WO2013046259A1 - 光源点灯装置 - Google Patents
光源点灯装置 Download PDFInfo
- Publication number
- WO2013046259A1 WO2013046259A1 PCT/JP2011/005456 JP2011005456W WO2013046259A1 WO 2013046259 A1 WO2013046259 A1 WO 2013046259A1 JP 2011005456 W JP2011005456 W JP 2011005456W WO 2013046259 A1 WO2013046259 A1 WO 2013046259A1
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- WIPO (PCT)
- Prior art keywords
- light source
- winding
- lighting device
- transformer
- power supply
- Prior art date
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M3/00—Conversion of dc power input into dc power output
- H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
- H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
- H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
- H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
- H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
- H02M3/33507—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters
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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
- 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
- H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
- H05B45/30—Driver circuits
- H05B45/37—Converter circuits
- H05B45/3725—Switched mode power supply [SMPS]
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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
- H01F27/2804—Printed windings
- H01F2027/2819—Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0003—Details of control, feedback or regulation circuits
- H02M1/0006—Arrangements for supplying an adequate voltage to the control circuit of converters
-
- 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
- H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
- H05B45/30—Driver circuits
- H05B45/37—Converter circuits
- H05B45/3725—Switched mode power supply [SMPS]
- H05B45/38—Switched mode power supply [SMPS] using boost topology
Definitions
- an intermediate tap (leader wire) is provided in a transformer or a coil used in a DC / DC converter that supplies lighting power to a light source of an in-vehicle lamp, and a voltage generated in the intermediate tap (leader wire) is used.
- the present invention relates to a light source lighting device that generates a control power source.
- HID lamps High Intensity Discharge; HID lamps
- LEDs Light Emitting Diodes; light-emitting diodes
- Patent Document 1 is an invention relating to a laminated printed coil in which a plurality of substrates each having a winding formed of a conductive pattern are stacked and each conductive pattern is electrically connected to form a set of coils.
- a conductive pattern for an intermediate tap that branches off from the conductive pattern of the substrate is provided on one substrate surface that is an intermediate layer of the plurality of substrates.
- this printed coil can structurally arrange the conductive pattern for the intermediate tap only on the outer periphery of the conductive pattern for winding. Therefore, among the plurality of stacked substrates, a coil and a coil terminal are formed on the substrate surface on the front surface side and the back surface side, and a coil and an intermediate tap are formed on the substrate surface sandwiched between them. It is not the structure which pulls out an intermediate tap on a substrate surface.
- Patent Document 2 is configured by a plurality of spiral patterns formed on one surface and the other surface of a printed board on a pair of spiral and concentric coils having substantially the same coil length used for an antenna. It is an invention.
- One coil reaches the central part while winding from the outer peripheral part on one surface provided with the coil terminals, and reaches the outer peripheral part while connecting to the coil on the other surface at the central part and winding from the central part.
- the other coil reaches the center while winding from the outer peripheral portion on one surface provided with the coil terminals, and reaches the outer peripheral portion while being connected to the coil on the other surface at the center and winding from the central portion. Both coils are connected in series by connecting one coil terminal of the outer peripheral portion, and the connection point of both coils is a pattern for an intermediate tap.
- Patent Document 1 In the structure of Patent Document 1, four or more layers of spiral conductive foil are required to form a coil with an intermediate tap. Therefore, in order to configure a transformer having a secondary winding with this structure, a multilayered conductive foil is required. Therefore, the cost required for the multi-layer substrate is expensive, which is not preferable for an inexpensive device. Further, in the structure of Patent Document 2 described above, the structure of the winding is complicated because the main winding is divided into a plurality of parts, and at the same time, the cross-sectional area of the main winding is narrowed to ensure a sufficient cross-sectional area for flowing current. There are harmful effects such as difficulty. Therefore, it is not a preferable configuration from the viewpoint of miniaturization and high efficiency.
- the conventional sheet type transformer or sheet type coil has a problem that the cost is high due to the large number of windings and it is not suitable for miniaturization and high efficiency. It was. Therefore, the conventional sheet type transformer or sheet type coil cannot be used as it is for the DC / DC converter, and the voltage of the intermediate tap cannot be used as the control power source. Even if the said patent documents 1 and 2 are seen, there is no description of the structure which uses a sheet-type coil for a DC / DC converter and guides electric power from an intermediate tap to a control power supply. Moreover, in the said patent documents 1, 2, there is no description of the structure which pulls out the lead wire used as an intermediate
- an object of the present invention is to provide a light source lighting device that achieves a reduction in size and cost, and generates a power source for DC / DC converter control by taking out an arbitrary voltage from an intermediate tap to stabilize a lighting operation.
- the light source lighting device of the present invention uses a transformer or a coil composed of a winding formed of a spiral conductive member and a magnetic member, and generates a power for lighting from a power source, Power is supplied from the intermediate tap (leader line) drawn from the same plane as the terminal of the winding forming the transformer or coil, the control circuit part for controlling the DC / DC converter part, and the intermediate tap (leader line). And a control power supply unit for supplying control power to the control circuit unit.
