformer for converting a low voltage input to a high voltage output as called an igniter to generate a high voltage for energizing a high intensity discharge lamp.
- the conventional device shown in FIG. 72 comprises a bar-like magnetic core 3PA, a bobbin 4PA, a pair of coil windings 9 and 10 mounted on the bobbin 4PA mounted to the magnetic core 3PA, a casing 5PA made of a resin material for enclosing those components therein, and terminals 6 connected to coil windings 9 and 10 at one end and extending at the other end from the casing 5PA.
- the coil winding 9 incorporates an insulation coated wire (of round wire) comprising an electrical conductor having a round shape in the cross section and an insulating coating provided over the wire conductor and serving as the primary winding while the coil winding 10 serves as the secondary winding.
- the coil winding 9 is connected to one ( 61 ) of the terminals 6 and the coil winding 10 is connected to another ( 62 ).
- This conventional electromagnetic device is fabricated by winding the coil windings 9 and 10 on the bobbin 4PA, inserting the magnetic core 3PA into the bobbin 4PA, assembling those in the casing 5PA, connecting the terminals 6 to the corresponding coil windings 9 and 10 , and filling the casing 5PA with an amount of epoxy resin (by vacuum filling process).
- FIG. 73 is a perspective view of a conventional welding joiner welded to the insulation coated wire.
- a welding joiner 6PA which can be welded to the insulation coated wire without stripping the insulation coating comprises, as shown in FIG. 73 , a flat base portion 61 extending along one direction and a folded portion 62 extending from one side of the base portion 61 at a right angle to the direction and folded along its width at a portion 63 so that the two portions 61 and 62 confront each other.
- the welding joiner 6PA is preferably utilized as the terminal 6 of the conventional electromagnetic device.
- One example of this arrangement is disclosed in Japanese Patent Laid-open Publication 11-114674.
- the bobbin When the bobbin is provided between the magnetic core and the coil windings, its terminals are fixedly connected to the coil windings. In case of a bobbin-less device, the terminals connected with the coil windings may be secured with much difficulty.
- the process of fabricating an electromagnetic device shown in FIG. 72 requires substantially four or more hours for carrying out the major processing steps including preparation, drying, and curing steps. For implementing a scheme of mass production, extra investments for expanding the existing production facility has to be needed. Also, when the epoxy resin vacuum filling process is employed, it may limit the lead-out of the terminals 6 from the casing 5PA to one single direction. This prevents the terminals 6 from being respectively bent and oriented in a desired pattern of the circuitry planning. Since the coil windings of a metallic material create undesired events of spring back, their ends have to be bound together or supported by any proper means. The epoxy resin vacuum filling process may generally develop an interface between the casing 5PA and the epoxy resin material thus allowing a high voltage to leak from the interface. The edge-wise winding may cause the coating of the coil windings to be peeled off when its curvature radius is too small.
- the convention welding joiner 6PA may often cause the insulation coated wire to be dislocated when held between the base portion 61 and the folded portion 62 and pressed with a pair of welding electrodes. If worse, the insulation coated wire may completely be slipped off from between the base portion 61 and the folded portion 62 . As the welding of the insulation coated wire to the welding joiner is carried out only with poor consistency, it is much desired to modify the welding joiner for improvement of its stable joining function and operational reliability.
- the present invention has been developed in view of the foregoing aspects and its object is to provide an electromagnetic device, a high-voltage generating apparatus, and a method for making the electromagnetic device where the dimensional reduction and the improvement of properties are achieved, and the duration of time required for carrying out the production steps is minimized.
- an electromagnetic device comprises a magnetic core having a curved side and a flat rectangular wire conductor wound in an edge-wise winding form directly on the curved side of the magnetic core. Accordingly, as any insulator such as a coil bobbin is not needed between the flat rectangular wire conductor and the magnetic core, the winding can be decreased in the overall size or thickness, thus contributing to the dimensional reduction and the improvement of characteristics of the device.
- the magnetic core has an intrinsic resistance of not smaller than 1000 ⁇ .m.
- the electromagnetic device further comprises a winding provided on the outer surface of the flat rectangular wire conductor. Accordingly, a resultant transformer can be reduced in the thickness.
- the magnetic core is rough finished at the surface. Accordingly, as no extra step such as polishing is needed after the completion of the magnetic core, the production cost of the magnetic core can be lowered. Also, the flat rectangular wire conductor can be protected from slipping and tilting down during the edge-wise winding process.
- the flat rectangular wire conductor and the winding are joined to each other by fusing their coatings. Accordingly, as the positioning between the windings is securely determined, variations in the properties resulting from relative dislocation between the windings will be avoided.
- the magnetic core of an edge-wise winding form of the flat rectangular wire conductor is located between a group of leads joined together. Accordingly, the winding is arranged with its leads extending over the outer surface of the flat rectangular wire conductor.
- the electromagnetic device further comprises a first insulating member arranged of a cylindrical shape to which the magnetic core of the flat rectangular wire conductor is fitted and a secondary insulating material covering over the first insulating member and the winding which is made of an electrically conductive resin material and provided on the outer side of the first insulating member. Accordingly, the insulation between the winding of the flat rectangular wire conductor and the winding of the electrically conductive resin material can be ensured by the first insulating material.
- the first insulating member has a groove provided in the outer side thereof and the winding is fabricated by filling the groove with an electrically conductive resin material. Accordingly, the insulation between the high-voltage end of the winding of the flat rectangular wire conductor and the winding of the electrically conductive resin material can be ensured.
- the flat rectangular wire conductor serves as a secondary winding and the winding serves as a primary winding.
- the primary winding is located adjacent to the low-voltage end of the secondary winding. Accordingly, the surface distance between the high-voltage side of the secondary winding and the primary winding can be increased thus improving the insulating function.
- One of two ends of the primary winding disposed at the high-voltage end side of the secondary winding is drawn to the low-voltage end of the secondary winding. Accordingly, the insulation can be improved to a desired level.
- the primary winding is an insulated wire or a magnet wire protected with an insulation coating for electrically insulating between the primary winding and the secondary winding. Accordingly, the insulation can be improved to a desired level.
- the magnetic core has an elliptical shape in the cross section and its flat rectangular wire conductor is drawn out at both ends through a space between a transformer consisting mainly of the magnetic core and the flat rectangular wire conductor and a rectangular housing mounted outwardly of the transformer. Accordingly, the transformer can be reduced in both the size and the cost.
- the magnetic core has a bottomed hole provided in each end thereof and the hole is arranged of a tapered shape which becomes gradually smaller in the diameter from the opening to the bottom. Accordingly, when the magnetic core is fallen down about the point at the edge of its bottom with its bottomed hole accepting the projection of the rod during the preparation of the magnetic core using the paired rods and a pair of punching dies, its portion about the bottomed hole can clear the projection of the rod. As- a result, the magnetic core can be protected from being tipped off at its edge about the bottomed hole of its bottom.
- the magnetic core has an elliptical shape in the cross section. Accordingly, the overall size can be thinned.
- an electromagnetic device having a transformer arrangement includes a bar-like magnetic core and a flat rectangular wire conductor wound on the outer surface of the magnetic core for generation of a high voltage, the flat rectangular wire conductor drawn out at both ends from two ends of the magnetic core respectively, characterized by a resin outer housing provided about the transformer by filling or molding an insulating resin material and having at least one side thereof configured up and down along a direction substantially parallel with the axial direction of the magnetic core. Accordingly, as the surface distance is increased by the effect of the up and down configuration, the insulation function can be improved.
- the up and down configuration is provided at the high-voltage end side of the flat rectangular wire conductor. Accordingly, the insulation function can be improved.
- an electromagnetic device having a transformer arrangement includes a magnetic core, a winding and a flat rectangular wire conductor both provided on the magnetic core, and at least two terminals for connection of the winding and the flat rectangular wire conductor with the outside, characterized in that the transformer is sealed in an injection molded form of a thermoset resin material. Accordingly, the production of the transformer can be simplified.
- the electromagnetic device further comprises a lead frame for supporting the components during the injection molding. Accordingly, the production can be simplified.
- thermoset resin material is covered with a molded form of a thermoplastic resin material. Accordingly, the insulation can be ensured while the protection against moisture is effectively improved.
- the winding and the flat rectangular wire conductor are secured at least at one end with an adhesive. Accordingly, the coil winding can hardly be loosened by the effect of spring back.
- the flat rectangular wire conductor acts as a secondary winding and is insulated by coating and provided in an edge-wise winding form on the magnetic core. Accordingly, the overall size can be minimized.
- an insulation coated wire is joined with a welding joiner which comprises a flat base portion extending in one direction and a folded portion extending from one side along the one direction of the base portion substantially at a right angle to the one direction, where the folded portion is folded down along the one side to face the base portion, and the base portion has a tab portion extending from the other side than the one side thereof and bent upright to form a positional error inhibitor.
- the length of the tab positional error inhibiting portion from the base portion is equal to or slightly greater than the diameter of the insulation coated wire. Accordingly, as the insulation coated wire when dislocated is securely held by the positional error inhibitor of the welding joiner, it can definitely remain protected from being detached from the welding joiner.
- the positional error inhibiting portion is distanced from the folded portion. Accordingly, as any short-circuit between the positional error inhibiting portion and the folded portion is avoided, Joule heat generated by energization can successfully be radiated from the extending side of the folded portion of the joiner.
- a high-voltage generating device comprises: a pulse transformer having a magnetic core, a flat rectangular wire conductor wound in an edge-wise winding form directly on the outer surface of the magnetic core, and a winding provided on the outer side of the flat rectangular wire conductor; a capacitor connected in parallel with the primary winding of the pulse transformer; a switching element for opening and closing the discharging path extending from the capacitor to the primary winding; and a resistor connected to the primary winding. Accordingly, as any insulator such as a coil bobbin is not needed between the magnetic core and the winding (of the flat rectangular wire conductor), the winding can be decreased in the overall size or thickness thus implementing a thin, property improved high-voltage generating device.
- the pulsed high-voltage output of the secondary winding of the pulse transformer can favorably be corrected to substantially a fundamental waveform.
- any unwanted stress on the components including the capacitor can successfully be eased. As a result, the components to be used may be declined in the resistance to high voltage and reduced in the size and the cost.
- a high-voltage generating device comprises: a pulse transformer having a magnetic core, a flat rectangular wire conductor wound in an edge-wise winding form directly on the outer surface of the magnetic core, and a winding provided on the outer side of the flat rectangular wire conductor; a capacitor connected in parallel with the primary winding of the pulse transformer; a switching element for opening and closing the discharging path extending from the capacitor to the primary winding; and metal strips provided adjacent to at least one end of the pulse transformer in an open magnetic circuit.
- the winding can be decreased in the overall size or thickness thus implementing a thin, property improved high-voltage generating device.
- the pulse transformer, the capacitor, and the switching element are installed in a housing which has a socket for connecting the base of a discharge lamp electrically and mechanically, whereby the base of the discharge lamp is supplied with a pulsed high voltage generated at the secondary winding of the pulse transformer. Accordingly, a thin, property improved high-voltage generating device can be realized having the socket for connection to the base of a discharge lamp.
- a method for making an electromagnetic device comprises the steps of: winding a flat rectangular wire conductor in an edge-wise winding form on a magnetic core; and fixedly joining ends of the flat rectangular wire conductor provided in the edge-wise winding form to corresponding terminals which are provided integrally on a single metal strip. Accordingly, the duration required for the production can be decreased. Also, with no use of insulators, the ends of the coil winding can be joined to the corresponding terminals.
- the metal strip is arranged of a linear form to which the ends of the flat rectangular wire conductor are joined as drawn out in one direction towards the metal strip. Accordingly, the metal strip can be arranged of a simple shape.
- the electromagnetic device with its coil winding joined at the ends to the corresponding terminals with no use of insulators can be fabricated by using simpler steps.
- the magnetic core has an elliptical shape in the cross section. Accordingly, the downsizing and the cost down can be feasible.
- a method for making an electromagnetic device with the use of a winding jig for holding one end of a magnetic core, a center shaft for supporting the center axis of the magnetic core, a hold-down jig arranged slidable on the magnetic core and the center shaft, a hold-down spring urging a stress against the hold-down jig, and a spring holder arranged slidable in response to the width of winding comprises the steps of: coupling one end of a flat rectangular wire conductor to the winding jig joined to the magnetic core and rotating the winding jig; winding the flat rectangular wire conductor on the magnetic core which is rotated by the rotating action of the winding jig; and allowing the hold-down jig and the spring holder to be slid to protect the flat rectangular wire conductor from tilting down as the width of winding increases during the edge-wise winding of the flat rectangular wire conductor on the magnetic core between the winding jig and the hold
- FIG. 1 is a perspective view showing Embodiment 1 of the present invention
- FIG. 2 is a cross sectional view of the same
- FIG. 3 is a perspective view showing Embodiment 2 of the present invention
- FIG. 4 is an explanatory view illustrating a process of fabricating the same
- FIG. 5 is a perspective view showing Embodiment 3 of the present invention
- FIG. 6 is a cross sectional view of the same in use
- FIG. 7 is a cross sectional view of a magnetic core in Embodiment 4
- FIG. 8 is a perspective view of the magnetic core on which a flat rectangular wire conductor is being wound
- FIG. 9 is a perspective of the same
- FIG. 10 is a perspective view showing Embodiment 5 of the present invention
- FIG. 11 is a cross sectional view of the same;
- FIG. 12 is a perspective view showing Embodiment 6 of the present invention;
- FIG. 13 is a cross sectional view of a magnetic core in Embodiment 7;
- FIG. 14 is a perspective view of the same;
- FIG. 15 is a perspective view showing Embodiment 8 of the present invention;
- FIG. 16 is a cross sectional view of the same;
- FIG. 17 is a perspective view showing Embodiment 9 of the present invention;
- FIG. 18 is a cross sectional view of the same,
- FIG. 19 illustrates a magnetic core in the embodiment where FIG. 19 a is a front view and FIG. 19 b is a side view of the same;
- FIG. 20 is a cross sectional view of a modification;
- FIG. 19 is a front view and
- FIG. 19 b is a side view of the same;
- FIG. 20 is a cross sectional view of a modification;
- FIG. 20 is
- FIG. 21 is a perspective view showing Embodiment 10 of the present invention
- FIG. 22 is a cross sectional view of the same
- FIG. 23 is a perspective view showing Embodiment 11 of the present invention
- FIG. 24 is a cross sectional view of the same
- FIG. 25 is an explanatory view illustrating a process of fabricating the same
- FIG. 26 is a perspective view showing Embodiment 12 of the present invention
- FIG. 27 is a cross sectional view of the same
- FIG. 28 is a perspective view showing Embodiment 13 of the present invention
- FIG. 29 is a partially omitted perspective view showing Embodiment 14 of the present invention
- FIG. 30 is a perspective view showing Embodiment 15 of the present invention
- FIG. 31 is a cross sectional view of the same;
- FIG. 32 is a perspective view of a cylindrical body in the same;
- FIG. 33 is an explanatory view showing a process of fabricating the same;
- FIG. 34 is a perspective view of a primary winding in the same;
- FIG. 35 is an explanatory view of the same;
- FIG. 36 is a plan view showing Embodiment 16 of the present invention;
- FIG. 37 is a waveform diagram illustrating an action of the same;
- FIG. 38 is a schematic circuitry diagram showing a conventional high-voltage generating device;
- FIG. 39 is a waveform diagram showing an action of the conventional device;
- FIG. 40 is a schematic circuitry diagram showing Embodiment 17 of the present invention;
- FIG. 41 is a schematic circuitry diagram of a modification of the same;
- FIG. 42 is a perspective view showing Embodiment 18 of the present invention;
- FIG. 43 is an exploded perspective view of the same;
- FIG. 44 is a perspective view seen from the back of a body of the same;
- FIG. 45 is a side view of a pulse transformer in the same;
- FIG. 46 is a schematic view of an electromagnetic device showing Embodiment 19 of the present invention;
- FIG. 47 is an explanatory view of the shape of recess provided in each end of a magnetic core showing Embodiment 20 of the present invention;
- FIG. 48 is a view of a magnetic core in an electromagnetic device showing Embodiment 21 of the present invention;
- FIG. 49 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 22 of the present invention
- FIG. 50 is a view of a magnetic core, coil windings, and an insertion molded member in an electromagnetic device showing Embodiment 23 of the present invention
- FIG. 51 is a view of a magnetic core, coil windings, and an insertion molded member in an electromagnetic device showing Embodiment 24 of the present invention
- FIG. 52 is a schematic view of an electromagnetic device during its production showing Embodiment 25 of the present invention
- FIG. 53 is a plan view of the electromagnetic device shown in FIG. 52
- FIG. 54 is a view of a magnetic core and coil windings used for fabricating the electromagnetic device shown in FIG. 52 ;
- FIG. 55 is a schematic view of the electromagnetic device prior to that shown in FIG. 52 ;
- FIG. 56 is a plan view of the electromagnetic device shown in FIG. 55 ;
- FIG. 57 illustrates a perspective view and a partial cross sectional view of an electromagnetic device showing Embodiment 26 of the present invention;
- FIG. 58 is a plan view of the electromagnetic device-shown in FIG. 57 ;
- FIG. 59 is an explanatory view showing a process of fabricating the electromagnetic device shown in FIG. 58 from its previous form;
- FIG. 60 is a view showing a discharge lamp igniter employing the electromagnetic device;
- FIG. 61 is a view showing an igniter circuit provided in the discharge lamp igniter shown in FIG. 60 ;
- FIG. 62 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 27 of the present invention
- FIG. 63 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 28 of the present invention
- FIG. 64 is a view of a welding joiner showing Embodiment 29 of the present invention
- FIG. 65 is an exploded perspective view of a prior art
- FIG. 66 is a perspective view of the same
- FIG. 67 is a cross sectional view of the same
- FIG. 68 is a perspective view of a coil bobbin in the same
- FIG. 69 illustrates a perspective view and a cross-sectional view of a conventional electromagnetic device
- FIG. 70 is an explanatory view showing a process of fabricating a bar-like magnetic core having a bottomed hole provided in each end thereof;
- FIG. 71 is an explanatory view of the magnetic core shown in FIG. 69 ;
- FIG. 72 is a perspective view of another conventional electromagnetic device;
- FIG. 73 is a perspective view of a conventional welding joiner welded to an insulation coated wire.
