WO2004055840A1

WO2004055840A1 - Coil unit and compound coil unit

Info

Publication number: WO2004055840A1
Application number: PCT/JP2003/015930
Authority: WO
Inventors: Ichiro Tatsusawa; Takaaki Cyuzawa
Original assignee: Matsushita Electric Works, Ltd.
Priority date: 2002-12-13
Filing date: 2003-12-12
Publication date: 2004-07-01
Also published as: AU2003289050A1

Abstract

A coil unit and a compound coil unit, the production process of which can be simplified for reduced production costs and which are resistant to vibration and highly reliable. In the coil unit, electric wires (21) with a substantially letter-U shape are embedded in an insulating body (22) such that they are spaced from each other and that an end portion of each wire is exposed as a terminal portion (21a). A leg portion of the insulating body (22) with a substantially letter-U shape is inserted in a core (24) of a magnetic body. Winding wires can be formed by connecting the terminal portions (21a) with connection members.

Description

Technical field of coil units and composite coil units

The present invention relates to a coil unit and a composite coil unit. Background art

Figures 57 and 58 show conventional toroidal choke coils. Here, the toroidal choke coil refers to a core 100 or 101 having a closed magnetic path and a winding 102 wound around the core. The core shape may be a cylindrical shape, a letter or a rectangular parallelepiped shape, and the hole may be a round hole or a square hole.

The pore radius a of the toroidal core can be obtained by the following equation (1) from the NI value in consideration of the saturation caused by the current I and the number of turns N. (B: magnetic flux density, ίΐ: magnetic permeability) Ν I = (Β Χ 27Τ Χ a) / ιι · · · (1)

The NI value indicates that, for example, if NI = 40, if the current I is 2 OA, the number of turns N can be up to 2 turns, and the hole radius a at that time is NI> 40 or more according to equation (1). It is sufficient to ask for

In recent years, in-vehicle electrical systems and the like have had a problem that the hole diameter determined by the NI value must be considerably increased in order to prevent core saturation with the increase in current, leading to an increase in the size of the entire choke coil.

Conventionally, switching transformers have been used in isolated DC-DC converters. DC-DC converters use a high-voltage battery used for in-vehicle applications such as electric vehicles and hybrid power sources to transform the high voltage of the high-voltage battery into a low voltage to charge the low-voltage battery and supply power to the load It does. In recent years, large-capacity switching transformers with output capacities of several hundred W to several kW have been provided.

In such a large-capacity choke coil or switching transformer, a large core is used to cope with a large current, and the winding is made of a thick stranded wire or a flat wire. The electric power capacity was increased by forming.

However, the use of thick stranded wires inevitably increased the outer diameter of the windings for insulation between the wires, and thus required a specially enlarged core to increase the cost. In addition, to wind a rectangular wire, expensive equipment was required to prevent bending, bending, biting, etc., occurring when the rectangular wire was broken. In addition, rectangular windings require expensive equipment to make windings as the current value increases, and it is difficult to bring the wires into close contact with each other and to wind them accurately, so the winding thickness increases, leading to a further increase in size. There were many cases.

On the other hand, as a method of forming a winding using a rectangular wire, instead of forming a winding by winding a rectangular wire, a rectangular conductor plate forming a winding while interposing an insulating layer is used. A method of laminating the layers one by one is disclosed, for example, in Japanese Patent Application Laid-Open No. 1-27204 (hereinafter referred to as Patent Document 1). This conventional technique has the advantage that a rectangular wire can be wound around a seamless (uncut) core without deformation. Here, a seamless core is a state in which a winding is inserted in a divided state, and a core that has a seam formed by connecting divided pieces thereafter has no seam and is not split. And refers to a core of a type into which the conductor constituting the winding is inserted. Seamless cores have the advantage of significantly reducing the man-hours required to manufacture the cores themselves, as well as having no problem of deterioration in the magnetic properties of the cores themselves and further reducing core loss and copper loss. . Seamless cores also have the advantage of not causing the noise problems associated with seam vibration.

However, this conventional technology requires that an insulating layer having a width larger than the width of the conductor plate be inserted between the windings in order to satisfy the insulation standard between the conductors. It is necessary to use a material with a sufficient thickness to prevent breakage due to the end of the rectangular conductor plate, and to use an insulating layer to secure between the conductor plate and the insulating layer. However, it is necessary to use a high-strength coil, which causes a decrease in the space factor of the winding, resulting in an increase in coil size and an increase in copper loss due to an increase in leakage inductance. Was.

As a solution to this problem, Japanese Patent Application Laid-Open Publication No. 2002-237374 (hereinafter referred to as Patent Document 2) discloses that an insulating tape is provided in advance as shown in FIG. A rectangular, substantially U-shaped (in other words, substantially U-shaped) conductive plate 350, insulated by 3501, A method of forming a coil by stacking layers one by one while inserting into a core is disclosed. Each time the conductive plates 350 are stacked, one end thereof is connected to one end of the connecting conductive plate 352. The other end of the conductor plate 352 is connected to the other end of the conductor plate 350 to be laminated next. By repeating this process, a coil is formed. This conventional technology has the advantage of being able to be wound around a seamless core without deforming a rectangular wire, and the fact that each conductor plate 350 is insulated in advance by an insulating tape 351 allows the coil to be wound. It has the advantage of realizing miniaturization and low loss.

However, even in the prior art disclosed in Patent Document 2, since the coil is assembled by laminating the conductor plates 350 one by one, the manufacturing process is still complicated, and high manufacturing costs are required. Further, there is a possibility that the interval between the conductor plates 350 constituting each layer of the winding may fluctuate due to vibration. Disclosure of the invention

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a coil unit and a composite coil unit which can simplify a manufacturing process, reduce a manufacturing cost, and are highly resistant to vibration. It is in.

The coil unit of the present invention embeds and holds the plurality of electric wires so that the plurality of electric wires keep an interval from each other and at least the first and second ends of each of the plurality of electric wires are exposed. It has a structure in which an insulator is inserted into a through hole of a magnetic core.

The objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view showing a wiring portion of a coil unit according to Embodiment 1 of the present invention. FIG. 2 is a perspective view showing the single flat wire of FIG.

FIG. 3 is a diagram illustrating a state in which the holding unit is inserted into the toroidal core in the coil unit of FIG.

FIG. 4 is a perspective view illustrating the connecting plate of FIG.

Fig. 5 shows the coil unit of Fig. 1 with a single rectangular wire connected to a connecting plate. FIG. 4 is a perspective view showing the inside of the wiring section of FIG.

FIG. 6 is a perspective view showing a configuration example of a coil unit according to Embodiment 2 of the present invention. FIG. 7 is a perspective view showing another configuration example of the coil unit according to Embodiment 2 of the present invention.

FIG. 8 is a perspective view showing still another configuration example of the coil unit according to Embodiment 2 of the present invention.

FIG. 9 is a perspective view schematically showing an example of the coil unit according to Embodiment 2 of the present invention.

FIG. 10 is a diagram showing a conventional toroidal choke coil compared with the coil unit of FIG.