- a transformer or a coil can be reduced in size and cost by pulling out a lead wire serving as an intermediate tap from the same surface as the terminal of the winding forming the transformer or coil and supplying power to the control power supply unit.
- a light source lighting device capable of performing a stable lighting operation by taking out an arbitrary voltage from an intermediate tap and generating a power source for controlling a DC / DC converter.
- FIG. 1 is an exploded perspective view of a sheet-type transformer used in a light source lighting device according to Embodiment 1 of the present invention. It is sectional drawing which cut
- 3 is an exploded perspective view of a sheet-type coil used in the light source lighting device according to Embodiment 1.
- FIG. It is a circuit diagram which shows the modification of the light source lighting device which concerns on Embodiment 1, and is an example using the coil shown in FIG.
- FIG. 8A is a plan view
- FIG. 8B is a cross-sectional view taken along line BB, illustrating a sheet-type transformer used in a light source lighting device according to Embodiment 2 of the present invention. It is sectional drawing which shows the modification of the transformer shown in FIG.
- the sheet-type transformer 1 includes windings P1 and P2 formed by winding a conductive foil on each of the front and back layers of a multilayer printed board 2 one turn, and two intermediate layers. Windings S1 and S2 formed by winding the conductive foil in a spiral shape three turns each, a lead wire formed by drawing the conductive foil from the outer periphery of the winding P1, that is, the intermediate tap X, the magnetic member 8, 13.
- FIG 3 is an exploded perspective view in which the structure of the windings P1, P2, S1, and S2 is visualized with the illustration of the printed circuit board 2 omitted, and a circuit configuration example of the printed circuit board 2 is shown in addition to the transformer 1. Details of the circuit configuration will be described later.
- ends P1a and P2a inside the vortex of the windings P1 and P2 are connected by a through hole 3 formed through the printed circuit board 2, and these windings P1 and P2 A set of primary windings.
- Ends P1b and P2b outside the vortices of the windings P1 and P2 are connected to circuit components mounted on the printed circuit board 2.
- Ends S1a and S2a inside the vortices of the windings S1 and S2 are connected by a through hole 4 formed through the printed board 2, and the windings S1 and S2 form a set of secondary windings.
- Outer ends S1b and S2b of the vortices of the windings S1 and S2 are connected to circuit components mounted on the printed circuit board 2.
- an intermediate tap X (leading line) is formed by drawing out the conductive foil at the outer peripheral portion of the end portion P1a, which is a connection point between the winding P1 and the winding P2.
- This intermediate tap X is formed on the same surface layer of the printed circuit board 2 as the winding P ⁇ b> 1, and is connected to a circuit component mounted on the printed circuit board 2.
- the intermediate tap X can be provided on the same surface as the end portion P1b corresponding to the terminal of the primary winding, the configuration is more than that of the conventional sheet type transformers such as Patent Documents 1 and 2 above. It is simple and can be reduced in size and cost.
- the intermediate tap X is formed on the outer peripheral portion of the winding P1 on the surface layer of the printed circuit board 2, but the present invention is not limited to this. An intermediate tap X may be formed.
- the core of the transformer 1 is a so-called EIR core that combines an ER type core and an I type core
- an ER type magnetic member 8 includes a flat plate portion 9 and a central leg portion 10 projecting from the central portion of the flat plate portion 9.
- the outer leg portions 11 and 12 project from both ends of the flat plate portion 9.
- the central leg 10 is inserted into the central leg insertion hole 5 of the printed circuit board 2, and the outer legs 11 and 12 are inserted into the outer leg insertion holes 6 and 7, respectively.
- the I-type magnetic member 13 is disposed at a position facing the magnetic member 8 with the printed board 2 interposed therebetween.
- These magnetic members 8 and 13 may be, for example, cores formed by solidifying iron (ferrite) powder, or cores formed by resin kneaded with magnetic powder. Further, the shape may be other than the EIR type.
- FIG. 4 is a circuit diagram showing a configuration of the light source lighting device 100 according to the first embodiment.
- the same parts as those in FIGS. 1 to 3 are denoted by the same reference numerals.
- the light source lighting device 100 is a lighting device for lighting an LED 108 used as an in-vehicle light source (head lamp, tail lamp, stop lamp, etc.) using a DC voltage of a DC power supply 101, and is mainly a DC / DC converter.
- Unit 103, control power supply unit 104, control unit 105, and driver 106 is an in-vehicle battery (DC voltage 12V or 24V), and a DC voltage to the DC / DC converter unit 103 is supplied or cut off by the power switch 102.
- the DC / DC converter unit 103 includes a transformer 1 having the configuration shown in FIGS. 1 to 3, a switching element Q1 composed of a MOS field effect transistor (FET), a rectifier diode D1, a smoothing capacitor C1, and a current detecting device.
- one end of the primary winding of the transformer 1 (end P1b of the winding P1) is connected to the positive pole of the DC power supply 101 via the power switch 102, and the primary winding of the transformer 1 is connected.
- the other end (end P2b of winding P2) is connected to the negative pole of DC power supply 101 via switching element Q1.