- An electromagnetic device of this embodiment is a single-winding inductor having a winding wound directly on a rod magnetic core 3 arranged of substantially a cylindrical shape with no need of an insulator such as a coil bobbin as-shown in FIGS. 1 and 2 .
- the magnetic core 3 is made of an Ni—Zn ferrite material which is high in the resistivity (intrinsic resistance) and about 8 mm in the diameter of its cylindrical shape.
- the winding is a flat rectangular wire conductor 2 (for example, having a thickness of 70 ⁇ m and a width of 1.4 mm) wound in a single layer of edge-wise winding form on substantially the entire length of the magnetic core 3 . More specifically, the flat rectangular wire conductor 2 is wound on the magnetic core 3 which is secured at both axial ends to jigs and then rotated by a rotating motion of the jigs.
- the inductor eliminates the use of any insulator such as the coil bobbin 60 between the winding (of the flat rectangular wire conductor 2 ) and the magnetic core 3 and can thus be minimized in the thickness with its winding reduced in the external dimensions. Also, as the flat rectangular wire conductor 2 is directly wound on the magnetic core 3 , its winding can be shortened in the overall length thus declining the level of resistance. Moreover, as the inductor develops no gap between the winding and the magnetic core 3 , its self-inductance can comparatively be decreased with the dimensions and the number of windings remaining unchanged.
- the conventional electromagnetic device having the flat rectangular wire conductor wound in an edge-wise winding form on an insulator such as the coil bobbin develops a gap between the winding and the magnetic core which then makes the relative positional relationship between the winding and the magnetic core unstable, hence creating variations in the properties including the inductance. Because the flat rectangular wire conductor 2 is directly wound on the magnetic core 3 in the embodiment, they are closely secured to each other and their relative position can be, secured thus minimizing variations in the properties.
- This embodiment is characterized by a magnetic core 3 having an elliptical shape in the cross section as shown in FIG. 3 .
- like components are denoted by like numerals and will be described in no more detail (throughout the embodiments and their drawings).
- the magnetic core 3 is made of an Ni—Zn ferrite material identical to that of Embodiment 1 but having an elliptical shape in the cross section on which a flat rectangular wire conductor 2 is directly wound in an edge-wise winding form. As its magnetic core 3 has an elliptical shape in the cross section, the inductor can be lower in the height than that of Embodiment 1.
- the magnetic core 3 has a hemispheric recess (pit) 3 c of about 2 mm in diameter provided at the center in each end thereof. While the flat rectangular wire conductor 2 is being wound on the magnetic core 3 by the action of a winder 4 , the magnetic core 3 is secured to the winder with its recess 3 c tightly accepting the-corresponding projection of a jig of the winder.
- the winder 4 has a magnetic core holding jig 4 b mounted on a rotary shaft 4 a thereof, as shown in FIG. 4 a .
- the magnetic core 3 is then inserted into the center recess of the magnetic core holding jig 4 b and held at its hemispheric recess 3 c engaged with the tip of a center shaft 4 c of the winder 4 .
- a hold-down jig 4 d is also provided for rotating and sliding motion on and along the center shaft 4 c .
- the hold-down jig 4 d remains urged by a hold-down spring 4 e so as to hold the flat rectangular wire conductor 2 in the vertical position during the edge-wise winding action.
- a slidable spring support 4 f is provided for loading the flat rectangular wire conductor 2 with substantially a uniform pressure.
- the flat rectangular wire conductor 2 is joined at the end to a conductor retainer 4 g on the magnetic core holding jig 4 b as shown in FIG. 4 c .
- the rotary shaft 4 a of the winder 4 starts rotating together with the magnetic core holding jig 4 b , the magnetic core 3 , the hold-down jig 4 d , and the center shaft 4 c , the flat rectangular wire conductor 2 is directly wound on the magnetic core 3 .
- FIG. 4 f illustrates the hold-down jig 4 d and the spring support 4 f shifted to the right by a width of the winding.
- the inductor having the flat rectangular wire conductor 2 wound directly on the magnetic core 3 of the elliptical shape in the cross section can be minimized in the size, particularly the height and in the inductance variation.
- the core may be covered with a coating for increasing the level of insulation or protected at the sides (where the flat rectangular wire conductor is wound) with a tape of insulating material. This also allows the flat rectangular wire conductor to be wound by the rotating action of the magnetic core, thus contributing to the small size of the inductor.
- This embodiment is characterized by, a magnetic core 3 having a through hole 3 d provided along the axial direction therein as shown in FIG. 5 .
- the magnetic core 3 like that of Embodiment 2 is arranged of an elliptical shape in the cross section and its through hole 3 d , of about 2 mm in the diameter extends along the axial direction between two ends thereof. This allows the magnetic core 3 to be securely held by a jig inserting into the through hole 3 d for ease of the winding of the flat rectangular wire conductor 2 .
- the magnetic core 3 can tightly be secured to a housing 7 of the winder with its through hole 3 d accepting and engaging with a bar-like projection 7 a extending from the housing 7 , as shown in FIG. 6 .
- the projection 7 a may be implemented by a retaining screw.
- the magnetic core 3 may be arranged of a cylindrical shape similar to that of Embodiment 1.
- This embodiment is characterized by a magnetic core 3 having a, pair of outer flanges 8 provided on both ends thereof to extend outwardly, as shown in FIGS. 7 to 9 .
- the magnetic core 3 like that of Embodiment 2 has an elliptical shape in the cross section and its outer flanges 8 project from the lengthwise ends radially (outwardly) at substantially a right angle to the lengthwise direction.
- a flat rectangular wire conductor 2 may be loosened out at both ends of the magnetic core 3 . This is inhibited by the outer flanges 8 which holds the flat rectangular wire conductor 2 at the two ends.
- a plurality (two in this embodiment) of hemispheric recesses 3 c are provided in each end of the magnetic core 3 .
- the magnetic core 3 is tightly secured to the winder with its recesses 3 c accepting and engaging with corresponding projections of a winder 4 which can rotate. This allows the winding of the flat rectangular wire conductor 2 to be more stable than in Embodiment 2.
- the magnetic core 3 may be arranged of a cylindrical shape similar to that of Embodiment 1.
- This embodiment is characterized by a magnetic core 3 having a particular shape shown in FIGS. 10 and 11 .
- the shape of the magnetic core 3 on which a flat rectangular wire conductor 2 is directly wound in an edge-wise winding form becomes smaller in the diameter of the cross section from both lengthwise ends to the center. Accordingly, the outer surface of the magnetic core 3 is sloped down from the two ends to the center and allows the flat rectangular wire conductor 2 to be closely wound without loosening towards the lengthwise ends of the magnetic core 3 , thus ensuring a stability of the winding form.
- the magnetic core 3 may be arranged of an elliptical shape in the cross section similar to that of Embodiment 2.
- An electromagnetic device of this embodiment is a two-winding transformer having a primary winding and a secondary winding wound directly on a substantially cylindrical, rod-like magnetic core 3 thereof, shown in FIG. 12 , with no use of an insulator such as a coil bobbin.
- the magnetic core 3 is substantially identical in the construction to that of Embodiment 1 where flat, rectangular wire conductors 2 are wound in an edge-wise winding form on the magnetic core 3 to implement the primary winding 9 and the secondary winding 10 .
- the transformer can be decreased in the overall size as compared with the conventional arrangement having the windings wound on the coil bobbin and declined in the direct-current resistance of both the primary winding 9 and the secondary winding 10 , hence improving its properties.
- the primary winding 9 and the secondary winding 10 are separated from each other along the lengthwise direction of the magnetic core 3 , the insulation between them can highly be ensured.
- the magnetic core 3 may be arranged of an elliptical shape in the cross section similar to that of Embodiment 2.
- This embodiment is characterized by a magnetic core 3 having a particular shape shown in FIGS. 13 and 14 .
- the magnetic core 3 has a pair of outer flanges 8 a and 8 b provided on both lengthwise ends thereof to extend radially (outwardly) from their edge at substantially a right angle to the lengthwise direction and a partition flange 11 provided at a region biased from the center to one end thereof to extend radially (outwardly) at substantially a right angle to the lengthwise direction.
- the outer flanges 8 a and 8 b can inhibit the edge-wise winding form of the flat rectangular wire conductor 2 from being loosened at the two lengthwise ends of the magnetic core 3 while the partition flange 11 provided between the primary winding 9 and the secondary winding 10 on the magnetic core 3 can definitely separate and electrically insulate the two windings 9 and 10 from each other thus improving the insulation as compared with that of Embodiment 6.
- the magnetic core 3 may be arranged of an elliptical shape in the cross section similar to that of Embodiment 2.
- This embodiment is characterized by a magnetic core 3 having a particular shape shown in FIGS. 15 and 16 .
- the shape of the magnetic core 3 comprises two halves separated at substantially the center and each half becomes smaller in the diameter of the cross section from each lengthwise end to an intermediate region.
- Flat rectangular wire conductors 2 are wound in an edge-wise winding form directly on the two halves of the magnetic core 3 thus implementing the primary winding 9 and the secondary winding 10 .
- a recess 3 c is provided in each length end of the magnetic core 3 .
- Each half of the magnetic core 3 on which the primary winding 9 or the secondary winding 10 is directly wound is sloped down from both ends, the lengthwise end and the center of the magnetic core 3 , to the intermediate region. This allows the winding of the flat rectangular wire conductor 2 to be securely wound along the lengthwise direction without loosening outwardly at the two ends. Also, the cross section at the center of the magnetic core 3 between the primary winding 9 and the secondary winding 10 is greater than the halves on which the primary winding 9 and the secondary winding 10 are directly wound, the two windings 9 and 10 can be separated and insulated from each other at a higher level of certainty than in Embodiment 6.
- the magnetic core 3 may be arranged of an elliptical shape in the cross section similar to that of Embodiment 2.
- An electromagnetic device of this embodiment is a two-winding transformer having a primary winding and a secondary winding wound directly on a substantially cylindrical, rod-like magnetic core 3 thereof, shown in FIGS. 17 and 18 , with no use of an insulator such as a coil bobbin.
- the magnetic core 3 is made of an Ni—Zn ferrite material and arranged of substantially an elliptical shape, a combination of a rectangular region and two semi-circular regions, in the cross section shown in FIG. 19 .
- the diameter of the semi-circular regions is about 6 mm while the length of the rectangular region of the cross section is about 5 mm.
- the magnetic core 3 is about 30 mm in the length.
- a recess 3 c having a diameter of about 2 mm and a depth of about 2 mm is provided in each lengthwise end of the magnetic core 3 .
- the secondary winding 10 on the magnetic core 3 is fabricated by providing 220 turns of a flat rectangular wire conductor 2 (e.g. 0.070 mm thick and 1.4 mm wide) directly in an edge-wise winding form. It is found that the direct current resistance of the-secondary winding 10 is substantially 1.8 ⁇ .
- the primary winding 9 is fabricated by providing 6 turns (3 turns shown in FIGS. 17 and 18 ) of a wire conductor (e.g. 0.2 mm in the wire conductor diameter and 0.51 mm in the overall diameter) substantially between a low-voltage end 10 a of the secondary winding 10 and the lengthwise center of the magnetic core 3 over the secondary winding 10 .
- the wire conductor may be an insulated wire or magnet wire.
- the primary winding 9 is wound over the secondary winding 10 thus increasing the magnetic coupling between the two windings 9 and 10 and improving the efficiency of power transmission.
- the electromagnetic device of this embodiment can produce a higher secondary voltage as a pulse transformer than the previous embodiment 7 or 8 where the two windings 9 and 10 are separately wound on the magnetic core 3 .
- the pulsed output can be generated a peak value of 30 kV.
- the primary winding 9 is located close to the low-voltage end 10 a of the secondary winding 10 , it can be separated and insulated by a marginal distance from the high-voltage end 10 b of the secondary winding 10 .
- the primary winding 9 is implemented by the coated wire conductor, the insulation between the two windings 9 and 10 can be ensured.
- the primary winding 9 may be provided adjacent to the low-voltage end 10 a of the secondary winding 10 along the lengthwise direction of the magnetic core 3 with equal success, as shown in FIG. 20 .
- An electromagnetic device of this embodiment is a two-winding transformer having flat, rectangular wire conductors 2 a and 2 b wound in an edge-wise winding form directly on a substantially cylindrical rod-like magnetic core 3 thereof with no use of an insulator such as a coil bobbin to implement the primary winding 9 and the secondary winding 10 respectively shown in FIGS. 21 and 22 .
- the magnetic core 3 is substantially identical in the construction to that of Embodiment 1 on which the flat rectangular wire conductor 2 b is directly wound in an edge-wise winding form throughout the length thereof to develop the secondary winding 10 .
- the primary winding 9 is fabricated by winding the flat rectangular wire conductor 2 a in an edge-wise winding from as alternating several turns with the flat rectangular wire conductor 2 b of the secondary winding 10 at a region close to the low-voltage end 10 a of the secondary winding 10 of the magnetic core 3 .
- the primary winding 9 and the secondary winding 10 are implemented by the edge-wise winding form of the flat rectangular wire conductors 2 a and 2 b directly on the magnetic core 3 , their external dimensions are substantially equal to each other and can thus contribute to the smaller or thinner size of the electromagnetic device than that of Embodiment 9. Also, the flat rectangular wire conductor 2 a of the primary winding 9 like the secondary winding 10 is directly wound on the magnetic core 3 , the two windings 9 and 10 can be fabricated in one single step thus increasing the productivity.
- This embodiment is characterized by a construction of the-primary winding 9 shown in FIGS. 23 and 24 .
- the other arrangement is substantially identical to that of Embodiment 9.
- the primary-winding 9 in this embodiment is fabricated by winding rectangular foils of a wire conductor 12 and a rectangular sheet of an insulating film 13 alternately on the secondary winding 10 which has been fabricated by winding a flat rectangular wire conductor 2 in an edge-wise winding form directly on a magnetic core 3 .
- the conductor foil 12 has a pair of conductors 12 a provided on both ends of one side thereof which serve as the terminals of the primary winding 9 .
- the process of fabricating the primary winding 9 is now explained in more detail. As shown in FIG.
- the wire conductor foil 12 is placed on one end of the insulating film 13 of a rectangular sheet and wound from the other end over the secondary winding 10 provided directly on the magnetic core 3 . More specifically, the insulating film 13 is first wound oh the secondary winding 10 and then, the wire conductor foil 12 on the insulating film 13 is wound. Accordingly, the conductor foil 12 is alternated with the insulating film 13 . As a result shown in FIG. 24 , the wire conductor foil 12 is wound in a multi-layer form via the insulating film 13 on the secondary winding 10 to implement the primary winding 9 . This allows the insulating film 13 to insulate between the primary winding 9 and the secondary winding 10 and simultaneously between the layers of the wire conductor foil 12 .
- the primary winding 9 of this embodiment is provided between a region close to the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of the magnetic core 3 .
- an electromagnetic device of this embodiment can further be decreased in the thickness. Also, as the distance between the primary winding 9 and the secondary winding 10 is minimized, the magnetic coupling between the same can be enhanced thus increasing the efficiency of power transmission and thus producing a higher amplitude of the output voltage. Moreover, as the primary winding 9 is increased in the cross section of the wire conductor, its direct current resistance can be reduced hence producing a greater level of the primary current.
- This embodiment is characterized by a construction of the primary winding 9 shown in FIGS. 26 and 27 .
- the other arrangement is substantially identical to that of Embodiment 9.
- the primary winding 9 is fabricated by winding a flat rectangular wire conductor 2 in an edge-wise winding form on a magnetic core 3 to develop the secondary winding 10 , installing the magnetic core 3 in a substantially cylindrical insulation casing 14 made of an insulating material, and winding a wire on the insulation casing 14 .
- the insulation casing 14 is sized not shorter than the overall length of the magnetic core 3 to completely enclose the magnetic core 3 and the secondary winding 10 therein.
- the primary winding 9 incorporates several turns of the wire (for example, a flat rectangular wire conductor) provided substantially between the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of the magnetic core 3 .
- the insulation casing 14 can definitely insulate between the primary winding 9 and the secondary winding 10 . Also, as the secondary winding 10 is entirely enclosed in the insulation casing 14 , its marginal surface can be protected from dielectric breakdown throughout the length from its high-voltage end 10 b to the primary winding 9 .