FIG. 11 is an explanatory diagram showing the specifications of the choke coil of FIG. 10 in a table format.

FIG. 12 is an explanatory diagram showing the specifications of the choke coil in FIG. 9 in a table format.

FIG. 13 is a graph showing the relationship between core thickness and volume for the coils of FIGS. 9 and 10.

FIG. 14 is a perspective view schematically showing another example of the coil unit according to Embodiment 2 of the present invention.

FIG. 15 is a perspective view showing a conventional square-hole toroidal choke coil.

FIG. 16 is a perspective view showing a wiring portion of the coil unit according to Embodiment 3 of the present invention.

FIG. 17 is a perspective view showing the inside of the wiring section of FIG.

FIG. 18 is a perspective view showing a state in which a coil unit having a two-turn winding is configured using the wiring section of FIG.

FIG. 19 is a perspective view showing the inside of the coil unit of FIG.

FIG. 20 is a perspective view showing a state in which a coil unit having a three-turn winding is formed using the wiring section of FIG.

FIG. 21 is a perspective view showing the inside of the coil unit of FIG.

FIG. 22 is a perspective view showing a wiring section according to Embodiment 4 of the present invention.

FIG. 23 is a perspective view showing a state where the wiring section of FIG. 22 is inserted into a toroidal core. FIG. 24 is a perspective view showing a coil unit according to Embodiment 5 of the present invention.

FIG. 25 is a schematic configuration diagram showing a coil unit according to Embodiment 6 of the present invention. FIG. 26 is a schematic configuration diagram showing a wiring portion of the coil unit of FIG.

FIG. 27 is an explanatory diagram showing the arrangement of electric wires in the wiring section of FIG.

FIG. 28 is a perspective view showing an example of the shape of the core of the coil unit of FIG. 25. FIG. 29 is an explanatory diagram showing how to attach the core in the coil unit of FIG. 25.

FIG. 30 is a schematic configuration diagram showing another example of the arrangement of the cores in the coil unit of FIG.

FIG. 31 is a perspective view showing another example of the shape of the core in the coil unit of FIG. 25.

FIG. 32 is a schematic configuration diagram showing another example of the coil unit according to Embodiment 6 of the present invention.

FIG. 33 is a schematic configuration diagram showing how to attach a core in the coil unit of FIG.

FIG. 34 is a perspective view showing a main part of still another example of the coil unit according to Embodiment 6 of the present invention, with a part thereof broken away.

FIG. 35 is an explanatory view showing still another example of the coil unit according to Embodiment 6 of the present invention.

FIG. 36 is an explanatory diagram illustrating a configuration example of a winding in the coil unit according to Embodiment 7 of the present invention.

FIG. 37 is an explanatory diagram showing another configuration example of the winding in the coil unit according to Embodiment 7 of the present invention.

FIG. 38 is a schematic configuration diagram of a coil unit having the windings of FIG.

FIG. 39 is a schematic configuration diagram showing another example of the coil unit according to Embodiment 7 of the present invention.

FIG. 40 is an explanatory diagram showing the arrangement of electric wires according to the eighth embodiment of the present invention.

FIG. 41 is an explanatory diagram illustrating an example of the arrangement of the electric wires and the connection portions in FIG. 40.

FIG. 42 is a circuit diagram illustrating a conversion using another example of the coil unit according to the eighth embodiment of the present invention.

FIG. 43 is an explanatory view showing the coil unit of FIG.

FIG. 44 is a perspective view showing a coil unit according to Embodiment 9 of the present invention. FIG. 45 is an exploded perspective view of the coil unit of FIG.

FIG. 46 is a perspective view showing the coil unit according to the tenth embodiment.

FIG. 47 is a perspective view showing a coil unit according to Embodiment 11. FIG.

FIG. 48 is a manufacturing process diagram of the coil unit according to Embodiment 12.

FIG. 49 is a manufacturing process diagram of the coil unit according to Embodiment 12.

FIG. 50 is a diagram showing the manufacturing process of the coil unit according to Embodiment 12.

FIG. 51 is a manufacturing process diagram of the coil unit according to Embodiment 12.

FIG. 52 is a perspective view of the coil unit according to Embodiment 12. FIG.

FIG. 53 is a drawing illustrating the manufacturing process of the coil unit according to the thirteenth embodiment.

FIG. 54 is a manufacturing process diagram of the coil unit according to Embodiment 13.

FIG. 55 is a drawing showing the manufacturing process of the coil unit according to Embodiment 13.

FIG. 56 is a perspective view of the coil unit according to Embodiment 13.

FIG. 57 shows a conventional toroidal choke coil.

FIG. 58 is a diagram showing another example of the conventional toroidal choke coil.

FIG. 59 is a perspective view showing a single-layer winding of a conventional coil. BEST MODE FOR CARRYING OUT THE INVENTION

(Embodiment 1)

FIG. 1 is a perspective view showing a wiring portion that is a main portion of the coil unit according to the first embodiment. As shown in FIG. 1, the wiring portion 31 according to the present embodiment includes a holding portion 3 which is a resin insulator formed in a substantially U shape (in other words, a substantially U shape), and a flat rectangular wire 2 a which is an electric wire. , 2b, and an output rectangular single wire 5 which is also an electric wire. The rectangular single wires 2a and 2b are conductor plates, and are bent into a substantially U shape in plan view along the holding portion 3 and embedded in the holding portion 3 with both ends protruding outward. .

The output rectangular single wire 5 is a conductor plate extending linearly, and has one end protruding from the tip of one leg 3 a of the holding portion 3 and the other end as shown in FIGS. 1 and 2. The holder 3 is embedded in the holder 3 so as to protrude from the central piece 3 c to the outside. In this way, the rectangular single wires 2a and 2b as the conductor plates and the rectangular single wire for output 5 are held by being embedded in the holding section 3 in a state where they are stacked at predetermined intervals. The wiring section 31 connects the rectangular single wires 2a and 2b and the output rectangular single wire 5 between each other. It can be easily formed by integrally molding the insulating material of the holding portion 3 so as to embed these single wires 5, 2a, and 2b while supporting them with a jig (not shown) so as to keep the gap. .

As shown in FIG. 3, the shape of the leg 3a of the holding part 3 is substantially the same as the shape of the through hole 1a of the toroidal core 1 which is a core of a magnetic material made of ferrite, for example. The distance between one leg piece 3a and the other leg piece 3b is substantially equal to the distance between the outer peripheral surface and the inner peripheral surface of the toroidal core 1. The toroidal core 1 is inserted into the through hole 1a and the other leg 3b. As described above, the toroidal core 1 used in the present embodiment is a core having a rectangular parallelepiped shape and having square holes. However, the shape of the core 1 of the coil unit of the present invention is not limited to the present embodiment.