- One end of the secondary winding of the transformer 1 (end S2b of the winding S2) is connected to the anode of the rectifier diode D1, and the other end of the secondary winding (end of the winding S1) and the cathode of the rectifier diode D1.
- a smoothing capacitor C1 is connected to S1b).
- an intermediate tap X that divides the primary winding into the windings P1 and P2 is connected to the control power supply unit 104 via the diode D2.
- the switching element Q1 is controlled to be switched by a control signal input from the control unit 105 via the driver 106, magnetic energy is stored in the transformer 1, and this is discharged. 1 is rectified by a rectifier diode D1 and smoothed by a smoothing capacitor C1 to generate a DC voltage.
- the control power supply unit 104 receives the voltage Vps generated at the intermediate tap X through the rectifying diode D2, and the constant voltage circuit configured by the capacitors C2 and C3, the resistor R2, the zener diode D3, and the transistor Q2 supplies 10V. A constant voltage is generated and applied to the driver 106. Further, the control power supply unit 104 steps down the constant voltage 10V generated by the constant voltage circuit to 5V by the power supply unit 104a configured by the series power supply, smoothes it by the capacitor C4, and applies it to the power input terminal of the control unit 105.
- the control circuit unit 107 includes a control unit 105 and a driver 106, and each receives a voltage supply of 5V and 10V from the control power supply unit 104.
- the control unit 105 operates with a 5V power supply generated by the control power supply unit 104.
- the control unit 105 includes a CPU and an A / D converter (not shown), and is detected by the input voltage Vin and output voltage Vout of the DC / DC converter unit 103 and the shunt resistor R1 using the A / D converter. Each of the output currents of the DC / DC converter unit 103 is input.
- control unit 105 generates a control signal for turning on / off the switching element Q1 based on the input voltage Vin, the output voltage Vout, and the output current, operates the DC / DC converter unit 103, and supplies a predetermined lighting power to the LED 108.
- the driver 106 operates with a 10V power supply generated by the control power supply unit 104, and applies a predetermined voltage to the gate of the switching element Q1 based on a control signal from the control unit 105.
- the transformer for DC / DC converters used for equipment with low power supply voltage such as in-vehicle equipment originally has a small number of turns of the primary (power supply side) winding, but in addition, the operating frequency of the DC / DC converter It is possible to further reduce the number of turns by increasing the height and facing the winding with the magnetic member (core) approaching the winding. As a result, a transformer or a coil in which a one-turn winding is formed on one surface and the other surface of the printed circuit board can be realized. In the transformer or coil using one turn of winding on one surface, the intermediate tap of the winding corresponds to one point on the conductive foil for winding of one turn formed on one surface of the printed board.
- the surfaces of the magnetic members 8 and 13 are made to face each other close to the windings P1 and P2 formed on the front and back layers of the printed circuit board 2, and the DC /
- the transformer 1 (or coil) composed of the windings P1 and P2 wound around one surface of the printed circuit board 2 can be formed.
- a lead line as the intermediate tap X can be drawn from the middle of the line P1 or P2. Since the voltage generated by the winding P1 or P2 of this one turn is sufficient, it can be used as an intermediate tap X for supplying power for generating a control power supply.
- the transformer 1 includes a primary winding in which the winding P1 has one turn and the winding P2 has one turn, and a secondary winding in which the winding S1 has three turns and the winding S2 has three turns. Separated (insulated). Further, an intermediate tap X is formed on the outer peripheral portion of the end portion P1a corresponding to the connection point between the windings P1 and P2.
- windings P1 and P2 and the magnetic members 8 and 13 are brought close to each other to obtain good characteristics.
- the winding P1 is brought close to and opposed to the magnetic member 13.
- winding P2 are arrange
- Vps Vin + Vout ⁇ ⁇ p1 / (s1 + s2) ⁇ (1)
- Vin is a power supply voltage supplied from the DC power supply 101 to the transformer 1 via the power switch 102 (normally 12V)
- Vout is an output voltage (30V) generated by the DC / DC converter unit 103
- p1 is The number of turns of the winding P1 (1 turn)
- s1 and s2 are the number of turns of the windings S1 and S2 (each 3 turns).
- the voltage Vps generated at the intermediate tap X is 12V from the equation (1A). Therefore, even when the power supply voltage Vin decreases, a voltage for securing a control 10V power supply to be supplied to the driver 106 can be supplied.
- the voltage Vps is 17V when the power supply voltage Vin is steady 12V.
- Vd Vin + Vout ⁇ ⁇ (p1 + p2) / (s1 + s2) ⁇ (2)
- p2 is the number of turns (1 turn) of the winding P2.
- FIG. 5 is an exploded perspective view of the coil 1a in which the printed circuit board 2 is omitted and the winding structure is visualized, and the circuit configuration of the printed circuit board 2 is also shown in addition to the coil 1a.
- FIG. 6 is a circuit diagram of the light source lighting device 100 when a step-up power supply is configured using the coil 1a in the DC / DC converter unit 103a.