- This embodiment is characterized by a construction of the primary winding 9 shown in FIG. 28 .
- the other arrangement is substantially identical to that of Embodiment 9.
- the primary winding 9 is positioned by winding a fusible resin coated wire on the secondary winding 10 and fusing between the coating of a flat rectangular wire conductor 2 of the secondary winding 10 and the resin coated wire of the primary winding 9 .
- the coating of the flat rectangular wire conductor 2 of the secondary winding 10 provided in an edge-wise winding form may be made of a fusible resin material and directly bonded by fusion to the magnetic core 3 for positioning the secondary winding 10 .
- This embodiment is characterized by a construction of the primary winding 9 shown in FIG. 29 .
- a magnetic core 3 is provided with leads 16 of thin metal strips fabricated by insertion forming, arranged on which a flat rectangular wire conductor 2 is wound in an edge-wise winding from to develop the secondary winding 10 , and installed in the interior 15 a of a synthetic resin casing 15 .
- Each pair of the leads 16 provided on both sides of the magnetic core 3 are bridged at their distal end by a thin metal lead strip 17 .
- the lead strip 17 is joined at both ends to the distal ends of the paired leads 16 , they extend about the secondary winding 10 as serving as the primary winding 9 (its two turns only shown in the drawing). This arrangement can contribute to the smaller size or the lower dimension of the electromagnetic device (a transformer) of this embodiment.
- the primary winding 9 is implemented by the coated wire of which the overall diameter is set to substantially five times greater than the diameter of its wire conductor because of a point of view that a dielectric breakdown between the primary winding 9 and the secondary winding 10 possibly occurs at the marginal surface close to the high-voltage end 10 b of the secondary winding 10 .
- a resultant electromagnetic device a transformer
- the coated wire becomes greater in dimensions thus interrupting the reduction of the overall size.
- the coated wire is round in the cross section, it may hardly be positioned on the secondary winding 10 and, if worse, may be wound to a greater thickness. While the diameter of the wire of the primary winding 9 in Embodiment 12 is successfully decreased, the overall dimensions of the electromagnetic device (transformer) become greater due to the size of the insulation casing 14 and may be increased in the number of components or assembled with much difficulty.
- This embodiment is an electromagnetic device (a transformer) comprising a primary winding assembly 18 including the primary winding 9 with insulators and a magnetic core 3 having a flat rectangular wire conductor 2 wound in an edge-wise winding form thereon and coupled to the primary winding assembly 18 , as shown in FIGS. 30 and 31 . While this embodiment is characterized by the installation of the primary winding 9 , its other arrangement is identical to that of Embodiment 9.
- the primary winding assembly 18 includes a substantially cylindrical housing 19 of an insulating resin material (a first insulating material) arranged of an elliptical shape in the cross section as shown in FIG. 32 .
- the housing 19 is made of a thermoplastic resin material such as poly-ether-imide and has several turns of a groove 19 a provided circumferentially in the outer surface thereof for holding the primary winding. Also, the housing 19 has a couple of lengthwisely extending projections 19 c provided thereon, each projection having a groove 19 b provided thereon for accepting each end of the primary winding.
- the primary winding assembly 18 containing the housing 19 covered with the secondary insulating material of a shape 22 is completed.
- the electromagnetic device (a transformer) of this embodiment is completed (See FIGS. 30 and 31 ).
- the primary winding assembly 18 is arranged extending substantially between the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of the magnetic core 3 .
- the insulation between the primary winding 9 and the secondary winding 10 can be implemented by the primary winding assembly 18 .
- the secondary insulating material of the shape 22 encloses the housing 19 on which the primary winding 9 has been developed with the electrically conductive resin material 21 , it can favorably insulate the primary winding 9 from the high-voltage end of the secondary winding 10 .
- the primary winding 9 is fabricated by filling the grooves 19 a and 19 b of the housing 19 with the highly flowable electrically conductive resin material 21 with no need of the conventional step for winding a wire to develop the primary winding 9 , its assembling process can be facilitated thus improving the overall productivity.
- the primary winding 9 can be small or thin. As a result, the electromagnetic device can hence be minimized in the overall size or thickness.
- the magnetic cores 3 of this embodiment and the previous embodiments 1 to 14 are made of a bar-like ferrite material and polished at the surface, they may not be polished but remain rough.
- the surface roughness or mathematical average roughness (Ra) of the magnetic core 3 can preferably be 0.8 ⁇ m or greater. This eliminates the step of polishing the magnetic core 3 and can hence reduce the production cost of the magnetic core 3 .
- the surface roughness of the magnetic core 3 is declined, it may cause the flat rectangular wire conductor 2 to be slipped down and fractured during the edge-wise winding as shown in FIG. 35 .
- the magnetic core 3 remains rough at the surface, it can inhibit the flat rectangular wire conductor 2 from being fractured thus permitting ease of the edge-wise winding.
- the conventional device acts as an igniter for supplying a high intensity discharge lamp Lp with a pulsed high voltage and comprises a pair of input ports T 1 and T 2 for receiving the high voltage, a pair of output ports T 3 and T 4 connected to the high intensity discharge lamp Lp, a pulse transformer PT of which the secondary winding is connected between the input port T 1 and the output port T 3 at the high voltage side and the primary winding is connected between the two-input ports T 1 and T 2 , a switching element SW connected between the low voltage side of the primary winding of the pulse transformer PT and the input port T 2 at the lower voltage side, a resistor R 1 connected between the input port T 1 at the high voltage side and the high voltage side of the primary winding of the pulse transformer PT, and a capacitor C 1 connected in parallel with both the primary winding of the pulse transformer PT and the switching element SW.
- a voltage input received by the two inputs T 1 and T 2 while the high intensity discharge lamp Lp is not lighted is passed via the resistor R 1 to the capacitor C 1 which is thus charged.
- the voltage at both ends of the capacitor C 1 is increased to a given level, it turns the switching element SW on. This allows the power to be discharged from the capacitor C 1 and transmitted via the switching element SW to the primary winding of the pulse transformer PT which then generates a pulsed high voltage at its secondary winding.
- the pulsed high voltage is then received by the high intensity discharge lamp Lp which in turn creates dielectric breakdown.
- FIG. 39 illustrates an exemplary waveform of the pulsed high voltage output of the conventional device where a high frequency component is superimposed on the waveform of a resonant voltage generated by the action of the capacitor C 1 at the primary winding of the pulse transformer PT and boosted by the pulse transformer PT.
- This may result from the effect of any parasitic capacitance since the pulse transformer PT is not of an ideal form. It is however essential for allowing the high intensity discharge lamp Lp to start a dielectric breakdown promptly that the waveform of the pulsed high voltage is as close to its fundamental form as possible without the effect of the high frequency component.
- the voltage output of the conventional device is rapidly settled down to zero in the amplitude, its stressing effect on the components including the capacitor C 1 can be minimized.
- the components of the circuitry arrangement- to be employed can be eased in the resistance to high voltage and thus reduced in both the size and the price.
- the high-voltage generating device of this embodiment has a couple of metal strips 24 provided adjacent to both ends of the magnetic core 3 in a pulse transformer PT as shown in FIG. 36 , thus minimizing the oscillation of the high frequency component. More specifically, the magnetic core 3 is magnetically open at both ends. When the magnetic flux leaked from the two ends of the magnetic core 3 and passed across the metal strips 24 is varied by the effect of the high frequency oscillation, it generates an eddy current on the metal strips 24 . As a result, the eddy current loss will occur and offset the high frequency oscillation.
- the pulse transformer PT in this embodiment is implemented by the electromagnetic device (a transformer) of any of Embodiments 6 to 15.
- the high voltage waveform supplied to the high intensity discharge lamp Lp can be corrected to close to the fundamental form shown in FIG. 37 with its high frequency component successfully offset by the eddy current loss created on the metal strips 24 .
- the oscillation of the voltage output is rapidly reduced to zero, its stressing effect on the components including the capacitor C 1 can be minimized. This allows the components to be used which are eased in the resistance to high voltage and thus decreased in both the size and the price.
- the metal strips 24 may be replaced by leads which are provided for electrically connecting between the components and located adjacent to both ends of the magnetic core 3 of the pulse transformer PT. As a result, the components to be used can be reduced in the total number and their arrangement can be simplified.
- This embodiment is characterized by a high-voltage generating device where the primary winding of a pulse transformer PT is connected in parallel with a resistor Ra as shown in FIG. 40 .
- the other arrangement is substantially identical to that of the conventional device shown in FIG. 38 .
- the high frequency oscillation can thus be offset by the loss created in the resistor Ra which is connected in parallel with the primary winding.
- the primary winding of the pulse transformer PT may be connected in series with a resistor Rb as shown in FIG. 41 .
- This embodiment is characterized by a high-voltage generating device where a high intensity discharge lamp Lp is provided integral with a socket which is arranged detachable as shown in FIG. 42 .
- the high-voltage generating device of this embodiment comprises a main assembly 30 made of a synthetic resin material and a shield cover 50 covering the back and lateral sides, but not the front side, of the main assembly 30 as best shown in FIG. 43 .
- the main assembly 30 includes a body 31 containing major components including the pulse transformer PT described with Embodiment 16, a cover 32 covering the front side of the body 31 , and a lid 33 closing the rear side of the body 31 .
- the cover 32 has a socket opening 34 of substantially a round shape provided in the front side thereof and a group of bayonet stoppers 35 provided on the circumferential edge about the socket opening thereof.
- the stoppers 35 are formed integral with the circumferential edge about the socket opening 34 and provided in the form of notches opening towards the center. More particularly, the stopper 35 is an L shaped recess comprising a vertical groove 35 a for accepting each engaging tab (not shown) provided on the outer surface of a base of the high intensity discharge lamp Lp which is inserted from the front to the back in the socket opening 34 and a horizontal groove 35 b continuously communicated with the vertical groove 35 a .
- the stopper 35 has a stopper recess 35 c provided in the innermost thereof for holding the engaging tab at the engaging position.
- the body 31 includes a substantially cylindrical tube 36 accommodated in the socket opening 34 of the cover 32 and an engaging projections 38 provided thereon for engaging with engaging slots 37 provided in the lateral side of the cover 32 .
- the body 31 also has a center tube 39 of substantially a cylindrical shape provided upright in the center of the tube 36 and a center electrode 40 provided in the center tube 39 for direct contact with a center electrode (not shown) of the discharge lamp base.
- a group of-outer electrodes 41 are provided on the tube 36 for direct contact with corresponding outer electrodes (not shown) mounted on the outer side of the lamp base.
- contacts 41 a of the outer electrodes 41 of its tube 36 come to face the inner side about the socket opening 34 of the cover 32 .
- the lamp base is inserted into the socket opening 34 of the cover 32 , its engaging tabs move into the vertical grooves 35 a of the stoppers 35 .
- the lamp base is twisted, its engaging tabs move into the horizontal grooves 35 b and finally come in direct engagement with the corresponding stopper recesses 35 c .
- the center electrode of the lamp base is inserted into the center tube 39 to come into direct contact with the center electrode 40 .
- the outer electrodes of the lamp base come into direct contact with the corresponding contacts 41 a of the outer electrodes 41 about the socket opening 34 of the tube 36 .
- the high intensity discharge lamp Lp is coupled to the high-voltage generating device of this embodiment electrically and mechanically.
- the body 31 also has a first component recess 42 provided in the front side thereof for accommodating the circuitry components including a resistor Ri and a capacitor C 1 .
- the body 31 has a transformer recess 43 provided in the back side thereof for accommodating a pulse transformer PT.
- the pulse transformer PT is identical in the construction to the electromagnetic device (a transformer) of Embodiment 9, having a flat rectangular wire conductor 2 wound in edge-wise winding form on a rod-like magnetic core 3 of substantially a cylindrical shape in the cross section to implement the secondary winding 10 and substantially six turns of a wire provided on the secondary winding 10 to implement the primary winding 9 , as shown in FIG. 45 .
- the lid 33 has a group of engaging slots 45 provided in a circumferential wall 33 a thereof for engagement with corresponding engaging projections 44 provided on the outer surface of the body 31 .
- corresponding engaging projections 44 provided on the outer surface of the body 31 .
- the shield cover 50 is a box shape of an electrically conductive magnetic material having one side opened.
- the shield cover 50 has a fitting slot 47 provided in a circumferential wall thereof for engagement with a fitting projection 46 provided on the outer side of the cover 32 .
- the pulse transformer PT in the main assembly 30 As the pulse transformer PT in the main assembly 30 is accommodated in the body 31 with its magnetic core 3 facing at both ends the inner side of the shield cover 50 , its magnetic core 3 of the main assembly 30 when coupled to the shield cover 50 develops a closed magnetic circuit together with the shield cover 50 . Because the main assembly 30 is protected with the shield cover 50 and its pulse transformer PT allows the magnetic core 3 to develop the closed magnetic circuit together with the shield cover 50 , any noise generated and emitted from the high-voltage generating device can favorably be attenuated and simultaneously the (high voltage) output- of -the pulse transformer PT can be increased. Also, the device itself can be minimized in the overall size or thickness.
- the shield cover 50 of this embodiment also acts as the metal strips 24 of Embodiment 16. As the metal strips 24 are not needed, the components can thus be decreased in the total number and their arrangement can be simplified.
- FIG. 46 is a construction view of an electromagnetic device of this embodiment and FIG. 47 is an explanatory cross sectional view showing the shape of a recess provided in the magnetic core 3 shown in FIG. 46 .
- the electromagnetic device shown in FIG. 46 comprises the rod-like magnetic core 3 having an intrinsic resistance of not smaller than 10 3 ⁇ m a coil winding 2 provided on the magnetic core 3 by winding a flat rectangular wire in an edge-wise winding form with no use of a bobbin as the insulator, a coil winding 1 of an insulator coated wire (acting as the primary winding 9 ) provided directly over the coil winding 2 , a resin casing 5 arranged for accommodating those components, and a group of terminals 6 extending outwardly from the casing 5 and connected to the coil windings.
- the terminals 6 of this embodiment are joined with non of the bobbin.
- This embodiment allows the terminals 6 to be connected together by a hoop material 60 as shown in FIG. 46 c .
- the terminals 6 joined to the hoop material 60 are connected to the corresponding coil windings. Since the terminals 6 are drawn out in one direction as shown in FIG. 46 a , the hoop material 60 can be arranged of a simpler shape. Even if the casing 5 is made by filling or molding of a resin material for giving the electrical insulation as shown in FIG. 46 b , the terminals 6 are aligned in a row and they can thus be joined to the corresponding coil windings with much ease at the succeeding step.
- this embodiment allows a magnetic core 3 to have a recess 3 c provided in each end thereof defining a bottom 3 c 2 .
- the recess 3 c is arranged to have a tapered shape which becomes smaller in the diameter from an opening 3 c 1 to the bottom 3 c 2 .
- the magnetic core 3 is supported by not a rod jig shown in FIG. 70 but a rod K having a tapered projection K1.
- FIG. 48 a illustrates the magnetic core of an electromagnetic device of this embodiment.
- the magnetic core 3 A of the electromagnetic device has a recess 3 c provided in each end thereof which is identical to that of the previous embodiment and is arranged of an elliptical shape in the cross section. The other arrangement is identical to that of the previous embodiment.
- the electromagnetic device can be implemented as a thin transformer.
- the recess 3 c has a tapered shape as described.
- the magnetic core 3 A is elliptical in the cross section, it may hardly be tilted down in a direction denoted by the arrow shown in FIG. 48 b but easily fallen in another direction denoted by the arrow shown in FIG. 48 c .
- the tapered effect may be provided in the recess 3 c only along the direction orthogonal to the lengthwise direction of the magnetic core 3 A for inhibiting any undesired tipping off.
- FIG. 49 illustrates an electromagnetic device of this embodiment having a magnet core and a group of coil windings.
- the electromagnetic device is differentiated from that of Embodiment 19 by the fact that the coil winding 1 wound on the coil winding 2 has two leads 1L and 1R thereof drawn out specifically.
- the coil winding 1 acts as the primary winding and the coil winding 2 acts as the secondary winding
- the coil winding 2 is fabricated by winding a flat rectangular wire of foil shape, which is high in the engaging rate, in an edge-wise winding form on the magnetic core 3 . Accordingly, the coil winding 2 can be increased in the number of turns without decreasing the cross sectional size.
- the electromagnetic device is hence used as a small sized, high-voltage transformer which can easily produce a high voltage of, for example, several to tens kilovolts across its secondary winding 2 when the coil winding 1 is loaded as the primary winding with a voltage of hundreds bolts to a few kilovolts.
- the magnetic circuit of the coil windings 1 and 2 is an open circuit coaxial with the magnetic core 3 .
- the open circuit allows the coupling between the primary and secondary windings to be more increased when the coil winding 1 is located as the primary winding on the center of the magnetic core 3 than on either end of the same.
- the coil winding 1 shown in FIG. 46 is biased towards the center of the coil winding 2 and more particularly located leftwardly of the center of the coil winding 2 of which the right lead 2R acts as a high-voltage end.
- the location of the coil winding 1 leftwardly of the center of the coil winding 2 is based on the following reason. As shown in FIG.
- the potential between 2R and 1L (1R ) is as high as several to tens kilovolts while the potential between 2L and 1L (1R ) ranges from hundreds volts to a few kilovolts.