Further, after the holding portion 3 is arranged on the toroidal core 1, as shown in FIG. 4, a substantially S-shaped connecting plate 6a as a connecting member is arranged so that the opening side of the holding portion 3 is closed. One end of the winding is formed by connecting the end of the single rectangular wire 2a protruding from the tip of the other leg 3b of the holding portion 3 to one end of the connecting plate 6a. Further, the other end of the connecting plate 6a is connected to one end of a rectangular single wire 2b protruding from the tip of one leg 3a of the holding portion 3, and the other end of the rectangular single wire 2b is connected to another connecting plate. 6b is connected to one end, forming the next turn of the winding. The other end of the connecting plate 6b is connected to one end of a rectangular output single wire 5 protruding from the tip of one leg 3a of the holding portion 3. In this way, the coil unit is completed as a choke coil unit. Of the ends of the rectangular single wires 5 and 2a, the end to which the connecting plates 6a and 6b are not connected can be used as an end for connection to an external circuit (not shown).

FIG. 5 shows the inside of the wiring portion 31 to which the connecting plates 6a and 6b are connected. In the present embodiment, when the length of the portion of the flat rectangular solid lines 2a and 2b protruding from the tips of both legs of the holding portion 3 is viewed as one rectangular single line 2a or 2b, the length of one leg is The length of the other leg is longer than the length of the other leg, and when comparing the two rectangular single lines 2a and 2b, the length of the shorter leg of the rectangular single line 2a and the length of the rectangular single line 2b are longer. The length of the leg pieces is made equal to facilitate connection of the connecting plates 6a and 6b. In addition, since the output rectangular single wire 5, the rectangular single wire 2a, and the rectangular single wire 2b are stacked on each other, the connecting plates 6a and 6b can be attached to each other with a step. This also applies to the connection of the connecting plates 6a and 6b. Easy connection. Furthermore, since the main surfaces of the rectangular single wires 5, 2a and 2b are parallel to each other, the connecting plates 6a and 6b are connected to the fixed main surfaces of the rectangular single wires 5, 2a and 2b, that is, the example in FIG. Then, it may be connected to the upper main surface. This also facilitates connection of the connecting plates 6a and 6b.

As described above, according to the coil unit of the present embodiment, the flat rectangular solid wires 5, 2a, and 2b, which are the electric wires, are embedded and held in the holding unit 3, so that the holding unit constituting the wiring unit 31 is held. By inserting the part 3 into the through hole 1 a of the core 1, a structure in which a plurality of electric wires penetrate the core 1 is completed. Then, by connecting the connecting plates 6a and 6b to the ends of the rectangular single wires 5, 2a and 2b, a winding configuration can be easily realized. That is, it is not necessary to wind the rectangular winding, and unlike the conventional technology disclosed in Patent Document 2, it is also necessary to insert the rectangular single wires 5, 2a and 2b into the core 1 while laminating them one by one. Absent. This simplifies the manufacturing process, so that expensive equipment is not required for manufacturing, and manufacturing costs can be reduced. In addition, since it is not necessary to bring the wires into close contact with each other and accurately wind the wires, the problem of the winding thickness can be suppressed, and a compact coil unit can be realized. Further, since the rectangular single wires 5, 2a and 2b are embedded and held in the holding portion 3, a coil unit having high vibration resistance and high reliability is realized.

(Embodiment 2)

Since the basic configuration of the present embodiment is common to that of the first embodiment, the same reference numerals are given to the common parts and the description thereof will be omitted, and only the characteristic parts of the present embodiment will be described in detail.

In order to connect two toroidal choke coils according to the first embodiment in parallel, as shown in FIG. 6 or FIG. 7, one end of the side where the connecting plate 6 a of the rectangular single wire 2 a is not connected is connected to the input terminal. The ends of the flat rectangular output wires 5 protruding from the central piece 3 c of the holding portion 3 may be connected to each other by the output terminal plate 8 while being connected by the plate 7. At this time, the direction in which the winding thickness comes out can be arbitrarily selected as shown in FIG. 6 or FIG. Also, as shown in FIG. 8, it is possible to configure a unit by connecting a number of toroidal choke coils in parallel. FIG. 9 schematically shows the choke coil unit A of the present embodiment. This choke coil unit A is provided with two toroidal-type yoke coils A1 in which a rectangular winding 2 as a wiring portion is wound around a toroidal core 1 made of a core material such as ferrite. One choke coil unit A is formed by connecting the toroidal choke coils A 1 and A 1 in parallel with each other.

In the choke coil unit A, since the input current is divided into the toroidal cores 1 and 1, the hole diameter X of the toroidal core 1 determined from the NI value can be smaller than that of the conventional undivided toroidal choke coil.

At this time, in order to obtain the same inductance L as that of the conventional toroidal choke coil in the entire choke coil unit A, the inductance L required for each toroidal choke coil A1 is doubled. However, since the hole diameter X determined by the NI value can be small, the choke coil unit A can be made smaller than the conventional toroidal chiyoke coil even if the inductance L is doubled. .

The size of the conventional toroidal choke coil and the size of the yoke coil unit A of the present embodiment will be compared based on the volume occupied by the core, with numerical examples given below.

FIG. 10 shows an example of a conventional toroidal choke coil X using a rectangular winding 201 and has the specifications as shown in FIG.

The reason for determining this specification will be described. The design conditions are such that the height (outer diameter y) of the toroidal core 200 is 200 [mm] or less (as low as possible) and the thickness z is 100 [mm] at the maximum. And

The specification of the hole diameter X is determined from the condition that the current value I and the number of turns N do not cause saturation. That is, the condition of the pore size X in consideration of the saturation is as follows: Since the NI value is 2 [turns] X 20 [A] = 40, the above equation (1) gives

N I = (BX 2 πΧ a) / n

a = N I / (BX 27T)

Since the, B = 0. 3, NI = 40, = Substituting ^{4TC X 10- 7 X 3000, a} = 0. 08 [m], becomes i.e. pore size x = 160 [mm].

The outer diameter y of the toroidal core 200 can be obtained from the thickness z [m] of the toroidal core 200 and the inductance L [H] using the following equation (3). (B: core outer radius [m], a: hole radius [m], L: core L value [H],: permeability [N / A ² ], z: core thickness [m], N: Number of turns.)

y = 2Xb = 2X aXe "((LX 2 ττ) / (^ ζ ΧΝ ² )) • · · (2)

Therefore, in order to realize an inductance L = 10 [iiW in this condition, by substituting ^{L = 10X 10- 6, N =} 2, a = 0. 08, z = 0. 1 in equation (2), Obtain the outer radius of the toroidal core b = 83.4 [mm] and the outer diameter of the toroidal core y = 166.8 [mm].

From the above, when the volume V 200 occupied by the toroidal core 200 is obtained,

V200 = X b ² X z

Than

V200 = 2184045. 8 [mm ³ ]

It becomes.

Next, Fig. 1 shows the specifications of the choke coil unit A of this embodiment when the overall current value I, the inductance L, the number of evenings N, the core thickness z, and the core material are the same as the conventional one. See Figure 2.

The reason for determining this specification will be described. .

Since the current flowing per toroidal core 1 is half of the conventional value, the NI value may be half of the conventional value, and the pore size X when saturation is taken into account is given by B = 0.3, N 1 = 20, and substituting ^{= 4πΧ 10- 7 X 3000, a} = 0. 04 [m], the knob Riana径x = 80 [mm].