- the sheet-type coil 1a is formed by winding a conductive foil in a spiral shape on the surface layer of a printed board 2 (not shown) and winding the conductive foil in a spiral shape on the back layer for two turns, and the inner end portion P2a of the vortex in each layer. -1, P2a-2 are connected by a through hole 3 formed through the printed circuit board 2. Of the two turns on the surface layer, one turn on the outer periphery is designated as a winding P1, and one turn on the inner circumference on the surface layer and two turns on the back layer are designated as a winding P2.
- an intermediate tap X is formed by pulling out a conductive foil corresponding to a connection point between one turn of the outer periphery and one turn of the inner periphery of the two turns of the surface layer, that is, a connection point of the windings P1 and P2.
- This intermediate tap X is on the same surface layer of the printed circuit board 2 as the winding P1.
- a lead wire is drawn out from one point of the outermost peripheral turn to form the intermediate tap X.
- One end P1b of the set of windings is connected to the positive pole of the DC power supply 101 via the power switch 102, and the other end P2b is connected to the negative pole of the DC power supply 101 via the switching element Q1. Is done. Further, the anode of the rectifier diode D1 is connected to the end P2b, and the smoothing capacitor C1 is connected between the cathode of the rectifier diode D1 and the negative pole of the DC power supply 101. Further, an intermediate tap X that divides the coil 1a into the windings P1 and P2 is connected to the control power supply unit 104 via the diode D2.
- the voltage Vps generated at the intermediate tap X is expressed by the following equation (3).
- the voltage Vps generated at the intermediate tap X is 12V from the equation (3A). Therefore, even if the power supply voltage Vin decreases, a control 10V power supply to be supplied to the driver 106 can be secured.
- Vps Vin + (Vout ⁇ Vin) ⁇ ⁇ p1 / (p1 + p2) ⁇ (3)
- one point on the outer periphery of the winding made of the spiral conductive foil formed on one surface of the printed circuit board 2 is the intermediate tap X, the lead wire is connected, the voltage is led to the control power supply unit 104, and the control power supply is turned on. Can be generated.
- the light source lighting device 100 that supplies power for lighting to the LED 108 includes the windings P1, P2, S1, S2 and the magnetic members 8, 13 formed of a spiral conductive foil.
- the DC / DC converters 103 and 103a that generate power for lighting from the DC power source 101 and the terminals of the transformer 1 or the coil 1a of the winding P1 are used.
- a lead wire that is drawn out from the same plane as the end portion P1b and becomes the intermediate tap X, a control circuit portion 107 that controls the DC / DC converter portions 103 and 103a, and a power supply from the intermediate tap X receive the control circuit portion 107.
- a control power supply unit 104 for supplying a control power supply.
- the number of turns of the windings P1 and P2 is reduced.
- the voltage generated per turn of the winding is increased. Accordingly, since one point of the winding P1 (or P2) can be drawn out and used as the intermediate tap X, a small control power source with low loss (high efficiency) can be configured. As a result, it is possible to realize the light source lighting device 100 that can maintain the lighting operation even when the power supply voltage of the vehicle battery or the like decreases.
- the light source lighting device 100 having a simple configuration can be realized.
- the control power supply unit 104 is configured to receive a voltage generated in the winding P1 (or P2) from which the intermediate tap X is drawn and to output a voltage higher than the voltage of the DC power supply 101. did. For this reason, even if the DC power supply 101 drops from the steady voltage 12V to 7V, for example, the control power supply unit 104 can output a 10V voltage higher than 7V by introducing the voltage of the intermediate tap X. Therefore, the light source lighting device 100 that can maintain the lighting operation even when the power supply voltage is lowered can be realized.
- the windings P1, P2, S1, and S2 are configured such that a part of the conductive foil of the printed board 2 on which the electronic component is mounted is formed in a spiral shape.
- winding and magnetic member which are used for the coil 1a can be procured separately. Therefore, the assembly cost added to the transformer 1 or the coil 1a as a part can be reduced, and the inexpensive light source lighting device 100 can be realized.
- the DC / DC converter unit 103 using the transformer 1 in which the primary windings P1 and P2 and the secondary windings S1 and S2 are insulated is configured.
- the present invention is not limited to this, and the DC / DC converter unit 103b may be configured using a single-winding transformer 1b in which the primary windings P1 and P2 and the secondary windings S1 and S2 are connected.
- FIG. 7 is a modified example of the light source lighting device 100 according to the first embodiment, and shows a circuit diagram in the case of using the single-winding transformer 1b. In this example, the end of the primary winding P2 of the single-winding transformer 1b and the end of the secondary winding S1 are connected, and this connection point is connected to the negative electrode of the DC power supply 101 via the switching element Q1. is doing.
- the power supply voltage Vin can be superimposed on the output voltage Vout of the single-winding transformer 1b, and the efficiency of the DC / DC converter unit 103b can be increased.
- the insulation type transformer 1 as shown in FIG. 4 all the output voltages Vout are once converted into magnetic energy, but in the single-winding transformer 1b, the power corresponding to the difference between the output voltage Vout and the power supply voltage Vin is magnetized. Since it is sufficient to compensate with energy, the burden on the switching element Q1 on the primary side is small, and the switching loss is also small.
- small magnetic members (cores) 8 and 13 can be used.