- the joint between the lead of each coil winding and the terminal 6 is implemented by an uncovered metal-joint, it may trigger dielectric breakdown when a gap is generated between the resin material housing and the high-voltage transformer. For inhibiting any dielectric breakdown, the distance between 2R and 1L (1R ) is enlarged.
- the coil winding 1 When the coil winding 1 is located on the lead 2L of the coil winding 2 , the protection from dielectric breakdown can be enhanced but the coupling between the primary and secondary windings will be declined thus lowering the level of the high-voltage output at the secondary winding.
- the coil winding 1 of this embodiment is slightly biased towards the center of the coil winding 2 to guarantee the coupling between the primary and secondary windings as shown in FIG. 49 while its two leads 1L and 1R are biased towards the low-voltage end 2L of the coil winding 2 . This allows the high-voltage transformer to be improved in the resistance to dielectric breakdown while ensuring the coupling between the primary and secondary windings.
- FIG. 50 illustrates an electromagnetic device of this embodiment having a magnetic core, a group of coil windings, and an insertion molded member.
- the electromagnetic device is differentiated from the previous one by the fact that the casing 5 is replaced by an insertion molded member 5 A for drawing the leads of the coil windings 1 and 2 .
- As its magnetic core 3 A has an elliptical shape in the cross section as shown in FIG. 50 a , the electromagnetic device of this embodiment can be used as a thin transformer.
- the leads 1L and 1R of the coil winding 1 as the primary winding are drawn out from a location close to the low-voltage end 2L of the coil winding 2 in the previous embodiment, the lead 1R of the coil winding 1 of this embodiment close to the high-voltage end 2R of the coil winding 2 only is biased towards one particular end of the magnetic core 3 A where the low-voltage end 2L of the coil winding 2 is located.
- This arrangement will also improve the insulation function.
- the two leads of the coil winding 2 are drawn out along the thin side of the magnetic core 3 A. This allows the insertion molded member 5 A to remain minimum in the thickness as shown in FIG. 50 b .
- the two leads 2L and 2R of the coil winding 2 are located diagonal to each other so as to be distanced maximum from each other.
- the insertion molded member 5 A has a set of grooves 51 A provided circumferentially in the outer sides thereof between the high-voltage end 2R and the other end 2L (1L and 1R ). As the grooves 51 A extend throughout the outer sides of the insertion molded member 5 A to form a series of peaks and valleys on the surfaces. Accordingly, the surface (interface) distance between the high-voltage end 2R and the other end 2L. (1L and 1R ) on the insertion molded member 5 A can be elongated. As a result, the insulation function between the one end 2R and the other end 2L (1L and 1R ) can be improved thus allowing the small sized transformer to be easily fabricated having a higher level of the insulation.
- FIG. 51 illustrates an electromagnetic device of this embodiment having a magnetic core, a group of coil windings, and an insertion molded member.
- the electromagnetic device is similar to that of the previous embodiment, except that the insulation coated coil winding 1 is replaced by a coil winding 1 A of a single wire with a bobbin 40 having a pair of terminals 41 and serving as the insulation coating, the coil winding 1 A wrapped up at both ends with the paired terminals 41 of the bobbin 40 .
- the bobbin 40 can increase the insulation function between the primary winding and the secondary winding, the connection between its paired terminals 41 and the coil winding 1 A can be facilitated.
- the coil winding 1 A is fabricated by the single wire of a low price, not the high-voltage insulation coated wire which is relatively high in the cost, thus contributing to the low price of a resultant high-voltage transformer.
- FIG. 52 is a schematic view of an electromagnetic device of this embodiment at a step of its production.
- FIG. 53 is a plan view of the electromagnetic device shown in FIG. 52
- FIG. 54 is a perspective view of a magnetic core and coil windings used in the electromagnetic device shown in FIG. 52
- FIG. 55 is a schematic view of the electromagnetic device at a production step prior to the step of FIG. 52
- FIG. 56 is a plan view of the electromagnetic device shown in FIG. 55 .
- the process of fabricating the electromagnetic device prior to the steps of FIGS. 52 and 53 As shown in FIG.
- the coil windings 1 .and 2 are provided on the magnetic core 3 A of an elliptical shape in the cross section with no use of an insulator to develop a first intermediate product. More specifically, the coil winding 2 is fabricated by winding a flat rectangular wire in an edge-wise winding form on the outer side of the magnetic core 3 A and then the coil winding 1 is provided on a predetermined location of the coil winding 2 .
- FIGS. 55 and 56 This is followed, as shown in FIGS. 55 and 56 , by connecting ends of the coil windings 1 and 2 of the first intermediate product to corresponding terminals 6 of a lead frame 60 A made of a single metallic strip to develop a second intermediate product.
- the second intermediate product is then placed in a set of unshown molds which are in turn filled with a thermoset resin material such as unsaturated polyester (by injection molding).
- a third intermediate product is given having the lead frame 60 A joined with an insertion molded member 5 B as shown in FIGS. 52 and 53 .
- the above injection molding process can reduce the conventional vacuum filling process, which takes four or more hours, to as short as two minutes. Also, as the electromagnetic device employs a case-less arrangement, its overall dimensions can significantly be decreased.
- FIG. 57 illustrates a perspective view and a partially cross sectional view of an electromagnetic device of this embodiment.
- FIG. 58 is a plan view of the electromagnetic device shown in FIG. 57 and
- FIG. 59 is an explanatory view showing steps of shifting the electromagnetic device from an intermediate form to a finished form shown in FIG. 58 .
- the third intermediate product of the previous embodiment is provided with the coil windings 1 and 2 connected at their ends to corresponding terminals 6 of the lead frame 60 A and then, the redundancy of the lead frame 60 A is removed off for electrical isolation from the ends of the coil windings 1 and 2 .
- a fourth intermediate product shown in FIG. 59 a is given.
- the terminals 6 are folded down in their respective directions (for a desired pattern) as shown in FIG. 59 b , completing the electromagnetic device of this-embodiment shown in FIGS. 57 and 58 .
- FIG. 57 a there are a group of grooves 51 B provided between the terminal 6 (2R ) and the other terminals 6 (1L, 1R ) in one side of the insertion molded member 5 B, the terminal 6 (2R ) connected with the high-voltage end 2R of the coil winding 2 and the terminals 6 (1L, 1R) connected with the two ends 1L and 1R of the coil winding 1 .
- the insertion molded member 5 B has a series of peaks and valleys on the surface, its surface distance is between the two ends thus improving the insulation function and inhibiting any current leakage.
- the grooves 51 B are of no limitations and may be replaced by a row of projections.
- Denoted by 50 B in FIG. 57 b is a filling material of the insertion molded member 5 B.
- the electromagnetic device of this embodiment fabricated by the above manner is preferably used in a discharge lamp igniter which supplies a discharge lamp La as the headlight of vehicle with power and holds it at its lighting condition as shown in FIG. 60 .
- the discharge lamp igniter includes a starter (igniter) circuit IG for feeding the discharge lamp La with a pulsed high voltage for illumination, as shown in FIG. 61 .
- the igniter circuit IG is driven by an inverter INV.
- the electromagnetic device is installed at a region R2 in the igniter circuit IG denoted by the dotted line in FIG. 61 and its insertion molded member 5 B made of a thermoset resin material is also protected with an enclosure of thermoplastic resin material (to form a double insulation).
- the electromagnetic device with its terminals 6 exposed to the outside is covered with the thermoplastic resin enclosure. Because of the double insulation, the electromagnetic device is almost thoroughly protected by the thermoplastic resin except its terminals and can thus be improved in the insulation distance and the moisture-proof function. Also, the grooves 51 B extending from one end to the other end of one side of the insertion molded member 5 B can serve as passages for positively distributing flows of the thermoplastic resin material during the molding process, hence promoting the flowability of the thermoplastic resin material in molten form.
- FIG. 62 illustrates an electromagnetic device of this embodiment having a magnetic core and a group of coil windings.
- the electromagnetic device is modified in which the coil winding 1 of an insulation coated wire is replaced by a fusible coil winding 1 B.
- the process of fabrication starts with winding a flat rectangular wire in an edge-wise winding, form on the outer surface of the magnetic core 3 to develop the coil winding 2 .
- an UV curable adhesive is applied to two regions R3 and R4 and cured by irradiation of UV light.
- winding a fusible wire on a predetermined region of the coil winding 2 to develop the coil winding 1 B and energizing and fusing the coil winding 1 B for bonding with the coil winding 2 .
- the process can easily be carried out.
- the coil winding 2 can hardly be detached by its spring-back effect.
- FIG. 63 illustrates an electromagnetic device of this embodiment having a magnetic core and a coil winding.
- the electromagnetic device is substantially identical in the construction to that of Embodiment 1 except that the coil winding 2 excluding its two ends is almost entirely covered with a thin coating C.
- the coil winding 2 provided in an edge-wise winding form on the magnetic core 3 becomes smaller in the curvature radius and its coating may easily be torn off thus causing short-circuit between two adjacent turns of the coil winding 2 .
- the coil winding 2 is protected with the thin coating C. This can inhibit unwanted short-circuit between any two turns of the coil winding 2 .
- FIG. 64 a illustrates an electromagnetic device of this embodiment having welding joiners 70 .
- the welding joiner 70 is joined to one end of an insulation coated wire 8 of the primary winding and used as a terminal 6 of the electromagnetic device.
- the welding joiner 70 is arranged of a foldable shape comprising a flat base portion 71 extending in one direction, a folded portion 72 extending from one side at a right angle to the one direction, and an extending portion 73 allowing the folded portion 72 to face the flat portion 71 .
- a tab-like portion is provided extending from the other side than the folded portion 72 side of the base portion 71 and bent upwardly, thus acting as a positional error inhibitor 74 .
- the length of the positional error inhibitor portion 74 from the flat portion 71 is equal or slightly greater than the diameter of the insulation coated wire 8 .
- the positional error inhibitor portion 74 is located as spaced from the folded portion 72 .
- the welding joiner 70 is securely coupled to the insulation coated wire 8 when pressed and welded between welding electrodes 78 as shown in FIG. 64 b , thus holding but not detaching from the insulation coated wire 8 and giving the joint of improved stability and durability. Also, as its length from the base portion 71 is equal or slightly greater than the diameter of the insulation coated wire 8 , the positional error inhibitor portion 74 of the welding joiner 70 can certainly inhibit any further dislocation of the insulation coated wire 8 . Accordingly, no detachment of the insulation coated wire 8 from the welding joiner 70 will be allowed. Moreover, as the positional error inhibitor portion 74 is spaced by a distance from the folded portion 72 , any short-circuit between the positional error inhibitor portion 74 and-the folded portion 72 will be disallowed. This allows the extending portion 73 to emit a degree of Joule heat generated by the application of welding energy and transferred from the folded portion 72 thus fusing and removing the insulation coating of the coated wire 8 .
- the electromagnetic device, the high-voltage generating device, and the method for fabricating the electromagnetic device according to the present invention are favorably applicable to and can contribute to the reduction of the size or thickness of a pulse transformer also called an igniter for starting a common high intensity discharge lamp.
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Abstract
An electromagnetic device and a high-voltage generating device which are thin and improved in the characteristics are provided in which a magnetic core 3 is made of a cylindrical form of a ferrite material having a higher intrinsic resistance. A winding is provided by winding a flat rectangular wire conductor 2 in an edge-wise winding form directly on substantially the entire length of the magnetic core 3. As any insulator such as a coil bobbin is not needed between the flat rectangular wire conductor 2 and the magnetic core 3, the winding can be decreased in the overall size or thickness thus contributing to the dimensional reduction of the electromagnetic device. Also, as its flat rectangular wire conductor 2 is wound directly on the magnetic core 3, the winding can be minimized in the length and thus the overall resistance. Moreover, as there is no gap between the winding and the magnetic core 3, the self-inductance can be reduced while the size and the number of turns of the winding remain unchanged.
Description
- This application is a continuation of Application Ser. No. 09/129,105, filed Jul. 7, 2002, the contents of which are expressly incorporated by reference herein in its entireties.
- The present invention relates to an electromagnetic device, a high-voltage generating device, and a method for making the electromagnetic device.
- It is necessary for starting a high intensity discharge lamp such as a high-intensity discharge (HID) lamp to use a high-voltage generating device called an igniter. The high-voltage generating device is generally provided in the form of ant electromagnetic device such as a pulse transformer for converting a low-voltage input to a high-voltage output of pulsed waveform (as disclosed in, for example, Japanese Patent Laid-open Publications 11-16752 and 11-74132).
- One of such conventional electromagnetic devices is shown in structure in FIGS. 65 to 68. A
coil bobbin 60 is made of an insulating material such as synthetic resin having substantially a cylindrical shape which comprises twoouter flanges 61 at both ends and apartition flange 62 between the twoouter flanges 61. Aprimary winding 63 at the low voltage side is wound between one of the twoouter flanges 61 and thepartition flange 62 while asecondary winding 64 at the high voltage side is wound between the otherouter flange 61 and thepartition flange 62. In particular, thesecondary winding 64 is fabricated by winding a long, flat rectangular foil conductor with its wider sides facing each other (in the form of, so-called, edge-wise winding) for improving both the edge side insulation and the contact area of windings. Finally, a couple of U-shapedmagnetic cores 65 made of Mn—Zn ferrite are inserted and joined to both ends of thecoil bobbin 60 with theprimary winding 63 and thesecondary winding 64, hence forming an electromagnetic device (a pulse transformer). -
FIG. 69 a is a perspective view of another conventional electromagnetic device andFIG. 69 b is a cross sectional view taken along the line A-A′ ofFIG. 69 a. The another conventional electromagnetic device comprises a bar-like magnetic core 3PA and a coil winding 2 wound as the secondary winding on acoil bobbin 60 thereof mounted on the magnetic core 3PA. For ease of winding the coil winding 2 on thecoil bobbin 60 secured to the magnetic core 3PA, a recess 31PA is provided in each end of the magnetic core 3PA to determine its position along the axial direction. A process of fabricating the bar-like magnetic core 3PA having the recess in each end thereof will be explained referring toFIG. 70 . The process of fabricating the magnetic core 3PA employs a pair of rods K, each having a projection K1′ for shaping the recess 31PA and a swage die U having a through hole U1 provided therein for insertion of the rods K. As shown inFIG. 70 a, the process starts with shaping the magnetic core 3PA using the die U and the rods K. Then, the lower rod K is lifted up to the upper end of the die U as shown inFIG. 70 b to remove the magnetic core 3PA from the die U in the direction denoted by the arrow for increasing the efficiency. The magnetic core 3PA may however be injured at the edge R1 of the recess 31PA upon being removed from the die U as shown inFIG. 71 . -
FIG. 72 is a perspective view of a further conventional electromagnetic device. The electromagnetic device shown is a pulse transformer for converting a low voltage input to a high voltage output as called an igniter to generate a high voltage for energizing a high intensity discharge lamp. The conventional device shown inFIG. 72 comprises a bar-like magnetic core 3PA, a bobbin 4PA, a pair ofcoil windings terminals 6 connected tocoil windings terminals 6 and the coil winding 10 is connected to another (62). - This conventional electromagnetic device is fabricated by winding the
coil windings terminals 6 to thecorresponding coil windings -
FIG. 73 is a perspective view of a conventional welding joiner welded to the insulation coated wire. A welding joiner 6PA which can be welded to the insulation coated wire without stripping the insulation coating comprises, as shown inFIG. 73 , aflat base portion 61 extending along one direction and a foldedportion 62 extending from one side of thebase portion 61 at a right angle to the direction and folded along its width at aportion 63 so that the twoportions terminal 6 of the conventional electromagnetic device. One example of this arrangement is disclosed in Japanese Patent Laid-open Publication 11-114674. - It is common that high intensity discharge lamps are widely used as the head lights of vehicles because they are high in the brightness, low in the power consumption, and long in the operating life and thus much favorable in the safety than any halogen lamps. As such high intensity discharge lamps have increasingly been popular, the electromagnetic devices are now desired for minimizing the thickness in view of the dimensional requirements of igniters. However, the conventional devices are hardly reduced in the thickness with the
coil bobbin 60 provided between the magnetic core 65 (SeeFIG. 65 ) and the coil. Also, there is essentially provided a gap between thecoil bobbin 60 and themagnetic core 65 for ease of mounting, thus elongating the distance between themagnetic core 65 and the coil and creating differences in the properties between the electromagnetic devices. Although a modification is proposed where the coil bobbin is replaced by an insulating cover made of a resin material (disclosed in Japanese Patent Laid-open Publication 2000-36416), it retains the same drawbacks. - When the bobbin is provided between the magnetic core and the coil windings, its terminals are fixedly connected to the coil windings. In case of a bobbin-less device, the terminals connected with the coil windings may be secured with much difficulty.