Inductor evening Nsu L of the toroidal core 1, 1 per than do I have twice, the formula (2), L = 20X 10- 6, N = 2, a = 0. 04, z = 0. 1 Then, the core outer radius b = 43.5 [mm] and the core outer diameter y = 87.0 [mm]. From the above, the volume VI occupied by one or one toroidal core is

Than

Vl = 593515. 5 [mm ³ ]

And the volume V 2 when two toroidal cores 1 are combined is

V2 = V 1X2 = 1187030. 9 [mm ³ ]

And becomes smaller than the conventional core 200.

As described above, in the choke coil unit A of the present embodiment, the current flowing per toroidal core is reduced, so that the hole diameter X of the toroidal core can be reduced, and Even considering the large L value required for each toroidal core, the size can be reduced compared to conventional toroidal choke coils.

In addition, since the current is small, the wiring portion does not become large, and it becomes easy to wind.

Fig. 13 shows the conventional toroidal core when the thickness z of the toroidal core was changed.

The volume V200 of 200 and the volume V2 of two toroidal cores 1 of choke coil unit A are shown. According to this graph, in order to make the core outer diameter y as small as possible, the larger the thickness z of the core, the more the effect of miniaturization of the choke coil unit A of the present embodiment as compared with the conventional toroidal core 200. You can see that there is.

In this embodiment, the cylindrical core 1 having a round hole is used. However, in consideration of the processing conditions of the core and fixing of the rectangular winding, the rectangular core 1 ′ having a rectangular parallelepiped as shown in FIG. The choke coil unit A 'may be configured by using this.

In this case, since the L value of the coil is determined by the ratio of the inner diameter to the outer diameter, if the rectangular hole is used under the condition that the same rectangular winding 2 is used, the outer diameter will not be large because it will be larger than the round hole Although the L value is not the same as the above, the size can be reduced even when the rectangular hole choke coil unit A 'is used as compared with the conventional rectangular hole toroidal type choke coil unit. That is, in the conventional toroidal choke coil X ′ shown in FIG. 15, since the diagonal line of the square hole determines the outer diameter, the size X of the square hole is 226.3 [mm] X 226.

3 [mm], the core width y (= height y) is 235.9 [mm], and the core volume V200 'is

V200 '= 235.9 X 235.9X 100 = 5564881 [mm ³ ]

On the other hand, the size X of the square hole of the choke coil unit A 'shown in Fig. 14 is 113.1 [mm] X 113.1 [mm], and the width y (= height y) of the core is 122.9 [mm], and the core volume V 2 'is

V2 '= 122.9 × 122.9 × 100X2 = 3020882 [mm ³ ], which is smaller than the conventional core volume V200'.

(Embodiment 3)

Since the basic configuration of the present embodiment is common to that of the first embodiment, the same reference numerals are given to the common parts and the description thereof will be omitted, and only the characteristic parts of the present embodiment will be described in detail. That is, the present embodiment is characterized in that the configuration of the holding unit 3 is different from that of the first embodiment. FIG. 16 shows the holding section 3 of the present embodiment. The holding part 3 has an extension piece 3 d extending from the tip of one leg 3 a of the holding part 3 of the first embodiment so as to face one end of the rectangular single wire 2 a. An extension 3e is formed at the tip of d. In the extension 3e, an input switching piece 9 to which a current is input at one end and the other end is connected to the single rectangular wire 2a or 2b as described later is embedded with both ends exposed to the outside. .

As shown in FIG. 17, the input switching piece 9 has an end on the side connected to the single rectangular wire 2a or 2b, which is divided into two forks 9a and 9b and exposed to the outside. Further, the holding unit 3 holds the rectangular single wires 2a and 2b and the output rectangular single wire 5 in a stacked state at predetermined intervals, as in the second embodiment.

After the one leg 3a is inserted into the through hole 1a of the toroidal core 1, the holding portion 3 configured as described above, as shown in FIG. 18 and FIG. Of the bifurcated pieces 9a and 9b, the part 9b farthest from the extension piece 3d (Fig. 18) and one end of the conductor piece 2b are connected with the metal plate 10 and the conductor piece 2b When the other end of the wire and the one end of the output rectangular single wire 5 are connected by the connecting plate 6b, a two-turn winding can be formed.

Also, as shown in FIGS. 20 and 21, of the forked pieces 9a and 9b of the input switching piece 9, the portion 9a on the side closer to the extension piece 3d and one end of the conductor piece 2a are Connect the other end of the conductor piece 2a and one end of the conductor piece 2b with a connecting plate 6a, and connect the other end of the conductor piece 2b and one end of When connected by the connecting plate 6b, a three-turn winding can be formed.

In this manner, the number of turns can be changed by the holding unit 3 holding the plurality of flat rectangular single wires 2a and 2b and connecting the connecting plates 6a and 6b by selecting the flat rectangular single wires 2a and 2b. Thus, a choke coil having a plurality of inductances L can be realized with one holding unit 3.

(Embodiment 4)

Since the basic configuration of the present embodiment is common to that of the first embodiment, the same reference numerals are given to the common parts and the description thereof will be omitted, and only the characteristic parts of the present embodiment will be described in detail. That is, the present embodiment is different from the first embodiment in that the holding portion 3 inserted into the through hole 1a of the toroidal core is provided on one leg 3a of the holding portion 3 as shown in FIG. It is characterized in that a locking claw 3f is provided as a retaining part for preventing the core from coming off, that is, a fixing means for fixing the holding part 3 to the toroidal core 1. The locking claw 3 has two slopes on the outer surface at the tip of one leg piece 3a, which are parallel to the single rectangular wires 2a, 2b, and an inclined surface that slopes outward as it approaches the center piece 3c of the holding portion 3. It is formed so that it may have. Further, the distance from the rear surface 3 g of the locking claw 3 f to the central piece 3 c of the holding portion 3 is formed to be substantially the same as the thickness of the toroidal core 1.

In the holding portion 3 configured as described above, one leg piece 3a is inserted into the through hole 1a of the toroidal core 1 while elastically deforming the locking claw 3f inside the holding portion 3. 2 When the insertion of the holding part 3 is completed as shown in 3, the back surface 3 g of the locking claw 3 f engages with the peripheral edge 1 b of the toroidal core 1 and the toroidal core 1 engages the back surface of the locking claw 3 f 3 It is fixed to the toroidal core 1 by being sandwiched between g and the central piece 3 c of the holding portion 3.

In the holding section 3, the fixing strength between the toroidal core 1 and the holding section 3 after being inserted into the toroidal core 1 is increased, and for example, the seismic resistance, which is important when the Chiyo coil unit is mounted on a vehicle, is improved. Can be.

(Embodiment 5)

Since the basic configuration of the present embodiment is common to that of the first embodiment, the same reference numerals are given to the common parts and the description thereof will be omitted, and only the characteristic parts of the present embodiment will be described in detail. This embodiment is different from the first embodiment in that the toroidal core 1 is divided into two (toroidal cores 1A and 1B) as shown in FIG. 24, and the holding portion 3 is made of a flexible resin. It is characterized in that the rectangular single wires 2a, 2b and the output rectangular single wire 5 are formed of a conductive material having flexibility. The rectangular single wires 2a and 2b and the output rectangular single wire 5 can have flexibility by, for example, setting the thickness to a certain value or less.