- Embodiment 2 the second embodiment will be described with reference to FIGS.
- the magnetic members (cores) 8 and 13 to be used are disposed so as to oppose each other in the vicinity of the spiral conductive foil, and the ferrite magnetic members 8 and 13 are disposed.
- good characteristics can be obtained by assembling the flat plate portion 9 of the magnetic member 8 and the flat portion of the magnetic member 13 in contact with the windings P1 and P2.
- the rigid ferrite magnetic members 8 and 13 are used, some clearance is required as shown in FIG. 2 in order to prevent breakage due to component variations and the like and to improve assembly. For this reason, the magnetic member (core) can only abut against either one of the front and back windings P1 and P2 of the printed board 2, and the gap with the printed board 2 cannot be eliminated at all.
- the magnetic members 8 and 13 are replaced with the magnetic members 8 and 13 in order to similarly bring the magnetic members corresponding to the magnetic members 8 and 13 into contact with the front and back windings P1 and P2 of the printed circuit board 2.
- the magnetic member 22 is formed by casting the printed circuit board 2 with the resin-based magnetic material using a resin kneaded with magnetic powder (insert molding).
- the winding P1 and the flat portion of the magnetic member 13 are in close contact with each other, and the winding P2 and the flat plate portions 24 and 25 of the magnetic member 22 are in close contact with each other.
- the central leg portion 21 of the magnetic member 22 is formed of a magnetic material such as ferrite having a high magnetic permeability, and the remaining portion is formed of a magnetic powder kneaded resin.
- the outer leg insertion holes 6 and 7 are opened in advance in the printed circuit board 2 before casting.
- the magnetic powder kneaded resin that has entered the outer leg insertion holes 6 and 7 becomes the outer leg 23.
- FIG. 8A is a plan view of the magnetic member
- FIG. 8B is a cross-sectional view taken along the line BB.
- the printed circuit board 2 includes a central leg insertion hole 5c through which the central leg of the magnetic member (core) passes and a plurality of outer leg insertion holes 6c through which the plurality of outer legs pass. And are formed. Further, the windings P1 and P2 are spirally formed on the surface layer and the back layer of the printed circuit board 2, and the windings S1 and S2 are spirally formed on each of the two intermediate layers.
- a columnar magnetic member (core) 21 such as ferrite is passed through the central leg insertion hole 5c of the printed circuit board 2 installed in the mold.
- the magnetic member 22 corresponding to the magnetic members 8 and 13 (excluding the central leg portion 10) is insert-molded by pouring magnetic powder kneaded resin so that the printed board 2 is sandwiched therebetween.
- the magnetic powder kneaded resin that has entered the outer leg insertion holes 6 c becomes the outer legs 23.
- the windings P ⁇ b> 1 and P ⁇ b> 2 are in close contact with the flat plate portions 24 and 25 of the magnetic member 22.
- the radial extension prevents the magnetic flux path from being unnecessarily enlarged.
- the thickness of the magnetic member 22 is reduced, and the product of the circumferential length and thickness (cross-sectional area) is made equal regardless of the position in the radial direction.
- the central leg portion 21 made of a magnetic member such as ferrite is penetrated through the resin-based magnetic member 22, and the position of the central leg portion 21 can be arbitrarily displaced with respect to the magnetic member 22 (
- the central leg 21 is formed into a male screw shape, a female screw-like groove is formed in the central hole of the magnetic member 22, and the central leg 21 is screwed into the magnetic member 22 hole.
- the amount of insertion is adjusted and the magnetic resistance is adjusted.
- the variation can be absorbed by adjustment and the characteristics of the transformer or coil can be made constant.
- the light source lighting device 100 uses the resin obtained by kneading the magnetic powder in the magnetic member 22, the contact between the spiral conductive foil of the printed board 2 and the magnetic member 22 is achieved. Therefore, the transformer 1c having good characteristics can be realized. Further, by adopting a configuration in which the inductance can be adjusted, a stable quality transformer 1c can be realized. As a result, the DC / DC converter unit 103 having good characteristics and stable quality, and the light source lighting device 100 having good characteristics and stable quality can be realized. This configuration is not limited to the transformer 1c, but also applies to the single-winding transformer 1b and the coil 1a.
- the conductive foil is spirally formed on the surface or layer of the printed circuit board to form a sheet type transformer or coil.
- a conductive flat plate is used without using the printed circuit board. It may be formed in a spiral shape to constitute a sheet-type transformer or coil.
- a DC / DC converter unit using a sheet-type transformer or coil provided with an intermediate tap is applied to a light source lighting device that lights an LED.
- the present invention is not limited, and can be applied to a light source lighting device for lighting a discharge lamp. Even in the case of a light source lighting device for a discharge lamp, a light source lighting device having a simple configuration can be realized as in the case of an LED.
- an example of a flyback type DC / DC converter applied to a lighting device that lights an LED or a discharge lamp has been described.
- an intermediate tap is used for a forward type DC / DC converter. It is also possible to use a sheet-type transformer or a coil provided with. In this case as well, the power drawn by the intermediate tap can be used as described above.