- The process of fabricating an electromagnetic device shown in
FIG. 72 requires substantially four or more hours for carrying out the major processing steps including preparation, drying, and curing steps. For implementing a scheme of mass production, extra investments for expanding the existing production facility has to be needed. Also, when the epoxy resin vacuum filling process is employed, it may limit the lead-out of theterminals 6 from the casing 5PA to one single direction. This prevents theterminals 6 from being respectively bent and oriented in a desired pattern of the circuitry planning. Since the coil windings of a metallic material create undesired events of spring back, their ends have to be bound together or supported by any proper means. The epoxy resin vacuum filling process may generally develop an interface between the casing 5PA and the epoxy resin material thus allowing a high voltage to leak from the interface. The edge-wise winding may cause the coating of the coil windings to be peeled off when its curvature radius is too small. - The convention welding joiner 6PA may often cause the insulation coated wire to be dislocated when held between the
base portion 61 and the foldedportion 62 and pressed with a pair of welding electrodes. If worse, the insulation coated wire may completely be slipped off from between thebase portion 61 and the foldedportion 62. As the welding of the insulation coated wire to the welding joiner is carried out only with poor consistency, it is much desired to modify the welding joiner for improvement of its stable joining function and operational reliability. - The present invention has been developed in view of the foregoing aspects and its object is to provide an electromagnetic device, a high-voltage generating apparatus, and a method for making the electromagnetic device where the dimensional reduction and the improvement of properties are achieved, and the duration of time required for carrying out the production steps is minimized.
- In the present invention, an electromagnetic device comprises a magnetic core having a curved side and a flat rectangular wire conductor wound in an edge-wise winding form directly on the curved side of the magnetic core. Accordingly, as any insulator such as a coil bobbin is not needed between the flat rectangular wire conductor and the magnetic core, the winding can be decreased in the overall size or thickness, thus contributing to the dimensional reduction and the improvement of characteristics of the device. In the device, the magnetic core has an intrinsic resistance of not smaller than 1000 Ω.m.
- The electromagnetic device further comprises a winding provided on the outer surface of the flat rectangular wire conductor. Accordingly, a resultant transformer can be reduced in the thickness.
- The magnetic core is rough finished at the surface. Accordingly, as no extra step such as polishing is needed after the completion of the magnetic core, the production cost of the magnetic core can be lowered. Also, the flat rectangular wire conductor can be protected from slipping and tilting down during the edge-wise winding process.
- The flat rectangular wire conductor and the winding are joined to each other by fusing their coatings. Accordingly, as the positioning between the windings is securely determined, variations in the properties resulting from relative dislocation between the windings will be avoided.
- The magnetic core of an edge-wise winding form of the flat rectangular wire conductor is located between a group of leads joined together. Accordingly, the winding is arranged with its leads extending over the outer surface of the flat rectangular wire conductor.
- The electromagnetic device further comprises a first insulating member arranged of a cylindrical shape to which the magnetic core of the flat rectangular wire conductor is fitted and a secondary insulating material covering over the first insulating member and the winding which is made of an electrically conductive resin material and provided on the outer side of the first insulating member. Accordingly, the insulation between the winding of the flat rectangular wire conductor and the winding of the electrically conductive resin material can be ensured by the first insulating material.
- The first insulating member has a groove provided in the outer side thereof and the winding is fabricated by filling the groove with an electrically conductive resin material. Accordingly, the insulation between the high-voltage end of the winding of the flat rectangular wire conductor and the winding of the electrically conductive resin material can be ensured. The flat rectangular wire conductor serves as a secondary winding and the winding serves as a primary winding.
- The primary winding is located adjacent to the low-voltage end of the secondary winding. Accordingly, the surface distance between the high-voltage side of the secondary winding and the primary winding can be increased thus improving the insulating function.
- One of two ends of the primary winding disposed at the high-voltage end side of the secondary winding is drawn to the low-voltage end of the secondary winding. Accordingly, the insulation can be improved to a desired level.
- The primary winding is an insulated wire or a magnet wire protected with an insulation coating for electrically insulating between the primary winding and the secondary winding. Accordingly, the insulation can be improved to a desired level.
- The magnetic core has an elliptical shape in the cross section and its flat rectangular wire conductor is drawn out at both ends through a space between a transformer consisting mainly of the magnetic core and the flat rectangular wire conductor and a rectangular housing mounted outwardly of the transformer. Accordingly, the transformer can be reduced in both the size and the cost.
- The magnetic core has a bottomed hole provided in each end thereof and the hole is arranged of a tapered shape which becomes gradually smaller in the diameter from the opening to the bottom. Accordingly, when the magnetic core is fallen down about the point at the edge of its bottom with its bottomed hole accepting the projection of the rod during the preparation of the magnetic core using the paired rods and a pair of punching dies, its portion about the bottomed hole can clear the projection of the rod. As- a result, the magnetic core can be protected from being tipped off at its edge about the bottomed hole of its bottom.
- The magnetic core has an elliptical shape in the cross section. Accordingly, the overall size can be thinned.
- In the present invention, an electromagnetic device having a transformer arrangement includes a bar-like magnetic core and a flat rectangular wire conductor wound on the outer surface of the magnetic core for generation of a high voltage, the flat rectangular wire conductor drawn out at both ends from two ends of the magnetic core respectively, characterized by a resin outer housing provided about the transformer by filling or molding an insulating resin material and having at least one side thereof configured up and down along a direction substantially parallel with the axial direction of the magnetic core. Accordingly, as the surface distance is increased by the effect of the up and down configuration, the insulation function can be improved.
- The up and down configuration is provided at the high-voltage end side of the flat rectangular wire conductor. Accordingly, the insulation function can be improved.
- In the present invention, an electromagnetic device having a transformer arrangement includes a magnetic core, a winding and a flat rectangular wire conductor both provided on the magnetic core, and at least two terminals for connection of the winding and the flat rectangular wire conductor with the outside, characterized in that the transformer is sealed in an injection molded form of a thermoset resin material. Accordingly, the production of the transformer can be simplified.
- The electromagnetic device further comprises a lead frame for supporting the components during the injection molding. Accordingly, the production can be simplified.
- The thermoset resin material is covered with a molded form of a thermoplastic resin material. Accordingly, the insulation can be ensured while the protection against moisture is effectively improved.
- The winding and the flat rectangular wire conductor are secured at least at one end with an adhesive. Accordingly, the coil winding can hardly be loosened by the effect of spring back.
- While the winding acts as a primary winding, the flat rectangular wire conductor acts as a secondary winding and is insulated by coating and provided in an edge-wise winding form on the magnetic core. Accordingly, the overall size can be minimized.
- In the present invention, an insulation coated wire is joined with a welding joiner which comprises a flat base portion extending in one direction and a folded portion extending from one side along the one direction of the base portion substantially at a right angle to the one direction, where the folded portion is folded down along the one side to face the base portion, and the base portion has a tab portion extending from the other side than the one side thereof and bent upright to form a positional error inhibitor. Accordingly, when the welding joiner is pressed by welding electrodes for joining, the insulation coated wire can securely be held with but not detached from the welding joiner and its joining can hence be maintained and improved in both the stability and the durability.
- The length of the tab positional error inhibiting portion from the base portion is equal to or slightly greater than the diameter of the insulation coated wire. Accordingly, as the insulation coated wire when dislocated is securely held by the positional error inhibitor of the welding joiner, it can definitely remain protected from being detached from the welding joiner.
- The positional error inhibiting portion is distanced from the folded portion. Accordingly, as any short-circuit between the positional error inhibiting portion and the folded portion is avoided, Joule heat generated by energization can successfully be radiated from the extending side of the folded portion of the joiner.
- In the present invention, a high-voltage generating device comprises: a pulse transformer having a magnetic core, a flat rectangular wire conductor wound in an edge-wise winding form directly on the outer surface of the magnetic core, and a winding provided on the outer side of the flat rectangular wire conductor; a capacitor connected in parallel with the primary winding of the pulse transformer; a switching element for opening and closing the discharging path extending from the capacitor to the primary winding; and a resistor connected to the primary winding. Accordingly, as any insulator such as a coil bobbin is not needed between the magnetic core and the winding (of the flat rectangular wire conductor), the winding can be decreased in the overall size or thickness thus implementing a thin, property improved high-voltage generating device. Also, as its undesired oscillation is attenuated by resistance loss in the resistor connected in parallel with the primary winding, the pulsed high-voltage output of the secondary winding of the pulse transformer can favorably be corrected to substantially a fundamental waveform. Moreover, since the oscillation of the voltage is readily settled down, any unwanted stress on the components including the capacitor can successfully be eased. As a result, the components to be used may be declined in the resistance to high voltage and reduced in the size and the cost.
- In the present invention, a high-voltage generating device comprises: a pulse transformer having a magnetic core, a flat rectangular wire conductor wound in an edge-wise winding form directly on the outer surface of the magnetic core, and a winding provided on the outer side of the flat rectangular wire conductor; a capacitor connected in parallel with the primary winding of the pulse transformer; a switching element for opening and closing the discharging path extending from the capacitor to the primary winding; and metal strips provided adjacent to at least one end of the pulse transformer in an open magnetic circuit. Accordingly, as any insulator such as a coil bobbin is not needed between the magnetic core and the winding (of the flat rectangular wire conductor), the winding can be decreased in the overall size or thickness thus implementing a thin, property improved high-voltage generating device.
- The pulse transformer, the capacitor, and the switching element are installed in a housing which has a socket for connecting the base of a discharge lamp electrically and mechanically, whereby the base of the discharge lamp is supplied with a pulsed high voltage generated at the secondary winding of the pulse transformer. Accordingly, a thin, property improved high-voltage generating device can be realized having the socket for connection to the base of a discharge lamp.
- In the present invention, a method for making an electromagnetic device comprises the steps of: winding a flat rectangular wire conductor in an edge-wise winding form on a magnetic core; and fixedly joining ends of the flat rectangular wire conductor provided in the edge-wise winding form to corresponding terminals which are provided integrally on a single metal strip. Accordingly, the duration required for the production can be decreased. Also, with no use of insulators, the ends of the coil winding can be joined to the corresponding terminals.
- In the above method, the metal strip is arranged of a linear form to which the ends of the flat rectangular wire conductor are joined as drawn out in one direction towards the metal strip. Accordingly, the metal strip can be arranged of a simple shape.
- In the method, as the ends of the flat rectangular wire conductor have fixedly been joined to the corresponding terminals of the metal strip, the redundancy of the metal strip is separated from the terminals for electrically isolating the ends of the flat rectangular wire conductor from the metal strip. Accordingly, the electromagnetic device with its coil winding joined at the ends to the corresponding terminals with no use of insulators can be fabricated by using simpler steps.
- In the method, the magnetic core has an elliptical shape in the cross section. Accordingly, the downsizing and the cost down can be feasible.
- In the present invention, a method for making an electromagnetic device with the use of a winding jig for holding one end of a magnetic core, a center shaft for supporting the center axis of the magnetic core, a hold-down jig arranged slidable on the magnetic core and the center shaft, a hold-down spring urging a stress against the hold-down jig, and a spring holder arranged slidable in response to the width of winding, comprises the steps of: coupling one end of a flat rectangular wire conductor to the winding jig joined to the magnetic core and rotating the winding jig; winding the flat rectangular wire conductor on the magnetic core which is rotated by the rotating action of the winding jig; and allowing the hold-down jig and the spring holder to be slid to protect the flat rectangular wire conductor from tilting down as the width of winding increases during the edge-wise winding of the flat rectangular wire conductor on the magnetic core between the winding jig and the hold-down jig.
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FIG. 1 is a perspective view showing Embodiment 1 of the present invention;FIG. 2 is a cross sectional view of the same;FIG. 3 is a perspective view showing Embodiment 2 of the present invention;FIG. 4 is an explanatory view illustrating a process of fabricating the same;FIG. 5 is a perspective view showing Embodiment 3 of the present invention;FIG. 6 is a cross sectional view of the same in use;FIG. 7 is a cross sectional view of a magnetic core in Embodiment 4;FIG. 8 is a perspective view of the magnetic core on which a flat rectangular wire conductor is being wound;FIG. 9 is a perspective of the same;FIG. 10 is a perspective view showing Embodiment 5 of the present invention;FIG. 11 is a cross sectional view of the same;FIG. 12 is a perspective view showing Embodiment 6 of the present invention;FIG. 13 is a cross sectional view of a magnetic core in Embodiment 7;FIG. 14 is a perspective view of the same;FIG. 15 is a perspective view showing Embodiment 8 of the present invention;FIG. 16 is a cross sectional view of the same;FIG. 17 is a perspective view showing Embodiment 9 of the present invention;FIG. 18 is a cross sectional view of the same,FIG. 19 illustrates a magnetic core in the embodiment where FIG. 19 a is a front view andFIG. 19 b is a side view of the same;FIG. 20 is a cross sectional view of a modification;FIG. 21 is a perspective view showing Embodiment 10 of the present invention;FIG. 22 is a cross sectional view of the same;FIG. 23 is a perspective view showing Embodiment 11 of the present invention;FIG. 24 is a cross sectional view of the same;FIG. 25 is an explanatory view illustrating a process of fabricating the same;FIG. 26 is a perspective view showing Embodiment 12 of the present invention;FIG. 27 is a cross sectional view of the same;FIG. 28 is a perspective view showing Embodiment 13 of the present invention;FIG. 29 is a partially omitted perspective view showing Embodiment 14 of the present invention;FIG. 30 is a perspective view showing Embodiment 15 of the present invention;FIG. 31 is a cross sectional view of the same;FIG. 32 is a perspective view of a cylindrical body in the same;FIG. 33 is an explanatory view showing a process of fabricating the same;FIG. 34 is a perspective view of a primary winding in the same;FIG. 35 is an explanatory view of the same;FIG. 36 is a plan view showing Embodiment 16 of the present invention;FIG. 37 is a waveform diagram illustrating an action of the same;FIG. 38 is a schematic circuitry diagram showing a conventional high-voltage generating device;FIG. 39 is a waveform diagram showing an action of the conventional device;FIG. 40 is a schematic circuitry diagram showing Embodiment 17 of the present invention;FIG. 41 is a schematic circuitry diagram of a modification of the same;FIG. 42 is a perspective view showing Embodiment 18 of the present invention;FIG. 43 is an exploded perspective view of the same;FIG. 44 is a perspective view seen from the back of a body of the same;FIG. 45 is a side view of a pulse transformer in the same;FIG. 46 is a schematic view of an electromagnetic device showing Embodiment 19 of the present invention;FIG. 47 is an explanatory view of the shape of recess provided in each end of a magnetic core showing Embodiment 20 of the present invention;FIG. 48 is a view of a magnetic core in an electromagnetic device showing Embodiment 21 of the present invention;FIG. 49 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 22 of the present invention;FIG. 50 is a view of a magnetic core, coil windings, and an insertion molded member in an electromagnetic device showing Embodiment 23 of the present invention;FIG. 51 is a view of a magnetic core, coil windings, and an insertion molded member in an electromagnetic device showing Embodiment 24 of the present invention;FIG. 52 is a schematic view of an electromagnetic device during its production showing Embodiment 25 of the present invention;FIG. 53 is a plan view of the electromagnetic device shown inFIG. 52 :FIG. 54 is a view of a magnetic core and coil windings used for fabricating the electromagnetic device shown inFIG. 52 ;FIG. 55 is a schematic view of the electromagnetic device prior to that shown inFIG. 52 ;FIG. 56 is a plan view of the electromagnetic device shown inFIG. 55 ;FIG. 57 illustrates a perspective view and a partial cross sectional view of an electromagnetic device showing Embodiment 26 of the present invention;FIG. 58 is a plan view of the electromagnetic device-shown inFIG. 57 ;FIG. 59 is an explanatory view showing a process of fabricating the electromagnetic device shown inFIG. 58 from its previous form;FIG. 60 is a view showing a discharge lamp igniter employing the electromagnetic device;FIG. 61 is a view showing an igniter circuit provided in the discharge lamp igniter shown inFIG. 60 ;FIG. 62 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 27 of the present invention;FIG. 63 is a view of a magnetic core and coil windings in an electromagnetic device showing Embodiment 28 of the present invention;FIG. 64 is a view of a welding joiner showing Embodiment 29 of the present invention;FIG. 65 is an exploded perspective view of a prior art;FIG. 66 is a perspective view of the same;FIG. 67 is a cross sectional view of the same;FIG. 68 is a perspective view of a coil bobbin in the same;FIG. 69 illustrates a perspective view and a cross-sectional view of a conventional electromagnetic device;FIG. 70 is an explanatory view showing a process of fabricating a bar-like magnetic core having a bottomed hole provided in each end thereof;FIG. 71 is an explanatory view of the magnetic core shown inFIG. 69 ;FIG. 72 is a perspective view of another conventional electromagnetic device; andFIG. 73 is a perspective view of a conventional welding joiner welded to an insulation coated wire. - An electromagnetic device of this embodiment is a single-winding inductor having a winding wound directly on a rod