With this configuration, the holding portion 3 can be freely bent even after assembly, and the degree of freedom of the shape can be increased. Therefore, it is possible to cope with a change in the terminal position and the like to some extent.

(Embodiment 6)

As shown in FIG. 25, the coil unit according to the present embodiment holds a plurality of (two in FIG. 25) electric wires 21 side by side so that the directions of both ends are aligned, and holds each electric wire 21. And a core 24 made of a magnetic material and having a through-hole 24 a through which the wiring portion 23 passes. Terminals 21a exposed from the insulator 22 are provided at both ends of each wire 21. It is.

More specifically, the wiring portion 23 has a structure in which an insulator 22 made of synthetic resin embeds and holds two electric wires 21, and has a U-shape (U-shape) as shown in FIG. 26. Is formed. As shown in FIG. 27, inside the wiring portion 23, the electric wires 21 are respectively U-shaped, held apart from each other, and insulated from each other. The wiring portion 23 supports the plurality of electric wires 21 with a jig (not shown) so as to keep a distance from each other, and uses an insulating material of an insulator 22 so as to embed these electric wires 21. It can be easily formed by integrally molding using the illustrated mold.

The core 24 is a general one in which a wiring portion, which is a through-hole, is formed in a magnetic material such as ferrite and a through-hole 24 a is formed in a cylindrical shape as shown in FIG. As shown by arrow B1 in FIG. 29, both ends of the wiring portion 23 are attached to the wiring portion 23 by passing through the wiring portion insertion holes 24a. Here, as shown in FIG. 30, two cores 24 may be mounted side by side on one end of the wiring portion 23. Further, the core 24 may have a rectangular tube shape as shown in FIG.

According to the above configuration, since the electric wire 21 is embedded and held in the insulator 22, the same effect as described in the first embodiment can be obtained. That is, there is no need to wind the electric wire 21, and unlike the prior art disclosed in Patent Document 2, there is no need to insert the electric wire 21 into the core 1 one by one. Since the manufacturing process is simplified, expensive equipment is not required and manufacturing costs can be reduced. In addition, since a general single wire can be used as the electric wire 21 instead of a rectangular wire, the cost can be further reduced by using a general single wire. Further, by appropriately selecting the number and size of the cores 24, the shape and the specifications of the core capacity can be easily changed. In addition, since an inexpensive general cylindrical core 24 can be used, the cost can be reduced as compared with a case where an expensive core having a special shape is used. Further, since the electric wire 21 is embedded and held in the insulator 22, a coil unit having high vibration resistance and high reliability is realized. Here, similarly to the fourth embodiment, a retaining portion 41 for retaining the core 24 may be protruded from the insulator 22 as shown in FIG. The retaining portion 41 is provided at an end of the insulator 22 in a direction along the electric wire 21, for example. In addition, the shape of the retaining portion 41 is, for example, that the inclined surface 41 a inclined in a direction away from the electric wire 21 toward the direction approaching the center of the wiring portion 23 along the electric wire 21 is formed from the electric wire 21. 2 1 And so as to be able to change the distance between them to be able to change. . If the pull-out stopper 44 11 is formed as described above, it is arranged as shown by the arrow BB 22 in FIG. 33 33. Both ends of the wiring section 22 33 are pushed and pushed into the cocoa area 22 44's wiring section insertion hole 2244 aa. After the stopper portion 44 11 is radiused and passes through the wiring line portion of the cocoa hole 22 44 揷揷 through-hole hole 22 44 aa, after that as shown in FIG. As shown in the figure, it returns to its home position and is hooked on Cocoa 2244. . If this configuration is adopted, the cocoa core 2244 can be prevented from falling off, and the vibration and vibration resistance can be improved. It is suitable and suitable for use in vehicle mounting. . Also, the cocoa stove should be lowered as compared with the case where a separate component can be installed to prevent the cocoa door 22 44 from being pulled out. The place where you can lower it is complete. .

In the same manner as in the embodiment 55, the insulating insulator 22 22 and the electric wire 22 11 are connected as shown in FIG. Each of them may be formed of a material having flexible flexibility. . If this configuration is adopted and adopted, it is necessary to match the wiring and wiring section 2233 to the installation site and to deform and deform it. Can be completed. . In addition, instead of using a small number of cocoa cores 22 44 whose dimension is large, the length in the direction along the power line 22 11 is used instead. In addition, as shown in Fig. 33 55, a cocoa core 22 44 with a small length and a small dimension is used in the direction along the power line 22 11 as shown in Fig. 33 55. If a large number is used, it is possible to make the wiring and wiring portion 2233 deform and deform more and more flexibly and flexibly. . Further, the diameter of the electric power line 2211 can be suppressed to a certain degree or less, so that sufficient flexible bending can be achieved. Here, it is possible to make the power line 22 11 have the property. .

((Embodiment mode 77))

Since the basic basic structure of the coconut luminous unit according to the present embodiment is the same as that of the embodiment 66, ,,,,,,,,,,,,,,,,,,,,,,,,,, And, omitting the description thereof will be omitted, and It will be explained in detail in detail. . In the present embodiment, as shown in FIG. 3366, one end terminal portion 22 11 aa of one of the distribution wiring portions 2 33 is provided as shown in FIG. And the other end of the distribution wiring part 22 33 and the other terminal part 22 11 aa which are mutually different from each other. Depending on the location of the connecting member 22 55 for electrically connecting the members electrically and electrically, the plural number (( In Fig. 33 66, the winding wire is composed of 22 electric wires 22 11) and the connecting / connecting member 22 55. It is. . For example, as shown in Fig. 33 77, forty-four electric wires 2211 are provided in the distribution wiring part 2233 as shown in Fig. 3377. If the winding wire is formed as described above, a pair of winding windings of 22 turns is formed, and FIG. 33 88

As a result, a coil unit can be obtained. In FIGS. 36 and 37, the terminal portion 21 a to which the connection member 25 is not connected can be used as a terminal for connecting to an external circuit such as a circuit board (not shown).

According to the above configuration, the winding can be easily formed without using special equipment. Here, as shown in FIG. 39, the plurality of wiring parts 23 are connected to one terminal part 21 a of each wiring part 23 to one terminal part 21 a of the other wiring part 23. If used together, more cores 24 can be added, so the core capacity can be increased over a wider range. You can choose.

(Embodiment 8)

As shown in FIGS. 40 and 41, the coil unit according to the present embodiment embeds and holds a plurality of (six in FIGS. 40 and 41) electric wires 21 with an insulator 22. Thus, a U-shaped wiring portion 23 is formed, a core 24 is attached to the wiring portion 23, and one terminal portion 21a of the wiring portion 23 and the other terminal portion of the wiring portion 23 are formed. 21a, which is formed by adding a connecting member 25 for electrically connecting the ends of the wires 21 different from each other.