- the light source lighting device draws the spiral conductive foil on the same surface as the sheet-type transformer or coil terminal, and forms an intermediate tap. It is suitable for use in an in-vehicle light source lighting device that uses an in-vehicle battery as a power source.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Dc-Dc Converters (AREA)
- Circuit Arrangement For Electric Light Sources In General (AREA)
- Coils Of Transformers For General Uses (AREA)
Abstract
Description
ただし、このプリントコイルは構造的に、中間タップ用の導電パターンを巻線用の導電パターンの外周にしか配置できない。そのため、積層した複数の基板のうち、表面側と裏面側になる基板面にコイルとコイル端子を形成し、間に挟まれる基板面にコイルと中間タップを形成するものであり、コイル端子と同一基板面に中間タップを引き出す構成ではない。
これに対し、上記特許文献1,2のようなシート式では、プリント基板の複数の面あるいは層に渦巻き状の導電箔を形成し、これら複数の導電箔を渦巻きの中心部で接続して巻線とし、この巻線と磁性部材(コア)とを組み合わせて構成するため、構造的に中間タップとなる引き出し線の引き出し部は渦巻き状導電箔の外周側にしか配置できない。つまり裏表の2面それぞれに渦巻き状に多数巻回した導電箔の構成において、中間タップを渦巻き状導電箔の外周部分に設けても、中間タップ用の巻線として1ターン分の巻線しか使用できないため、中間電圧がDC/DCコンバータの制御電源として充分な電圧にはならない。
また、上記特許文献2の構造では、主巻線を複数に分割するために巻線の構成が複雑になると同時に、主巻線の断面積が狭くなって充分な電流を流す断面積の確保が困難になる等の弊害がある。従って、小形化と高効率化の観点からは好ましい構成ではない。
実施の形態1.
図1および図2に示すように、シート式のトランス1は、多層のプリント基板2の表裏層それぞれに導電箔を1ターンずつ巻回して形成した巻線P1,P2と、2層の中間層それぞれに導電箔を3ターンずつ渦巻き状に巻回して形成した巻線S1,S2と、巻線P1の外周部から導電箔を引き出して形成した引き出し線、即ち中間タップXと、磁性部材8,13とから構成されている。
図3は、プリント基板2の図示を省略して、巻線P1,P2,S1,S2の構造を可視化した分解斜視図であり、トランス1に加えてプリント基板2の回路構成例も示す。回路構成の詳細は後述する。
巻線S1,S2の渦の内側の端部S1a,S2aは、プリント基板2を貫通して形成されたスルーホール4により接続され、これら巻線S1,S2で一式の2次巻線とする。巻線S1,S2の渦の外側の端部S1b,S2bは、プリント基板2に実装された回路部品に接続する。
なお、図示例では、プリント基板2の表層において巻線P1の外周部に中間タップXを形成したが、これに限定されるものではなく、プリント基板2の裏層において巻線P2の外周部に中間タップXを形成してもよい。
これら磁性部材8,13は、例えば鉄(フェライト)系の粉体を固めて成形したコアであってもよいし、磁性粉末を混練した樹脂を成形したコアであってもよい。また、形状もEIR型以外の形状であってもよい。
この光源点灯装置100は、直流電源101の直流電圧を利用して、車載用光源(ヘッドランプ、テールランプ、ストップランプ等)として用いるLED108を点灯するための点灯装置であり、主にDC/DCコンバータ部103、制御電源部104、制御部105、ドライバ106を備える。直流電源101は車載バッテリ(直流電圧12Vまたは24V)であり、電源スイッチ102によってDC/DCコンバータ部103への直流電圧が供給または遮断される。
このDC/DCコンバータ部103では、制御部105からドライバ106を経由して入力される制御信号でスイッチング素子Q1をスイッチング制御して、トランス1に磁気エネルギを蓄え、これを放出することで、トランス1で発生した電圧を、整流ダイオードD1で整流し、平滑コンデンサC1で平滑して直流電圧を生成する。
また、制御電源部104は、定電圧回路で生成した定電圧10Vを、シリーズ電源で構成する電源部104aによって5Vに降圧し、コンデンサC4で平滑して制御部105の電源入力端子へ印加する。
制御部105は、制御電源部104の生成する5V電源で動作する。この制御部105は、不図示のCPUおよびA/Dコンバータなどから構成され、A/Dコンバータを使用して、DC/DCコンバータ部103の入力電圧Vinおよび出力電圧Vout、シャント抵抗R1によって検出されるDC/DCコンバータ部103の出力電流をそれぞれ入力する。また制御部105は、これらの入力電圧Vin、出力電圧Voutおよび出力電流に基づいてスイッチング素子Q1をオンオフする制御信号を生成してDC/DCコンバータ部103を操作し、LED108に所定の点灯用電力を供給する。
ドライバ106は、制御電源部104の生成する10V電源で動作し、制御部105からの制御信号に基づき所定の電圧をスイッチング素子Q1のゲートに印加する。