magnetic core 3 arranged of substantially a cylindrical shape with no need of an insulator such as a coil bobbin as-shown inFIGS. 1 and 2 . - The
magnetic core 3 is made of an Ni—Zn ferrite material which is high in the resistivity (intrinsic resistance) and about 8 mm in the diameter of its cylindrical shape. The winding is a flat rectangular wire conductor 2 (for example, having a thickness of 70 μm and a width of 1.4 mm) wound in a single layer of edge-wise winding form on substantially the entire length of themagnetic core 3. More specifically, the flatrectangular wire conductor 2 is wound on themagnetic core 3 which is secured at both axial ends to jigs and then rotated by a rotating motion of the jigs. - It is found from examination of the insulation coating (not show) of the flat rectangular wire,
conductor 2 wound on themagnetic core 3 in the inductor of this embodiment that the insulation between the winding (of the flat rectangular wire conductor 2) and themagnetic core 3 and between any two adjacent turns of the winding is highly ensured. Although the insulation between the winding and themagnetic core 3 depends on the resistivity which is one of the insulating properties of themagnetic core 3, it remains explicitly favorable when the resistivity is not smaller than 1000 Ω.m. It is also found that the magnetic and electric properties remain not declined. - As its flat
rectangular wire conductor 2 is directly wound in an edge-wise winding form on themagnetic core 3 made of a high-resistivity material, the inductor eliminates the use of any insulator such as thecoil bobbin 60 between the winding (of the flat rectangular wire conductor 2) and themagnetic core 3 and can thus be minimized in the thickness with its winding reduced in the external dimensions. Also, as the flatrectangular wire conductor 2 is directly wound on themagnetic core 3, its winding can be shortened in the overall length thus declining the level of resistance. Moreover, as the inductor develops no gap between the winding and themagnetic core 3, its self-inductance can comparatively be decreased with the dimensions and the number of windings remaining unchanged. The conventional electromagnetic device having the flat rectangular wire conductor wound in an edge-wise winding form on an insulator such as the coil bobbin develops a gap between the winding and the magnetic core which then makes the relative positional relationship between the winding and the magnetic core unstable, hence creating variations in the properties including the inductance. Because the flatrectangular wire conductor 2 is directly wound on themagnetic core 3 in the embodiment, they are closely secured to each other and their relative position can be, secured thus minimizing variations in the properties. - This embodiment is characterized by a
magnetic core 3 having an elliptical shape in the cross section as shown inFIG. 3 . As the other arrangement is identical to that ofEmbodiment 1, like components are denoted by like numerals and will be described in no more detail (throughout the embodiments and their drawings). - The
magnetic core 3 is made of an Ni—Zn ferrite material identical to that ofEmbodiment 1 but having an elliptical shape in the cross section on which a flatrectangular wire conductor 2 is directly wound in an edge-wise winding form. As itsmagnetic core 3 has an elliptical shape in the cross section, the inductor can be lower in the height than that ofEmbodiment 1. - The
magnetic core 3 has a hemispheric recess (pit) 3 c of about 2 mm in diameter provided at the center in each end thereof. While the flatrectangular wire conductor 2 is being wound on themagnetic core 3 by the action of awinder 4, themagnetic core 3 is secured to the winder with its recess 3 c tightly accepting the-corresponding projection of a jig of the winder. - This will be explained in more detail referring to
FIGS. 4 a to 4 f. Thewinder 4 has a magneticcore holding jig 4 b mounted on a rotary shaft 4 a thereof, as shown inFIG. 4 a. Themagnetic core 3 is then inserted into the center recess of the magneticcore holding jig 4 b and held at its hemispheric recess 3 c engaged with the tip of a center shaft 4 c of thewinder 4. A hold-downjig 4 d is also provided for rotating and sliding motion on and along the center shaft 4 c. The hold-downjig 4 d remains urged by a hold-down spring 4 e so as to hold the flatrectangular wire conductor 2 in the vertical position during the edge-wise winding action. Additionally, a slidable spring support 4 f is provided for loading the flatrectangular wire conductor 2 with substantially a uniform pressure. As a result, themagnetic core 3 is uniformly held along its axis of rotation and its rotation can be stable with minimum of the rotation error derived from its dimensional variations thus ensuring a stability of the winding action. - Then, with the
magnetic core 3 being held by the jigs as shown inFIG. 4 b, the flatrectangular wire conductor 2 is joined at the end to a conductor retainer 4 g on the magneticcore holding jig 4 b as shown inFIG. 4 c. As the rotary shaft 4 a of thewinder 4 starts rotating together with the magneticcore holding jig 4 b, themagnetic core 3, the hold-downjig 4 d, and the center shaft 4 c, the flatrectangular wire conductor 2 is directly wound on themagnetic core 3. As the winding proceeds, an edge-wise winding form of the flatrectangular wire conductor 2 is produced between the magneticcore holding jig 4 b and the hold-downjig 4 d and its width increases. As the width increases, the hold-downjig 4 d and the spring support 4 f are shifted together with the yielding length of the hold-down spring 4 e kept uniform. This allows the flatrectangular wire conductor 2 to remain at its vertical position, hence ensuring a stability of the winding action.FIG. 4 f illustrates the hold-downjig 4 d and the spring support 4 f shifted to the right by a width of the winding. - As described, the inductor having the flat
rectangular wire conductor 2 wound directly on themagnetic core 3 of the elliptical shape in the cross section, like that ofEmbodiment 1, can be minimized in the size, particularly the height and in the inductance variation. - While the flat rectangular wire conductor is directly wound on the core according to
Embodiment 1, the core may be covered with a coating for increasing the level of insulation or protected at the sides (where the flat rectangular wire conductor is wound) with a tape of insulating material. This also allows the flat rectangular wire conductor to be wound by the rotating action of the magnetic core, thus contributing to the small size of the inductor. - This embodiment is characterized by, a
magnetic core 3 having a through hole 3 d provided along the axial direction therein as shown inFIG. 5 . Themagnetic core 3 like that ofEmbodiment 2 is arranged of an elliptical shape in the cross section and its through hole 3 d, of about 2 mm in the diameter extends along the axial direction between two ends thereof. This allows themagnetic core 3 to be securely held by a jig inserting into the through hole 3 d for ease of the winding of the flatrectangular wire conductor 2. In addition, themagnetic core 3 can tightly be secured to ahousing 7 of the winder with its through hole 3 d accepting and engaging with a bar-like projection 7 a extending from thehousing 7, as shown inFIG. 6 . The projection 7 a may be implemented by a retaining screw. Themagnetic core 3 may be arranged of a cylindrical shape similar to that ofEmbodiment 1. - This embodiment is characterized by a
magnetic core 3 having a, pair ofouter flanges 8 provided on both ends thereof to extend outwardly, as shown in FIGS. 7 to 9. Themagnetic core 3 like that ofEmbodiment 2 has an elliptical shape in the cross section and itsouter flanges 8 project from the lengthwise ends radially (outwardly) at substantially a right angle to the lengthwise direction. When wound in an edge-wise winding form, a flatrectangular wire conductor 2 may be loosened out at both ends of themagnetic core 3. This is inhibited by theouter flanges 8 which holds the flatrectangular wire conductor 2 at the two ends. - Also, a plurality (two in this embodiment) of hemispheric recesses 3 c are provided in each end of the
magnetic core 3. During the winding of the flatrectangular wire conductor 2, themagnetic core 3 is tightly secured to the winder with its recesses 3 c accepting and engaging with corresponding projections of awinder 4 which can rotate. This allows the winding of the flatrectangular wire conductor 2 to be more stable than inEmbodiment 2. Themagnetic core 3 may be arranged of a cylindrical shape similar to that ofEmbodiment 1. - This embodiment is characterized by a
magnetic core 3 having a particular shape shown inFIGS. 10 and 11 . The shape of themagnetic core 3 on which a flatrectangular wire conductor 2 is directly wound in an edge-wise winding form becomes smaller in the diameter of the cross section from both lengthwise ends to the center. Accordingly, the outer surface of themagnetic core 3 is sloped down from the two ends to the center and allows the flatrectangular wire conductor 2 to be closely wound without loosening towards the lengthwise ends of themagnetic core 3, thus ensuring a stability of the winding form. Themagnetic core 3 may be arranged of an elliptical shape in the cross section similar to that ofEmbodiment 2. - An electromagnetic device of this embodiment is a two-winding transformer having a primary winding and a secondary winding wound directly on a substantially cylindrical, rod-like
magnetic core 3 thereof, shown inFIG. 12 , with no use of an insulator such as a coil bobbin. - The
magnetic core 3 is substantially identical in the construction to that ofEmbodiment 1 where flat,rectangular wire conductors 2 are wound in an edge-wise winding form on themagnetic core 3 to implement the primary winding 9 and the secondary winding 10. As its primary winding 9 and secondary winding 10 are implemented by the edge-wise winding of the flatrectangular wire conductors 2 directly on themagnetic core 3, the transformer can be decreased in the overall size as compared with the conventional arrangement having the windings wound on the coil bobbin and declined in the direct-current resistance of both the primary winding 9 and the secondary winding 10, hence improving its properties. Also, as the primary winding 9 and the secondary winding 10 are separated from each other along the lengthwise direction of themagnetic core 3, the insulation between them can highly be ensured. Themagnetic core 3 may be arranged of an elliptical shape in the cross section similar to that ofEmbodiment 2. - This embodiment is characterized by a
magnetic core 3 having a particular shape shown inFIGS. 13 and 14 . Themagnetic core 3 has a pair ofouter flanges rectangular wire conductor 2 to be directly wound in an edge-wise winding form between theouter flange 8 a and the partition flange 11 on themagnetic core 3 implementing the primary winding 9 and another flatrectangular wire conductor 2 to be directly wound in an edge-wise winding form between the partition 11 and theouter flange 8 b on themagnetic core 3 implementing the secondary winding 10. - Accordingly, the
outer flanges rectangular wire conductor 2 from being loosened at the two lengthwise ends of themagnetic core 3 while the partition flange 11 provided between the primary winding 9 and the secondary winding 10 on themagnetic core 3 can definitely separate and electrically insulate the twowindings Embodiment 6. Themagnetic core 3 may be arranged of an elliptical shape in the cross section similar to that ofEmbodiment 2. - This embodiment is characterized by a
magnetic core 3 having a particular shape shown inFIGS. 15 and 16 . The shape of themagnetic core 3 comprises two halves separated at substantially the center and each half becomes smaller in the diameter of the cross section from each lengthwise end to an intermediate region. Flatrectangular wire conductors 2 are wound in an edge-wise winding form directly on the two halves of themagnetic core 3 thus implementing the primary winding 9 and the secondary winding 10. Similar toEmbodiment 2, a recess 3 c is provided in each length end of themagnetic core 3. - Each half of the
magnetic core 3 on which the primary winding 9 or the secondary winding 10 is directly wound is sloped down from both ends, the lengthwise end and the center of themagnetic core 3, to the intermediate region. This allows the winding of the flatrectangular wire conductor 2 to be securely wound along the lengthwise direction without loosening outwardly at the two ends. Also, the cross section at the center of themagnetic core 3 between the primary winding 9 and the secondary winding 10 is greater than the halves on which the primary winding 9 and the secondary winding 10 are directly wound, the twowindings Embodiment 6. Themagnetic core 3 may be arranged of an elliptical shape in the cross section similar to that ofEmbodiment 2. - An electromagnetic device of this embodiment is a two-winding transformer having a primary winding and a secondary winding wound directly on a substantially cylindrical, rod-like
magnetic core 3 thereof, shown inFIGS. 17 and 18 , with no use of an insulator such as a coil bobbin. Themagnetic core 3 is made of an Ni—Zn ferrite material and arranged of substantially an elliptical shape, a combination of a rectangular region and two semi-circular regions, in the cross section shown inFIG. 19 . In this embodiment, the diameter of the semi-circular regions is about 6 mm while the length of the rectangular region of the cross section is about 5 mm. Themagnetic core 3 is about 30 mm in the length. Also, a recess 3 c having a diameter of about 2 mm and a depth of about 2 mm is provided in each lengthwise end of themagnetic core 3. - The secondary winding 10 on the
magnetic core 3 is fabricated by providing 220 turns of a flat rectangular wire conductor 2 (e.g. 0.070 mm thick and 1.4 mm wide) directly in an edge-wise winding form. It is found that the direct current resistance of the-secondary winding 10 is substantially 1.8 Ω. As shown inFIGS. 17 and 18 , the primary winding 9 is fabricated by providing 6 turns (3 turns shown inFIGS. 17 and 18 ) of a wire conductor (e.g. 0.2 mm in the wire conductor diameter and 0.51 mm in the overall diameter) substantially between a low-voltage end 10 a of the secondary winding 10 and the lengthwise center of themagnetic core 3 over the secondary winding 10. The wire conductor may be an insulated wire or magnet wire. - Because of the above described arrangement of this embodiment, the primary winding 9 is wound over the secondary winding 10 thus increasing the magnetic coupling between the two
windings previous embodiment windings magnetic core 3. For example, when the primary voltage is 600 V, the pulsed output can be generated a peak value of 30 kV. Also, as the primary winding 9 is located close to the low-voltage end 10 a of the secondary winding 10, it can be separated and insulated by a marginal distance from the high-voltage end 10 b of the secondary winding 10. Moreover, since the primary winding 9 is implemented by the coated wire conductor, the insulation between the twowindings voltage end 10 a of the secondary winding 10 along the lengthwise direction of themagnetic core 3 with equal success, as shown inFIG. 20 . - An electromagnetic device of this embodiment is a two-winding transformer having flat,
rectangular wire conductors magnetic core 3 thereof with no use of an insulator such as a coil bobbin to implement the primary winding 9 and the secondary winding 10 respectively shown inFIGS. 21 and 22 . Themagnetic core 3 is substantially identical in the construction to that ofEmbodiment 1 on which the flatrectangular wire conductor 2 b is directly wound in an edge-wise winding form throughout the length thereof to develop the secondary winding 10. Then, the primary winding 9 is fabricated by winding the flatrectangular wire conductor 2 a in an edge-wise winding from as alternating several turns with the flatrectangular wire conductor 2 b of the secondary winding 10 at a region close to the low-voltage end 10 a of the secondary winding 10 of themagnetic core 3. - As the primary winding 9 and the secondary winding 10 are implemented by the edge-wise winding form of the flat
rectangular wire conductors magnetic core 3, their external dimensions are substantially equal to each other and can thus contribute to the smaller or thinner size of the electromagnetic device than that ofEmbodiment 9. Also, the flatrectangular wire conductor 2 a of the primary winding 9 like the secondary winding 10 is directly wound on themagnetic core 3, the twowindings - This embodiment is characterized by a construction of the-primary winding 9 shown in
FIGS. 23 and 24 . The other arrangement is substantially identical to that ofEmbodiment 9. The primary-winding 9 in this embodiment is fabricated by winding rectangular foils of awire conductor 12 and a rectangular sheet of an insulatingfilm 13 alternately on the secondary winding 10 which has been fabricated by winding a flatrectangular wire conductor 2 in an edge-wise winding form directly on amagnetic core 3. Theconductor foil 12 has a pair ofconductors 12 a provided on both ends of one side thereof which serve as the terminals of the primary winding 9. The process of fabricating the primary winding 9 is now explained in more detail. As shown inFIG. 25 , thewire conductor foil 12 is placed on one end of the insulatingfilm 13 of a rectangular sheet and wound from the other end over the secondary winding 10 provided directly on themagnetic core 3. More specifically, the insulatingfilm 13 is first wound oh the secondary winding 10 and then, thewire conductor foil 12 on the insulatingfilm 13 is wound. Accordingly, theconductor foil 12 is alternated with the insulatingfilm 13. As a result shown inFIG. 24 , thewire conductor foil 12 is wound in a multi-layer form via the insulatingfilm 13 on the secondary winding 10 to implement the primary winding 9. This allows the insulatingfilm 13 to insulate between the primary winding 9 and the secondary winding 10 and simultaneously between the layers of thewire conductor foil 12. The primary winding 9 of this embodiment is provided between a region close to the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of themagnetic core 3. - As its primary winding 9 is fabricated by winding the
wire conductor foil 12 and the insulatingfilm 13, an electromagnetic device of this embodiment can further be decreased in the thickness. Also, as the distance between the primary winding 9 and the secondary winding 10 is minimized, the magnetic coupling between the same can be enhanced thus increasing the efficiency of power transmission and thus producing a higher amplitude of the output voltage. Moreover, as the primary winding 9 is increased in the cross section of the wire conductor, its direct current resistance can be reduced hence producing a greater level of the primary current. - This embodiment is characterized by a construction of the primary winding 9 shown in
FIGS. 26 and 27 . The other arrangement is substantially identical to that ofEmbodiment 9. The primary winding 9 is fabricated by winding a flatrectangular wire conductor 2 in an edge-wise winding form on amagnetic core 3 to develop the secondary winding 10, installing themagnetic core 3 in a substantiallycylindrical insulation casing 14 made of an insulating material, and winding a wire on theinsulation casing 14. Theinsulation casing 14 is sized not shorter than the overall length of themagnetic core 3 to completely enclose themagnetic core 3 and the secondary winding 10 therein. In particular, the primary winding 9 incorporates several turns of the wire (for example, a flat rectangular wire conductor) provided substantially between the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of themagnetic core 3. - Because of the above described arrangement of this embodiment, the