According to the above configuration, by appropriately selecting the number of connection members 25 and the connection position, the number of windings of the winding can be freely set within a range that does not exceed the number of electric wires 21. Can be. For example, as shown in FIG. 41, one of the electric wires 21 forms a primary winding of one turn, and three of the electric wires 21 and two connecting members 5 and a force, etc. Constructs a secondary winding of three turns. As shown in FIG. 41, the surplus terminal 21a may be cut off.

FIG. 42 is a circuit diagram showing an example of a DC-DC converter using the coil unit according to the present embodiment. This DC-DC converter is a forward converter, and includes a DC power supply E, a switching transformer T having a primary winding connected between output terminals of the DC power supply E via a switching element SW, and a switching element SW. It includes a drive circuit P for controlling on / off and a smoothing circuit S for smoothing the output on the secondary side of the switching transformer T and supplying the output to the load W. In this forward converter, a technique for preventing magnetic saturation by a reset circuit R S in which a series circuit of a diode 26 and an auxiliary winding I is provided in parallel with a primary winding of a switching transistor T is known. In the coil unit of the present embodiment, as shown in FIG. 43, a diode 26 is previously connected in series to one of the electric wires 21, and a winding composed of the electric wire 21 and the connecting member 25 is provided. The auxiliary winding I is formed on the force source side of the diode 26, and these can be connected in parallel to the primary winding. Thus, the effect of the reset circuit RS of FIG. 42 can be obtained without providing a separate reset circuit RS, and the size can be reduced because there is no need to add a circuit board.

(Embodiment 9)

As shown in FIG. 44, the coil unit according to the present embodiment The two wiring portions 23 similar to the wiring portions 23 used in the above, and a core 24 having a plurality of (four in FIG. 44) wiring portions made of a magnetic material and having through holes 24 a formed therein. Is provided. Each end of each wiring portion 23 is passed through a wiring portion through hole 24a, which is one through hole.

For example, as shown in FIG. 45, the core 24 as described above includes a pair of halves 6 attached to the wiring part 23 from both sides in the direction in which the wiring parts 23 are arranged, as indicated by an arrow B3. Consist of one. Each half body 61 has a plate-like shape in which a groove 61 a for accommodating a part of the wiring part 23 is provided on the bottom surface. When the two half-pieces 6 1 are connected in such a manner that the positions of the grooves 61 a are aligned with each other, the wiring part through hole 4 a is formed from the groove 61 a of the two half-pieces 61. According to the above configuration, the cores 24 attached to the plurality of locations of the plurality of wiring portions 23 can be manufactured at once, instead of manufacturing them one by one. Also, unlike the case where a plurality of cores 24 each having one wiring portion and a through hole 24a are provided, the cores 24 do not collide with each other when subjected to vibration and are not damaged.

(Embodiment 10)

FIG. 46 is a perspective view showing the coil unit according to the tenth embodiment. The basic configuration of this coil unit is the same as that of the coil unit according to the sixth embodiment. In the coil unit of the present embodiment, the electric wire 21 is a rectangular wire that is a substantially U-shaped conductor plate in plan view, similarly to the coil unit according to the first embodiment, and a plurality of electric wires 21 are stacked on the main surface thereof. It is embedded in a substantially U-shaped insulator 22 in a layered state. Further, the core 24 is inserted into both of the pair of legs of the substantially U-shaped insulator 22, and the core 24 is divided into a plurality in each leg. By dividing the core 24 along the electric wire 21 in this way, a common core is prepared for coil units of various specifications, and the inductance is different only by changing the number of cores to be used. It is possible to form coil units of various specifications.

(Embodiment 11)

FIG. 47 is a perspective view showing a coil unit according to Embodiment 11. FIG. The basic configuration of this coil unit is the same as that of the coil unit according to the sixth embodiment. In the coil unit of the present embodiment, the insulator 22 embeds only the legs of the plurality of substantially U-shaped electric wires 21. Even with such a configuration, it is possible to hold the plurality of electric wires 21 with sufficient strength. Further, an insulator 22 is fixed to the support plate 71, and Therefore, the strength is reinforced. Further, the connection member 25 is substantially S-shaped in a side view, and is connected to the upper main surface of the end of one electric wire 21 and the lower main surface of the end of another electric wire 21. ing. Accordingly, when connecting the connection member 25 to the electric wire 21 by welding or the like, interference by another electric wire 21 can be eliminated, and the efficiency of the work of attaching the connection member 25 is improved.

(Embodiment 12)

FIGS. 48 to 51 are process diagrams showing the steps of manufacturing the coil unit according to Embodiment 12, and FIG. 52 is a completed view thereof. In order to manufacture the coil unit shown in FIG. 52 having one winding of two turns, first, wires 21 A and 21 B shown in FIG. 48 are prepared. Each of the electric wires 21A and 21B is a rectangular wire which is a substantially U-shaped conductor plate in side view. A pair of ends of each of the electric wires 21A and 21B is provided with a plate-like terminal portion 72 which is bent and protrudes from the main surface so as to stand upright on the main surface. The terminal portion 72 can be formed, for example, by bending.

Next, as shown in FIG. 49, the electric wires 21A and 21B are stacked at an interval from each other such that the electric wire 21A is on the outside and the electric wire 21B is on the inside. As shown in FIG. 49, the terminal portion 72 is provided for facilitating the connection between the end of the electric wire 21A and the end of the electric wire 21B with a flat connecting member 25. The connection members 25 are attached not in the process of FIG. 49 but in a later process.However, in order to show the positional relationship of the four terminal portions 72, the connection after the connection is performed for convenience. Member 25 is depicted in FIG. As shown in FIG. 49, a pair of terminal portions 72 to which the connecting member 25 is to be connected are arranged on the same plane. Next, as shown in FIG. 50, the wiring portion 23 is completed by embedding the two electric wires 21 A and 21 B with the insulator 22. For embedding, while holding the two electric wires 21A and 21B with the jig (not shown) so as to maintain the positional relationship shown in Fig. 49, the insulating material is integrally molded using a mold (not shown) This is easily achieved by: In the example of FIG. 50, the insulator 22 embeds the wires 21 A and 2 IB so that the connecting portion 75 of the pair of legs of the substantially U-shaped wire 21 is selectively exposed. .

Next, as shown in FIG. 51, the insulator 22 is inserted into the through hole 24 a of the wiring portion which is a through hole selectively formed in the core 24. Thereby, a pair of legs of the substantially U-shaped electric wires 21 A and 21 B penetrate the core 24. In this step, it is possible to insert the wiring portion 23 into the core 24 while holding the exposed connecting portion 75 with a holding tool (not shown). Wear. Thus, the wiring portion 23 can be firmly grasped and easily inserted into the core 24 without damaging or deforming the insulator 22. Also, in the process shown in FIG. 50, the exposed joint portion 75 is easily buried with the insulator 22 while holding the wires 21 A and 2 IB by holding the wires 21 A and 2 IB by a jig (not shown). be able to.