この1面に1ターンの巻線を使用するトランスまたはコイルにおいて、巻線の中間タップは、プリント基板の1面に形成した当1ターンの巻線用導電箔上の1点に相当する。換言すれば、光源点灯装置100のような車載の低電圧機器においては、プリント基板2の表裏層に形成した巻線P1,P2に磁性部材8,13の面を接近して対向させ、DC/DCコンバータ部103の動作周波数を高くすることで、プリント基板2の1面に1ターン巻回した巻線P1,P2からなるトランス1(またはコイル)を構成することができ、当1ターンの巻線P1またはP2の途中から中間タップXとしての引き出し線を引き出すことができる。そして、当1ターンの巻線P1またはP2の生成する電圧が充分な電圧となるため、制御電源を生成する電力を供給する中間タップXとして使用できる。
このトランス1は、上記説明のとおり、巻線P1が1ターンで巻線P2も1ターンの1次巻線と、巻線S1が3ターンで巻線S2も3ターンの2次巻線とが分離(絶縁)されている。さらに、巻線P1,P2の接続点に相当する端部P1aの外周部に中間タップXが形成されている。
また、上記説明のとおり、巻線P1,P2と磁性部材8,13とを接近させて良好な特性を得ることが望ましく、図示例では巻線P1を磁性部材13に接近して対向する位置に配置、巻線P2を磁性部材8の平板部9に当接して対向する位置に配置している。
Vps=Vin+Vout×{p1/(s1+s2)} (1)
ここで、Vinは電源スイッチ102を介して直流電源101からトランス1へ供給される電源電圧(定常は12Vとする)、VoutはDC/DCコンバータ部103で生成する出力電圧(30V)、p1は巻線P1の巻回数(1ターン)、s1,s2は巻線S1,S2の巻回数(それぞれ3ターン)である。
Vps=7[V]+30[V]×{1/(3+3)}
=12[V] (1A)
Vd=Vin+Vout×{(p1+p2)/(s1+s2)} (2)
ここで、p2は巻線P2の巻回数(1ターン)である。
Vd=7[V]+30[V]×{(1+1)/(3+3)}
=17[V] (2A)
Vd=12[V]+30[V]×{(1+1)/(3+3)}
=22[V] (2B)
図5は、コイル1aについて、プリント基板2の図示を省略して巻線の構造を可視化した分解斜視図であり、コイル1aに加えてプリント基板2の回路構成も示す。図6は、DC/DCコンバータ部103aにコイル1aを使用してステップアップ電源を構成した場合の、光源点灯装置100の回路図である。
また、表層の2ターンのうちの外周1ターンと内周1ターンの接続点、即ち巻線P1,P2の接続点に相当する導電箔を引き出して、中間タップXが形成されている。この中間タップXは、巻線P1と同じプリント基板2の表層にある。
なお、表層に3ターン以上の渦巻き状導電箔を形成した場合には、最外周1ターンの1点から引き出し線を引き出して中間タップXにする。
Vps=Vin+(Vout-Vin)×{p1/(p1+p2)} (3)
Vps=6[V]+(30-6)[V]×{1/(1+3)}
=12[V] (3A)
図7は、実施の形態1に係る光源点灯装置100の変形例であり、単巻トランス1bを使用する場合の回路図を示す。この例では、単巻トランス1bの1次巻線P2の端部と、2次巻線S1の端部とを接続し、この接続点をスイッチング素子Q1を介して直流電源101のマイナス電極に接続している。
ちなみに、図7のような単巻トランス1bを用いるDC/DCコンバータ部103においては、LED108の出力端子を短絡したときに流れる電流を、このDC/DCコンバータ部103bの制御では遮断できない。これに対して、図4のようなトランス1を用いると、出力端子を短絡したときに、磁性部材8,13に貯えた磁気エネルギ以上の出力はない、即ち、1次側のスイッチング素子Q1は貯えた磁気エネルギ相当の電力だけを負担するため、出力端子短絡時にも過剰な負担を強いられることはない。
ちなみに、図4のような絶縁タイプのトランス1では、全ての出力電圧Voutが一度磁気エネルギに変換されるが、単巻トランス1bにおいては出力電圧Voutと電源電圧Vinの差分に対応する電力を磁気エネルギで補填すれば充分なため、1次側のスイッチング素子Q1の負担が少なく、スイッチング損失も小さい。また、小形の磁性部材(コア)8,13を使用することができる。
以下、図1~図7を援用して、本実施の形態2を説明する。
上記実施の形態1で説明したトランス1において、使用する磁性部材(コア)8,13は、渦巻き状導電箔の極近傍に対向して配置することが望ましく、フェライト系の磁性部材8,13を用いる場合は、磁性部材8の平板部9および磁性部材13の平面部を巻線P1,P2に当接するように組み付ければ、良好な特性が得られる。
しかしながら、剛体のフェライト系磁性部材8,13を使用する限り、部品のばらつき等による破損防止のために、また組み立て性向上のために、図2に示すようにいくらかのクリアランスが必要である。そのため、磁性部材(コア)をプリント基板2の表裏どちらか一方の巻線P1,P2に対して当接することしかできず、プリント基板2との隙間を全く無くすことはできない。
ただし、磁束が集中する渦巻き状の巻線P1,P2,S1,S2の中央を貫通する磁性部材22の中央脚部21の断面積を小さくするためには、磁気抵抗の少ない磁性材料を使用する必要があるが、磁性粉末混練樹脂は透磁率が低く、中央脚部21を小径に保ちながら磁気抵抗を低くすることが困難である。そのため、磁性部材22のうち、中央脚部21を透磁率の高いフェライト等の磁性材料で形成し、残りの部位を磁性粉末混練樹脂で形成する。