insulation casing 14 can definitely insulate between the primary winding 9 and the secondary winding 10. Also, as the secondary winding 10 is entirely enclosed in theinsulation casing 14, its marginal surface can be protected from dielectric breakdown throughout the length from its high-voltage end 10 b to the primary winding 9. - This embodiment is characterized by a construction of the primary winding 9 shown in
FIG. 28 . The other arrangement is substantially identical to that ofEmbodiment 9. The primary winding 9 is positioned by winding a fusible resin coated wire on the secondary winding 10 and fusing between the coating of a flatrectangular wire conductor 2 of the secondary winding 10 and the resin coated wire of the primary winding 9. - As the two
windings rectangular wire conductor 2 of the secondary winding 10 provided in an edge-wise winding form may be made of a fusible resin material and directly bonded by fusion to themagnetic core 3 for positioning the secondary winding 10. - This embodiment is characterized by a construction of the primary winding 9 shown in
FIG. 29 . Amagnetic core 3 is provided withleads 16 of thin metal strips fabricated by insertion forming, arranged on which a flatrectangular wire conductor 2 is wound in an edge-wise winding from to develop the secondary winding 10, and installed in the interior 15 a of asynthetic resin casing 15. Each pair of theleads 16 provided on both sides of themagnetic core 3 are bridged at their distal end by a thin metal lead strip 17. As the lead strip 17 is joined at both ends to the distal ends of the paired leads 16, they extend about the secondary winding 10 as serving as the primary winding 9 (its two turns only shown in the drawing). This arrangement can contribute to the smaller size or the lower dimension of the electromagnetic device (a transformer) of this embodiment. - In
Embodiment 9, the primary winding 9 is implemented by the coated wire of which the overall diameter is set to substantially five times greater than the diameter of its wire conductor because of a point of view that a dielectric breakdown between the primary winding 9 and the secondary winding 10 possibly occurs at the marginal surface close to the high-voltage end 10 b of the secondary winding 10. However, when the coated wire of such a greater diameter is used, a resultant electromagnetic device (a transformer) becomes greater in dimensions thus interrupting the reduction of the overall size. Also, as the coated wire is round in the cross section, it may hardly be positioned on the secondary winding 10 and, if worse, may be wound to a greater thickness. While the diameter of the wire of the primary winding 9 inEmbodiment 12 is successfully decreased, the overall dimensions of the electromagnetic device (transformer) become greater due to the size of theinsulation casing 14 and may be increased in the number of components or assembled with much difficulty. - This embodiment is an electromagnetic device (a transformer) comprising a primary winding
assembly 18 including the primary winding 9 with insulators and amagnetic core 3 having a flatrectangular wire conductor 2 wound in an edge-wise winding form thereon and coupled to the primary windingassembly 18, as shown inFIGS. 30 and 31 . While this embodiment is characterized by the installation of the primary winding 9, its other arrangement is identical to that ofEmbodiment 9. - The primary winding
assembly 18 includes a substantiallycylindrical housing 19 of an insulating resin material (a first insulating material) arranged of an elliptical shape in the cross section as shown inFIG. 32 . Thehousing 19 is made of a thermoplastic resin material such as poly-ether-imide and has several turns of agroove 19 a provided circumferentially in the outer surface thereof for holding the primary winding. Also, thehousing 19 has a couple of lengthwisely extendingprojections 19 c provided thereon, each projection having agroove 19 b provided thereon for accepting each end of the primary winding. - When an electrically
conductive resin 21 which is highly flowable is poured into thegroove 19 a of thehousing 19 installed in a set ofmolds 20 shown inFIG. 33 , it easily runs from thegroove 19 a to thegrooves 19 b. As itsresin 21 is completely cured, the primary winding 9 is shaped extending along thegrooves housing 19. - As the
housing 19 with the primary winding 9 is entirely covered with a synthetic resin (a secondary insulating material, e.g. poly-ether-imide identical to the material of the housing 19) but its two lengthwise end openings remaining open, the primary windingassembly 18 containing thehousing 19 covered with the secondary insulating material of ashape 22 is completed. - Finally, as the
magnetic core 3 with the secondary winding 10 is installed in thehousing 19 of the primary winding-assembly 18 and the primary winding 9 is connected at both ends toterminal strips 23, the electromagnetic device (a transformer) of this embodiment is completed (SeeFIGS. 30 and 31 ). The primary windingassembly 18 is arranged extending substantially between the low-voltage end 10 a of the secondary winding 10 and the lengthwise center of themagnetic core 3. - Because of the above arrangement of this embodiment, the insulation between the primary winding 9 and the secondary winding 10 can be implemented by the primary winding
assembly 18. Since the secondary insulating material of theshape 22 encloses thehousing 19 on which the primary winding 9 has been developed with the electricallyconductive resin material 21, it can favorably insulate the primary winding 9 from the high-voltage end of the secondary winding 10. Also, as the primary winding 9 is fabricated by filling thegrooves housing 19 with the highly flowable electricallyconductive resin material 21 with no need of the conventional step for winding a wire to develop the primary winding 9, its assembling process can be facilitated thus improving the overall productivity. As its dimensional properties remain free from unwanted variations which are pertinent to the coated wire and its winding exhibits a minimum of winding faults, the primary winding 9 can be small or thin. As a result, the electromagnetic device can hence be minimized in the overall size or thickness. - While the
magnetic cores 3 of this embodiment and theprevious embodiments 1 to 14 are made of a bar-like ferrite material and polished at the surface, they may not be polished but remain rough. In the latter case, the surface roughness or mathematical average roughness (Ra) of themagnetic core 3 can preferably be 0.8 μm or greater. This eliminates the step of polishing themagnetic core 3 and can hence reduce the production cost of themagnetic core 3. In case that the surface roughness of themagnetic core 3 is declined, it may cause the flatrectangular wire conductor 2 to be slipped down and fractured during the edge-wise winding as shown inFIG. 35 . When themagnetic core 3 remains rough at the surface, it can inhibit the flatrectangular wire conductor 2 from being fractured thus permitting ease of the edge-wise winding. - Prior to the description of this embodiment, a circuitry arrangement in the conventional high-voltage generating device will be explained referring to
FIG. 38 . The conventional device acts as an igniter for supplying a high intensity discharge lamp Lp with a pulsed high voltage and comprises a pair of input ports T1 and T2 for receiving the high voltage, a pair of output ports T3 and T4 connected to the high intensity discharge lamp Lp, a pulse transformer PT of which the secondary winding is connected between the input port T1 and the output port T3 at the high voltage side and the primary winding is connected between the two-input ports T1 and T2, a switching element SW connected between the low voltage side of the primary winding of the pulse transformer PT and the input port T2 at the lower voltage side, a resistor R1 connected between the input port T1 at the high voltage side and the high voltage side of the primary winding of the pulse transformer PT, and a capacitor C1 connected in parallel with both the primary winding of the pulse transformer PT and the switching element SW. In action of the conventional device, a voltage input received by the two inputs T1 and T2 while the high intensity discharge lamp Lp is not lighted is passed via the resistor R1 to the capacitor C1 which is thus charged. When the voltage at both ends of the capacitor C1 is increased to a given level, it turns the switching element SW on. This allows the power to be discharged from the capacitor C1 and transmitted via the switching element SW to the primary winding of the pulse transformer PT which then generates a pulsed high voltage at its secondary winding. The pulsed high voltage is then received by the high intensity discharge lamp Lp which in turn creates dielectric breakdown. -
FIG. 39 illustrates an exemplary waveform of the pulsed high voltage output of the conventional device where a high frequency component is superimposed on the waveform of a resonant voltage generated by the action of the capacitor C1 at the primary winding of the pulse transformer PT and boosted by the pulse transformer PT. This may result from the effect of any parasitic capacitance since the pulse transformer PT is not of an ideal form. It is however essential for allowing the high intensity discharge lamp Lp to start a dielectric breakdown promptly that the waveform of the pulsed high voltage is as close to its fundamental form as possible without the effect of the high frequency component. Also, when the voltage output of the conventional device is rapidly settled down to zero in the amplitude, its stressing effect on the components including the capacitor C1 can be minimized. As a result, the components of the circuitry arrangement- to be employed can be eased in the resistance to high voltage and thus reduced in both the size and the price. - The high-voltage generating device of this embodiment has a couple of metal strips 24 provided adjacent to both ends of the
magnetic core 3 in a pulse transformer PT as shown inFIG. 36 , thus minimizing the oscillation of the high frequency component. More specifically, themagnetic core 3 is magnetically open at both ends. When the magnetic flux leaked from the two ends of themagnetic core 3 and passed across the metal strips 24 is varied by the effect of the high frequency oscillation, it generates an eddy current on the metal strips 24. As a result, the eddy current loss will occur and offset the high frequency oscillation. The pulse transformer PT in this embodiment is implemented by the electromagnetic device (a transformer) of any ofEmbodiments 6 to 15. - As described, the high voltage waveform supplied to the high intensity discharge lamp Lp can be corrected to close to the fundamental form shown in
FIG. 37 with its high frequency component successfully offset by the eddy current loss created on the metal strips 24. Also, as the oscillation of the voltage output is rapidly reduced to zero, its stressing effect on the components including the capacitor C1 can be minimized. This allows the components to be used which are eased in the resistance to high voltage and thus decreased in both the size and the price. The metal strips 24 may be replaced by leads which are provided for electrically connecting between the components and located adjacent to both ends of themagnetic core 3 of the pulse transformer PT. As a result, the components to be used can be reduced in the total number and their arrangement can be simplified. - This embodiment is characterized by a high-voltage generating device where the primary winding of a pulse transformer PT is connected in parallel with a resistor Ra as shown in
FIG. 40 . The other arrangement is substantially identical to that of the conventional device shown inFIG. 38 . The high frequency oscillation can thus be offset by the loss created in the resistor Ra which is connected in parallel with the primary winding. For providing the same effect, the primary winding of the pulse transformer PT may be connected in series with a resistor Rb as shown inFIG. 41 . - This embodiment is characterized by a high-voltage generating device where a high intensity discharge lamp Lp is provided integral with a socket which is arranged detachable as shown in
FIG. 42 . The high-voltage generating device of this embodiment comprises amain assembly 30 made of a synthetic resin material and ashield cover 50 covering the back and lateral sides, but not the front side, of themain assembly 30 as best shown inFIG. 43 . Themain assembly 30 includes abody 31 containing major components including the pulse transformer PT described withEmbodiment 16, acover 32 covering the front side of thebody 31, and alid 33 closing the rear side of thebody 31. - The
cover 32 has asocket opening 34 of substantially a round shape provided in the front side thereof and a group ofbayonet stoppers 35 provided on the circumferential edge about the socket opening thereof. Thestoppers 35 are formed integral with the circumferential edge about thesocket opening 34 and provided in the form of notches opening towards the center. More particularly, thestopper 35 is an L shaped recess comprising avertical groove 35 a for accepting each engaging tab (not shown) provided on the outer surface of a base of the high intensity discharge lamp Lp which is inserted from the front to the back in thesocket opening 34 and ahorizontal groove 35 b continuously communicated with thevertical groove 35 a. In addition, thestopper 35 has a stopper recess 35 c provided in the innermost thereof for holding the engaging tab at the engaging position. - The
body 31 includes a substantiallycylindrical tube 36 accommodated in thesocket opening 34 of thecover 32 and an engagingprojections 38 provided thereon for engaging with engagingslots 37 provided in the lateral side of thecover 32. As thecover 32 is placed over the front side of thebody 31, its engagingprojections 38 come into engagement with the corresponding engagingslots 37. As a result, thebody 31 and thecover 32 are joined together with itstube 36 accommodated in the socket opening 34 (SeeFIG. 42 ). Thebody 31 also has acenter tube 39 of substantially a cylindrical shape provided upright in the center of thetube 36 and acenter electrode 40 provided in thecenter tube 39 for direct contact with a center electrode (not shown) of the discharge lamp base. Also, a group of-outer electrodes 41 are provided on thetube 36 for direct contact with corresponding outer electrodes (not shown) mounted on the outer side of the lamp base. When thebody 31 and thecover 32 are joined together,contacts 41 a of theouter electrodes 41 of itstube 36 come to face the inner side about thesocket opening 34 of thecover 32. More particularly, when the lamp base is inserted into thesocket opening 34 of thecover 32, its engaging tabs move into thevertical grooves 35 a of thestoppers 35. As the lamp base is twisted, its engaging tabs move into thehorizontal grooves 35 b and finally come in direct engagement with the corresponding stopper recesses 35 c. Simultaneously, the center electrode of the lamp base is inserted into thecenter tube 39 to come into direct contact with thecenter electrode 40. Also, the outer electrodes of the lamp base come into direct contact with the correspondingcontacts 41a of theouter electrodes 41 about thesocket opening 34 of thetube 36. As a result, the high intensity discharge lamp Lp is coupled to the high-voltage generating device of this embodiment electrically and mechanically. - The
body 31 also has afirst component recess 42 provided in the front side thereof for accommodating the circuitry components including a resistor Ri and a capacitor C1. As best shown inFIG. 44 , thebody 31 has atransformer recess 43 provided in the back side thereof for accommodating a pulse transformer PT. The pulse transformer PT is identical in the construction to the electromagnetic device (a transformer) ofEmbodiment 9, having a flatrectangular wire conductor 2 wound in edge-wise winding form on a rod-likemagnetic core 3 of substantially a cylindrical shape in the cross section to implement the secondary winding 10 and substantially six turns of a wire provided on the secondary winding 10 to implement the primary winding 9, as shown inFIG. 45 . - The
lid 33 has a group of engagingslots 45 provided in acircumferential wall 33 a thereof for engagement with corresponding engagingprojections 44 provided on the outer surface of thebody 31. When thelid 33 is placed over the back side of thebody 31, its engagingslots 45 come to accept the corresponding engagingprojections 44. As thebody 31 is coupled with thelid 33, it can be closed up at the back side with thelid 33. - The
shield cover 50 is a box shape of an electrically conductive magnetic material having one side opened. Theshield cover 50 has afitting slot 47 provided in a circumferential wall thereof for engagement with afitting projection 46 provided on the outer side of thecover 32. When themain assembly 30 consisting mainly of thebody 31, thecover 32, and thelid 33 is inserted from the back into theshield cover 50, thefitting projection 46 of itscover 32 comes in engagement with thefitting slot 47 thus coupling the main assembly 30-with theshield cover 50. - As the pulse transformer PT in the
main assembly 30 is accommodated in thebody 31 with itsmagnetic core 3 facing at both ends the inner side of theshield cover 50, itsmagnetic core 3 of themain assembly 30 when coupled to theshield cover 50 develops a closed magnetic circuit together with theshield cover 50. Because themain assembly 30 is protected with theshield cover 50 and its pulse transformer PT allows themagnetic core 3 to develop the closed magnetic circuit together with theshield cover 50, any noise generated and emitted from the high-voltage generating device can favorably be attenuated and simultaneously the (high voltage) output- of -the pulse transformer PT can be increased. Also, the device itself can be minimized in the overall size or thickness. The shield cover 50 of this embodiment also acts as the metal strips 24 ofEmbodiment 16. As the metal strips 24 are not needed, the components can thus be decreased in the total number and their arrangement can be simplified. -
FIG. 46 is a construction view of an electromagnetic device of this embodiment andFIG. 47 is an explanatory cross sectional view showing the shape of a recess provided in themagnetic core 3 shown inFIG. 46 . The electromagnetic device shown inFIG. 46 comprises the rod-likemagnetic core 3 having an intrinsic resistance of not smaller than 103 Ωm a coil winding 2 provided on themagnetic core 3 by winding a flat rectangular wire in an edge-wise winding form with no use of a bobbin as the insulator, a coil winding 1 of an insulator coated wire (acting as the primary winding 9) provided directly over the coil winding 2, aresin casing 5 arranged for accommodating those components, and a group ofterminals 6 extending outwardly from thecasing 5 and connected to the coil windings. - As the
coil windings magnetic core 3 with no use of the bobbin, theterminals 6 of this embodiment are joined with non of the bobbin. This embodiment allows theterminals 6 to be connected together by ahoop material 60 as shown inFIG. 46 c. As apparent, theterminals 6 joined to thehoop material 60 are connected to the corresponding coil windings. Since theterminals 6 are drawn out in one direction as shown inFIG. 46 a, thehoop material 60 can be arranged of a simpler shape. Even if thecasing 5 is made by filling or molding of a resin material for giving the electrical insulation as shown inFIG. 46 b, theterminals 6 are aligned in a row and they can thus be joined to the corresponding coil windings with much ease at the succeeding step. - Referring to
FIG. 47 , this embodiment allows amagnetic core 3 to have a recess 3 c provided in each end thereof defining a bottom 3c 2. The recess 3 c is arranged to have a tapered shape which becomes smaller in the diameter from an opening 3 c 1 to the bottom 3c 2. In production, themagnetic core 3 is supported by not a rod jig shown inFIG. 70 but a rod K having a tapered projection K1. As themagnetic core 3 is removed and tilted down about the corner point P1 of the rod K, its bottom edge portion about the opening 3c 1 of the recess 3 c can successfully clear the projection K1 of the rod K where the radius of the movement of the edge portion P2 at the recess 3 c of themagnetic core 3 about the point P1 is slightly greater than the distance from the projection point P3 of the edge of the projection K1 to the corner point P1 of the rod K. This inhibits any undesired tipping off at the edge about the recess 3 c of the bottom of themagnetic core 3. -