Next, as shown in FIG. 52, by connecting the connecting member 25 to the terminal portion 72 by welding or the like, a coil unit is completed as a choke coil unit having one double-turned winding. In the coil unit according to the present embodiment, the conductor plates are used for the electric wires 21A and 21B, and they are laminated with an interval therebetween, so that a coil unit having a large current capacity is compactly realized. In addition, since the outline of the electric wires 21A and 21B in a side view is substantially U-shaped, similarly to the coil unit according to Embodiments 1 to 11, the direction of the end of the electric wire to which the connecting member 25 is to be connected. The connection members 25 are easy to install.

(Embodiment 13)

FIGS. 53 to 55 are process diagrams showing the steps of manufacturing the coil unit according to Embodiment 13, and FIG. 56 is a completed view thereof. The coil unit according to the present embodiment shown in FIG. 56 is different from the coil unit according to the embodiment 12 (FIG. 52) in that two coil windings of two turns are provided. That is, the coil unit according to the present embodiment is a switch unit.

In order to manufacture the coil unit shown in FIG. 56, first, wires 21 A and 21 B shown in FIG. 48 are prepared, and wires 21 C and 21 D shown in FIG. 53 are prepared. Like the electric wires 21A and 21B, each of the electric wires 21C and 21D is a flat wire that is a substantially U-shaped conductor plate in a side view, and has a terminal portion 72. The wires 21A and 21B are for forming the primary winding of the switching transformer, and the wires 21C and 21D are for forming the secondary winding.

Next, the four electric wires 21A to 21D are stacked at intervals from each other so that the electric wires 21A, 21B, 21C, 21D are located in order from the outside to the inside. . Of the four stacked electric wires 21A to 21D, FIG. 54 shows a part constituting a primary winding, and FIG. 55 shows a part constituting a secondary winding.

Thereafter, by performing the same process as in FIG. 50, the four electric wires 21A to 21D are embedded with the insulator 22. Next, the same steps as in Fig. 51 were performed. Thus, the core 24 is attached. Thereafter, as shown in FIG. 56, the two plate-shaped connecting members 25 are connected to the terminal portions 72 by welding or the like, thereby completing a coil unit having two twice-wound windings. In the coil unit according to the present embodiment, the same advantages as those in the embodiment 12 can be obtained.

(Summary of Embodiment)

The various embodiments of the present invention described above can be summarized as follows.

(1) That is, the coil unit has a plurality of electric wires each having a first end and a second end, and the first ends of the plurality of electric wires are aligned with each other. The direction of the second end is at least partly aligned with the first end, at least the first and second ends of each of the plurality of electric wires are exposed, and the plurality of electric wires are spaced from each other. And a magnetic core in which the insulator is inserted into a through hole formed selectively in the insulator to hold the plurality of electric wires.

In the coil unit having the above-described configuration, since a plurality of electric wires are embedded in the insulator so as to keep an interval from each other, an easy-to-handle component (referred to as a wiring portion) is formed in which the plurality of electric wires are integrated with each other while maintaining insulation. I do. Then, a structure in which a plurality of electric wires penetrate the core is completed by inserting an insulator constituting the wiring portion into the through hole of the magnetic core. Thus, the coil unit having the above configuration can be easily assembled without requiring expensive equipment. Also, the first ends of the plurality of electric wires are aligned, and the direction of the second end of at least a part of the plurality of electric wires is also aligned with the first end. By connecting the part and the second end with a connecting member, a winding of one or more turns can be easily formed. Furthermore, when the second end that is aligned with the first end is two or more, various specifications with different inductances or number of windings can be easily realized by changing the connection method using the connection member. be able to. Also, since a plurality of electric wires are embedded in the insulator, vibration resistance is high and reliability is improved.

(2) Preferably, the insulator is formed by integrally molding an insulating material.

With this configuration, it is possible to easily form an easy-to-handle component (wiring part) in which a plurality of electric wires are integrated with each other while maintaining insulation. (3) Preferably, at least a part of the plurality of electric wires is all of the plurality of electric wires.

With this configuration, the orientations of all of the first and second ends of the plurality of electric wires are aligned, so that the connection of the connection member for forming the winding and the connection between the winding and the other circuit have the same orientation. It is easy and compact through the first and second end portions.

(4) Preferably, at least a part of the plurality of electric wires has a substantially U shape.

With this configuration, it is possible to simplify the shape of at least a part of the plurality of electric wires and align the direction of the second end with the direction of the first end of the plurality of electric wires.

(5) Further, the plurality of electric wires may include a substantially linearly extending electric wire.

With this configuration, the first end of the substantially U-shaped electric wire and the second end of the substantially linearly extending electric wire are connected to an external circuit such as a circuit board, so that they are opposite to each other. Can be used as a connection portion with an external circuit.

(6) Preferably, the insulator embeds a pair of legs of a substantially U-shaped electric wire.

With this configuration, the strength of holding the plurality of electric wires by the insulator (referred to as holding strength) is increased. Thereby, the handling of the wiring portion is further facilitated and the reliability is further improved.

(7) Preferably, the insulator embeds the plurality of wires so that only the first and second ends of each of the plurality of wires are exposed.

In this configuration, since the insulator embeds all of the plurality of electric wires except for the first and second ends, the holding strength is further increased.

(8) Alternatively, the plurality of electric wires may be embedded in the insulator so that a joint portion between a pair of legs of the substantially U-shaped electric wire is selectively exposed.

With this configuration, it is possible to insert the wiring portion into the core while holding the joint portion of the pair of legs that is selectively exposed in the manufacturing process using the tom holder. Thereby, it is possible to easily hold and insert the wiring portion into the core without damaging or deforming the insulator. (9) Preferably, one leg of the pair of legs is inserted into the through hole of the core.

With this configuration, the wiring portion can be easily inserted into the core.

(10) The core may be divided into a plurality along the one leg.

With this configuration, it is possible to form coil units of various specifications having different inductances simply by preparing a common core for coil units of various specifications and changing the number of cores used. That is, coil units of various specifications can be formed simply and inexpensively.

(11) The core may be divided into a plurality of parts, and both of the pair of legs may be inserted into the divided core.

With this configuration, since both of the pair of legs are inserted into the core, the wiring unit can be easily inserted into the core, and a coil unit having a high inductance can be obtained.

(12) The core may be further divided into two or more along each of the pair of legs.

With this configuration, by simply preparing a common core for coil units of various specifications and changing the number of cores to be used, it is possible to form coils of various specifications having different inductances. That is, coil units of various specifications can be formed simply and inexpensively.

(13) Preferably, the plurality of electric wires are a plurality of conductor plates laminated with an interval therebetween, and the substantially U-shaped electric wire is a conductor plate having a substantially U-shaped contour in plan view.

With this configuration, a wiring portion having a large current capacity can be easily formed. In addition, since the main surfaces of the plurality of electric wires are parallel to each other, the first and second ends having the same orientation can be easily connected to each other by a connecting member in order to form a winding.

(14) Alternatively, it is preferable that the plurality of electric wires are a plurality of conductor plates laminated with an interval therebetween, and the substantially U-shaped electric wire is a conductor plate bent in a substantially U-shape in side view. .