FIG. 48 a illustrates the magnetic core of an electromagnetic device of this embodiment. Themagnetic core 3A of the electromagnetic device has a recess 3 c provided in each end thereof which is identical to that of the previous embodiment and is arranged of an elliptical shape in the cross section. The other arrangement is identical to that of the previous embodiment. As itsmagnetic core 3A is rather flat in the shape, the electromagnetic device can be implemented as a thin transformer. Also, the recess 3 c has a tapered shape as described. As themagnetic core 3A is elliptical in the cross section, it may hardly be tilted down in a direction denoted by the arrow shown inFIG. 48 b but easily fallen in another direction denoted by the arrow shown inFIG. 48 c. It is hence understood that the tapered effect may be provided in the recess 3 c only along the direction orthogonal to the lengthwise direction of themagnetic core 3A for inhibiting any undesired tipping off. -
FIG. 49 illustrates an electromagnetic device of this embodiment having a magnet core and a group of coil windings. The electromagnetic device is differentiated from that ofEmbodiment 19 by the fact that the coil winding 1 wound on the coil winding 2 has twoleads magnetic core 3. Accordingly, the coil winding 2 can be increased in the number of turns without decreasing the cross sectional size. The electromagnetic device is hence used as a small sized, high-voltage transformer which can easily produce a high voltage of, for example, several to tens kilovolts across its secondary winding 2 when the coil winding 1 is loaded as the primary winding with a voltage of hundreds bolts to a few kilovolts. In that case, the magnetic circuit of thecoil windings magnetic core 3. - It is known that the open circuit allows the coupling between the primary and secondary windings to be more increased when the coil winding 1 is located as the primary winding on the center of the
magnetic core 3 than on either end of the same. The coil winding 1 shown inFIG. 46 is biased towards the center of the coil winding 2 and more particularly located leftwardly of the center of the coil winding 2 of which theright lead 2R acts as a high-voltage end. The location of the coil winding 1 leftwardly of the center of the coil winding 2 is based on the following reason. As shown inFIG. 46 a, the potential between 2R and 1L (1R ) is as high as several to tens kilovolts while the potential between 2L and 1L (1R ) ranges from hundreds volts to a few kilovolts. Also, as the joint between the lead of each coil winding and theterminal 6 is implemented by an uncovered metal-joint, it may trigger dielectric breakdown when a gap is generated between the resin material housing and the high-voltage transformer. For inhibiting any dielectric breakdown, the distance between 2R and 1L (1R ) is enlarged. - When the coil winding 1 is located on the
lead 2L of the coil winding 2, the protection from dielectric breakdown can be enhanced but the coupling between the primary and secondary windings will be declined thus lowering the level of the high-voltage output at the secondary winding. For compensation, the coil winding 1 of this embodiment is slightly biased towards the center of the coil winding 2 to guarantee the coupling between the primary and secondary windings as shown inFIG. 49 while its twoleads voltage end 2L of the coil winding 2. This allows the high-voltage transformer to be improved in the resistance to dielectric breakdown while ensuring the coupling between the primary and secondary windings. -
FIG. 50 illustrates an electromagnetic device of this embodiment having a magnetic core, a group of coil windings, and an insertion molded member. The electromagnetic device is differentiated from the previous one by the fact that thecasing 5 is replaced by an insertion moldedmember 5A for drawing the leads of thecoil windings magnetic core 3A has an elliptical shape in the cross section as shown inFIG. 50 a, the electromagnetic device of this embodiment can be used as a thin transformer. - While the
leads voltage end 2L of the coil winding 2 in the previous embodiment, thelead 1R of the coil winding 1 of this embodiment close to the high-voltage end 2R of the coil winding 2 only is biased towards one particular end of themagnetic core 3A where the low-voltage end 2L of the coil winding 2 is located. This arrangement will also improve the insulation function. More particularly, the two leads of the coil winding 2 are drawn out along the thin side of themagnetic core 3A. This allows the insertion moldedmember 5A to remain minimum in the thickness as shown inFIG. 50 b. Also, the two leads 2L and 2R of the coil winding 2 are located diagonal to each other so as to be distanced maximum from each other. - As shown in
FIG. 50 b, the insertion moldedmember 5A has a set ofgrooves 51A provided circumferentially in the outer sides thereof between the high-voltage end 2R and theother end 2L (1L and 1R ). As thegrooves 51A extend throughout the outer sides of the insertion moldedmember 5A to form a series of peaks and valleys on the surfaces. Accordingly, the surface (interface) distance between the high-voltage end 2R and theother end 2L. (1L and 1R ) on the insertion moldedmember 5A can be elongated. As a result, the insulation function between the oneend 2R and theother end 2L (1L and 1R ) can be improved thus allowing the small sized transformer to be easily fabricated having a higher level of the insulation. -
FIG. 51 illustrates an electromagnetic device of this embodiment having a magnetic core, a group of coil windings, and an insertion molded member. The electromagnetic device is similar to that of the previous embodiment, except that the insulation coated coil winding 1 is replaced by a coil winding 1A of a single wire with abobbin 40 having a pair ofterminals 41 and serving as the insulation coating, the coil winding 1A wrapped up at both ends with the pairedterminals 41 of thebobbin 40. In this arrangement, while thebobbin 40 can increase the insulation function between the primary winding and the secondary winding, the connection between its pairedterminals 41 and the coil winding 1A can be facilitated. The coil winding 1A is fabricated by the single wire of a low price, not the high-voltage insulation coated wire which is relatively high in the cost, thus contributing to the low price of a resultant high-voltage transformer. -
FIG. 52 is a schematic view of an electromagnetic device of this embodiment at a step of its production.FIG. 53 is a plan view of the electromagnetic device shown inFIG. 52 ,FIG. 54 is a perspective view of a magnetic core and coil windings used in the electromagnetic device shown inFIG. 52 ,FIG. 55 is a schematic view of the electromagnetic device at a production step prior to the step ofFIG. 52 , andFIG. 56 is a plan view of the electromagnetic device shown inFIG. 55 . The process of fabricating the electromagnetic device prior to the steps ofFIGS. 52 and 53 . As shown inFIG. 54 , the coil windings 1.and 2 are provided on themagnetic core 3A of an elliptical shape in the cross section with no use of an insulator to develop a first intermediate product. More specifically, the coil winding 2 is fabricated by winding a flat rectangular wire in an edge-wise winding form on the outer side of themagnetic core 3A and then the coil winding 1 is provided on a predetermined location of the coil winding 2. - This is followed, as shown in
FIGS. 55 and 56 , by connecting ends of thecoil windings corresponding terminals 6 of alead frame 60A made of a single metallic strip to develop a second intermediate product. The second intermediate product is then placed in a set of unshown molds which are in turn filled with a thermoset resin material such as unsaturated polyester (by injection molding). As a result, a third intermediate product is given having thelead frame 60A joined with an insertion moldedmember 5B as shown inFIGS. 52 and 53 . The above injection molding process can reduce the conventional vacuum filling process, which takes four or more hours, to as short as two minutes. Also, as the electromagnetic device employs a case-less arrangement, its overall dimensions can significantly be decreased. -
FIG. 57 illustrates a perspective view and a partially cross sectional view of an electromagnetic device of this embodiment.FIG. 58 is a plan view of the electromagnetic device shown inFIG. 57 andFIG. 59 is an explanatory view showing steps of shifting the electromagnetic device from an intermediate form to a finished form shown inFIG. 58 . Particularly in this embodiment, the third intermediate product of the previous embodiment is provided with thecoil windings corresponding terminals 6 of thelead frame 60A and then, the redundancy of thelead frame 60A is removed off for electrical isolation from the ends of thecoil windings FIG. 59 a is given. Then, theterminals 6 are folded down in their respective directions (for a desired pattern) as shown inFIG. 59 b, completing the electromagnetic device of this-embodiment shown inFIGS. 57 and 58 . - As shown in
FIG. 57 a, there are a group ofgrooves 51B provided between the terminal 6 (2R ) and the other terminals 6 (1L, 1R ) in one side of the insertion moldedmember 5B, the terminal 6 (2R ) connected with the high-voltage end 2R of the coil winding 2 and the terminals 6 (1L, 1R) connected with the two ends 1L and 1R of the coil winding 1. As the insertion moldedmember 5B has a series of peaks and valleys on the surface, its surface distance is between the two ends thus improving the insulation function and inhibiting any current leakage. Thegrooves 51B are of no limitations and may be replaced by a row of projections. Denoted by 50B inFIG. 57 b is a filling material of the insertion moldedmember 5B. - The electromagnetic device of this embodiment fabricated by the above manner is preferably used in a discharge lamp igniter which supplies a discharge lamp La as the headlight of vehicle with power and holds it at its lighting condition as shown in
FIG. 60 . The discharge lamp igniter includes a starter (igniter) circuit IG for feeding the discharge lamp La with a pulsed high voltage for illumination, as shown inFIG. 61 . The igniter circuit IG is driven by an inverter INV. The electromagnetic device is installed at a region R2 in the igniter circuit IG denoted by the dotted line inFIG. 61 and its insertion moldedmember 5B made of a thermoset resin material is also protected with an enclosure of thermoplastic resin material (to form a double insulation). The electromagnetic device with itsterminals 6 exposed to the outside is covered with the thermoplastic resin enclosure. Because of the double insulation, the electromagnetic device is almost thoroughly protected by the thermoplastic resin except its terminals and can thus be improved in the insulation distance and the moisture-proof function. Also, thegrooves 51B extending from one end to the other end of one side of the insertion moldedmember 5B can serve as passages for positively distributing flows of the thermoplastic resin material during the molding process, hence promoting the flowability of the thermoplastic resin material in molten form. -
FIG. 62 illustrates an electromagnetic device of this embodiment having a magnetic core and a group of coil windings. The electromagnetic device is modified in which the coil winding 1 of an insulation coated wire is replaced by a fusible coil winding 1B. The process of fabrication starts with winding a flat rectangular wire in an edge-wise winding, form on the outer surface of themagnetic core 3 to develop the coil winding 2. Then, an UV curable adhesive is applied to two regions R3 and R4 and cured by irradiation of UV light. This is followed by winding a fusible wire on a predetermined region of the coil winding 2 to develop the coil winding 1B and energizing and fusing the coil winding 1B for bonding with the coil winding 2. As understood, the process can easily be carried out. Also, as its two ends are bonded by the adhesive to the side of themagnetic core 3, the coil winding 2 can hardly be detached by its spring-back effect. -
FIG. 63 illustrates an electromagnetic device of this embodiment having a magnetic core and a coil winding. The electromagnetic device is substantially identical in the construction to that ofEmbodiment 1 except that the coil winding 2 excluding its two ends is almost entirely covered with a thin coating C. When themagnetic core 3 is decreased in the diameter for downsizing, the coil winding 2 provided in an edge-wise winding form on themagnetic core 3 becomes smaller in the curvature radius and its coating may easily be torn off thus causing short-circuit between two adjacent turns of the coil winding 2. In this embodiment, after provided in an edge-wise winding form on themagnetic core 3, the coil winding 2 is protected with the thin coating C. This can inhibit unwanted short-circuit between any two turns of the coil winding 2. -
FIG. 64 a illustrates an electromagnetic device of this embodiment havingwelding joiners 70. Thewelding joiner 70 is joined to one end of an insulation coatedwire 8 of the primary winding and used as aterminal 6 of the electromagnetic device. Thewelding joiner 70 is arranged of a foldable shape comprising aflat base portion 71 extending in one direction, a foldedportion 72 extending from one side at a right angle to the one direction, and an extendingportion 73 allowing the foldedportion 72 to face theflat portion 71. Also, a tab-like portion is provided extending from the other side than the foldedportion 72 side of thebase portion 71 and bent upwardly, thus acting as apositional error inhibitor 74. The length of the positionalerror inhibitor portion 74 from theflat portion 71 is equal or slightly greater than the diameter of the insulation coatedwire 8. Particularly, the positionalerror inhibitor portion 74 is located as spaced from the foldedportion 72. - The
welding joiner 70 is securely coupled to the insulation coatedwire 8 when pressed and welded betweenwelding electrodes 78 as shown inFIG. 64 b, thus holding but not detaching from the insulation coatedwire 8 and giving the joint of improved stability and durability. Also, as its length from thebase portion 71 is equal or slightly greater than the diameter of the insulation coatedwire 8, the positionalerror inhibitor portion 74 of thewelding joiner 70 can certainly inhibit any further dislocation of the insulation coatedwire 8. Accordingly, no detachment of the insulation coatedwire 8 from thewelding joiner 70 will be allowed. Moreover, as the positionalerror inhibitor portion 74 is spaced by a distance from the foldedportion 72, any short-circuit between the positionalerror inhibitor portion 74 and-the foldedportion 72 will be disallowed. This allows the extendingportion 73 to emit a degree of Joule heat generated by the application of welding energy and transferred from the foldedportion 72 thus fusing and removing the insulation coating of thecoated wire 8. - Industrial Utilization
- As set forth above, the electromagnetic device, the high-voltage generating device, and the method for fabricating the electromagnetic device according to the present invention are favorably applicable to and can contribute to the reduction of the size or thickness of a pulse transformer also called an igniter for starting a common high intensity discharge lamp.
Claims (15)
1. An electromagnetic device comprising a magnetic core having a curved side and a flat rectangular wire conductor wound in an edge-wise winding form directly on the curved side of the magnetic core, the magnetic core having an intrinsic resistance of not smaller than 1000 Ω●m.
2. The electromagnetic device according to claim 1 , further comprising a winding provided on the outer surface of the flat rectangular wire conductor.
3. The electromagnetic device according to claim 1 , wherein the magnetic core includes a rough finished surface.
4. The electromagnetic device according to claim 2 , wherein the flat rectangular wire conductor and the winding are joined to each other by fusing their coatings.
5. The electromagnetic device according to claim 2 , wherein the magnetic core of an edge-wise winding form of the flat rectangular wire conductor is located between a group of leads joined together.
6. The electromagnetic device according to claim 2 , further comprising a first insulating member of a cylindrical shape to which the magnetic core of the flat rectangular wire conductor is fitted and a secondary insulating material covering the first insulating member and the winding which is made of an electrically conductive resin material and provided on the outer side of the first insulating member.
7. The electromagnetic device according to claim 6 , wherein the first insulating member has a groove provided in the outer side thereof and the winding is fabricated by filling the groove with an electrically conductive resin material.
8. The electromagnetic device according to claim 2 , wherein the flat rectangular wire conductor serves as a secondary winding and the winding serves as a primary winding.
9. The electromagnetic device of claim 1 having a transformer arrangement in which the core includes a bar-like magnetic core and the flat rectangular wire conductor wound on the outer surface of the magnetic core is for generation of a high voltage, the flat rectangular wire conductor being drawn out at both ends from two ends of the magnetic core respectively, wherein a resin outer housing is provided about the transformer by one of filling and molding an insulating resin material and having at least one side thereof configured along a direction substantially parallel with the axial direction of the magnetic core.
10. The electromagnetic device of claim 1 having a transformer arrangement which includes the magnetic core, a winding and the flat rectangular wire conductor both provided on the magnetic core, and at least two terminals for connection of the winding and the flat rectangular wire conductor with the outside, wherein the transformer is sealed in an injection molded form of a thermoset resin material.
11. The electromagnetic device according to claim 10 , wherein the thermoset resin material is covered with a molded form of a thermoplastic resin material.
12. The electromagnetic device according to claim 10 , wherein the winding and the flat rectangular wire conductor are secured, at least at one end with an adhesive, to a side of the magnetic core.
13. The electromagnetic device according to claim 10 , wherein while the winding acts as a primary winding, the flat rectangular wire conductor acts as a secondary winding and is insulated by coating and provided in an edge-wise winding form on the magnetic core.
14. A method for making the electromagnetic device of claim 1 comprising:
winding the flat rectangular wire conductor in the edge-wise winding form on the magnetic core; and
fixedly joining ends of the flat rectangular wire conductor provided in the edge-wise winding form to corresponding terminals that are provided integrally on a single metal strip.
15. The method for making an electromagnetic device according to claim 14 , wherein the metal strip is arranged of a linear form to which the ends of the flat rectangular wire conductor are joined as drawn out in one direction towards the metal strip.
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US11/009,152 US20050104698A1 (en) | 2000-09-14 | 2004-12-13 | Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device |
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JP2000280666A JP3777962B2 (en) | 2000-09-14 | 2000-09-14 | Electromagnetic device and high voltage generator |
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US10/129,105 US7142082B2 (en) | 2000-09-14 | 2001-09-14 | Electromagnetic device and high-voltage generating device and method of producing electromagnetic device |
US11/009,152 US20050104698A1 (en) | 2000-09-14 | 2004-12-13 | Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device |
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US11/009,152 Abandoned US20050104698A1 (en) | 2000-09-14 | 2004-12-13 | Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device |
US11/548,353 Expired - Fee Related US7394340B2 (en) | 2000-09-14 | 2006-10-11 | Electromagnetic device, high-voltage generating device, and method for making the electromagnetic device |
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US20100188180A1 (en) * | 2007-06-19 | 2010-07-29 | Sumida Corporation | Magnetic element, and antenna device using the magnetic element |
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Also Published As
Publication number | Publication date |
---|---|
EP1324357A4 (en) | 2008-10-22 |
US7394340B2 (en) | 2008-07-01 |
AU2001286255A1 (en) | 2002-03-26 |
US20070132535A1 (en) | 2007-06-14 |
CN1181509C (en) | 2004-12-22 |
US20020180572A1 (en) | 2002-12-05 |
CN1393020A (en) | 2003-01-22 |
US7142082B2 (en) | 2006-11-28 |
WO2002023561A1 (en) | 2002-03-21 |
EP1324357A1 (en) | 2003-07-02 |
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