With this configuration, a wiring portion having a large current capacity can be easily formed.

(15) Each of the plurality of electric wires is directly connected to a main surface at the first and second ends. It is desirable to have a plate-shaped terminal portion that is bent and protrudes from the main surface so as to stand upright. With this configuration, the plate-shaped terminal portions are parallel to each other, so that the first end and the second end, which are aligned in the same direction, can be easily connected by the connecting member to form the winding.

(16) Each of the plurality of electric wires and the insulator may be formed of a flexible material.

With this configuration, it is possible to change the shape of the wiring portion according to the installation location of the coil unit and the like. That is, a degree of freedom is created in the shape of the coil unit.

(17) Preferably, the insulator has a retaining portion for preventing the insulator from coming off the core.

With this configuration, the core can be prevented from falling off from the wiring portion, and the vibration resistance of the coil unit can be improved.

(18) The coil unit further includes at least one other structure configured identically to the structure having the plurality of electric wires and the insulator, wherein the through-hole is formed in the core. The insulator, which is divided into a plurality of rows arranged side by side and belongs to each of the structure and the at least one other structure, may be inserted into the divided through holes.

With this configuration, a coil unit having a plurality of wiring sections is realized, and since a plurality of wiring sections are inserted into a common core, there is no possibility that the plurality of cores may collide with each other due to vibration and may be damaged. A more excellent coil unit is realized. Further, since a common core is used, a core into which a plurality of wiring portions are inserted can be manufactured at a time.

(19) The coil unit may be configured such that the orientation of the plurality of wires is uniform among the first and second ends of the plurality of wires so that the plurality of wires form N (N≥l) windings. And a conductive connecting member for electrically connecting the connecting members.

With this configuration, it is possible to easily form N windings through a simple process of connecting the first end and the second end having the same orientation with a connecting member. Further, when the number of the second ends that are aligned with the first ends is two or more, various specifications having different inductances or the number of windings can be easily changed by changing the connection method by the connection members. It can be achieved.

(2 0) The N may be 1. In this case, a coil unit having one winding, for example, a coil unit as a choke coil is realized.

(21) Alternatively, N may be 2 or more.

In this case, a coil unit having two or more windings, for example, a coil unit as a transformer is realized.

(22) In the coil unit, the plurality of electric wires may include an electric wire in which a diode is inserted in series.

With this configuration, since the coil unit includes the reset circuit, the coil unit can be applied to the converter without separately providing a reset circuit.

(23) The composite coil unit is configured to electrically connect the coil unit, at least one other coil unit configured identically to the coil unit, and the coil unit and the at least one other coil unit in parallel. And a conductive connector that performs the following.

In the above-described composite coil unit, since a plurality of coil units are electrically connected in parallel, the current flowing through each coil unit is divided and reduced. As a result, the diameter of the core through-hole can be reduced, and taking into account the fact that the inductance required per core increases to obtain the same inductance as a single coil unit. However, miniaturization can be achieved.

Although the present invention has been described in detail, the above description is illustrative in all aspects and the present invention is not limited thereto. It is understood that innumerable modifications that are not illustrated can be assumed without departing from the scope of the present invention. Industrial applicability

INDUSTRIAL APPLICABILITY The coil unit and the composite coil unit according to the present invention facilitate the manufacturing process, reduce the manufacturing cost, increase the vibration resistance, and increase the reliability, and are industrially useful.

Claims

The scope of the claims

1. a plurality of wires each having a first end and a second end;

The directions of the first ends of the plurality of electric wires are aligned, and the directions of the second ends of at least some of the plurality of electric wires are also aligned with the first end. An insulator that embeds and holds the plurality of wires so that at least the first and second ends of each are exposed and the plurality of wires keep a distance from each other;

A coil unit, comprising: a magnetic core in which the insulator is inserted in a through hole selectively formed in the coil unit.

2. The coil unit according to claim 1, wherein the insulator is formed by integrally molding an insulating material.

3. The coil unit according to claim 1, wherein at least a part of the plurality of electric wires is all of the plurality of electric wires.

4. The coil unit according to any one of claims 1 to 3, wherein at least a part of the plurality of electric wires is substantially U-shaped.

5. The coil unit according to claim 4, wherein the plurality of electric wires include an electric wire extending substantially linearly.

6. The coil unit according to claim 4, wherein the insulator embeds a pair of legs of a substantially U-shaped electric wire.

7. The insulator according to any one of claims 1 to 6, wherein the insulator embeds the plurality of wires so that only the first and second ends of each of the plurality of wires are exposed. The coil unit according to the above.

8. The coil unit according to claim 6, wherein the insulator embeds the plurality of electric wires so that a joint portion between a pair of legs of the substantially U-shaped electric wire is selectively exposed. .

9. The coil unit according to claim 6, wherein one of the pair of legs is inserted into the through hole of the core.

10. The coil unit according to claim 9, wherein the core is divided into a plurality along the one leg.

1 1. The core is divided into a plurality of parts, and both of the pair of legs are divided. 9. The coil unit according to claim 6, wherein the coil unit is inserted into a core.

12. The coil unit according to claim 11, wherein said core is further divided into two or more along each of said pair of legs.

13. The plurality of electric wires are a plurality of conductor plates laminated with an interval therebetween, and the substantially U-shaped electric wire is a conductor plate having a substantially U-shaped outline in plan view. The coil unit according to any one of 6 and 8 to 12.

1 4. The plurality of electric wires are a plurality of conductor plates laminated at intervals from each other, and the substantially U-shaped electric wire is a conductor plate bent in a substantially U shape in side view. And the coil unit according to any one of 8 to 12.

15. The plurality of electric wires each having, at the first and second end portions, a plate-shaped terminal portion that bends and protrudes from the main surface so as to stand upright on the main surface. Coil unit.

16. The coil unit according to any one of claims 1 to 15, wherein the plurality of electric wires and the insulator are each formed of a flexible material.

17. The coil unit according to any one of claims 1 to 16, wherein the insulator has a retaining portion for preventing the insulator from coming off the core.

18. At least one other structure, which is the same as the structure having the plurality of electric wires and the insulator, is further provided.

The through-hole is divided into a plurality of pieces arranged side by side in the core,

The insulator according to any one of claims 1 to 17, wherein the insulator belonging to each of the structure and the at least one other structure is inserted into a divided through hole. Coil unit.

1 9. Among the first and second end portions of the plurality of electric wires, the plurality of electric wires are electrically connected so as to form N (N ≥ l) windings. The coil unit according to any one of claims 1 to 18, further comprising a conductive connection member for connection.

20. The coil unit according to claim 19, wherein said N is 1.

21. The coil according to claim 19, wherein N is 2 or more. knit.

22. The coil unit according to claim 21, wherein the plurality of electric wires include an electric wire in which a diode is inserted in series.

2 3. The coil unit according to claim 20,

A composite comprising at least one other coil unit configured the same as the coil unit, and a conductive connector electrically connecting the coil unit and the at least one other coil unit in parallel. Coulnit.