また、外側脚部23をインサート成形により磁性部材22と一体に形成するために、鋳込む前のプリント基板2に予め外側脚部挿通穴6,7を開設しておく。これにより、この外側脚部挿通穴6,7に入り込んだ磁性粉末混練樹脂が、外側脚部23となる。
このシート式のトランス1cにおいて、プリント基板2には、磁性部材(コア)の中央脚部が貫通する中央脚部挿通穴5cと、複数の外側脚部が貫通する複数の外側脚部挿通穴6cとが形成されている。また、プリント基板2の表層と裏層には巻線P1,P2が渦巻き状に形成され、2層の中間層それぞれに巻線S1,S2が渦巻き状に形成されている。
金型に設置したプリント基板2の中央脚部挿通穴5cには、フェライト等の円柱状の磁性部材(コア)21を貫通させる。また、プリント基板2を間に挟むように、磁性粉末混練樹脂を流し込むことによって、磁性部材8,13(中央脚部10を除く)に相当する磁性部材22をインサート成形する。このとき、プリント基板2には予め複数の外側脚部挿通穴6cが開設されているので、この外側脚部挿通穴6cに入った磁性粉末混練樹脂が外側脚部23になる。これにより、巻線P1,P2が磁性部材22の平板部24,25に密着する。
また、これら平板部24,25は、半径方向の広がりに伴い円周長が中心から外側に向かって拡大するので、磁束の通路が不必要に拡大しないように、半径方向の広がり(円周長の拡大)につれて磁性部材22の厚さを薄くして、円周長と厚さの積(断面積)を半径方向の位置によらず同等にしている。
この構成は、トランス1cに限らず、単巻トランス1bおよびコイル1aでも同様である。
Claims (8)
- 車載灯具の光源に点灯用の電力を供給する光源点灯装置であって、
渦巻き状の導電部材で形成された巻線と磁性部材とで構成されたトランスあるいはコイルを使用し、電源から前記点灯用の電力を生成するDC/DCコンバータ部と、
前記DC/DCコンバータ部を制御する制御回路部と、
前記制御回路部に制御用の電源を供給する制御電源部とを備え、
前記制御電源部への電力は、
前記トランスあるいは前記コイルを形成する巻線の端子と同一面から引き出した中間タップ(引き出し線)から供給することを特徴とする光源点灯装置。 - 前記制御電源部は、前記巻線の中間タップ(引き出し線)に生じる電圧を受けて、前記電源の電圧より高い電圧を出力することを特徴とする請求項1記載の光源点灯装置。
- 前記巻線は、電子部品を搭載するプリント基板の一部の導電箔を渦巻き状に形成したものであることを特徴とする請求項1記載の光源点灯装置。
- 前記磁性部材には、磁性粉末を混練した樹脂を用いることを特徴とする請求項1記載の光源点灯装置。
- 前記DC/DCコンバータ部は、1次巻線と2次巻線とが絶縁されたトランスを使用することを特徴とする請求項1記載の光源点灯装置。
- 前記DC/DCコンバータ部は、1次巻線の一端部と2次巻線の一端部とが接続された単巻トランスを使用することを特徴とする請求項1記載の光源点灯装置。
- 前記DC/DCコンバータ部は、中間タップ(引き出し線)を設けたコイルを使用することを特徴とする請求項1記載の光源点灯装置。
- 前記光源は、放電灯あるいはLEDであることを特徴とする請求項1記載の光源点灯装置。
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CN201180072873.8A CN103748776B (zh) | 2011-09-28 | 2011-09-28 | 光源点灯装置 |
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JP2016123166A (ja) * | 2014-12-24 | 2016-07-07 | 東芝ライテック株式会社 | 電源装置 |
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JP2017508284A (ja) * | 2014-02-14 | 2017-03-23 | フィリップス ライティング ホールディング ビー ヴィ | 給電信号及びデータ信号を提供するためのトランス |
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WO2021111566A1 (ja) * | 2019-12-04 | 2021-06-10 | 三菱電機株式会社 | スイッチング電源装置 |
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JP2017508284A (ja) * | 2014-02-14 | 2017-03-23 | フィリップス ライティング ホールディング ビー ヴィ | 給電信号及びデータ信号を提供するためのトランス |
US9595872B2 (en) | 2014-10-22 | 2017-03-14 | Bose Corporation | Adjustment of circuit operations in response to AC line distortion |
JP2016123166A (ja) * | 2014-12-24 | 2016-07-07 | 東芝ライテック株式会社 | 電源装置 |
US20180343742A1 (en) * | 2017-05-23 | 2018-11-29 | Omron Automotive Electronics Co., Ltd. | Transformer integrated type printed circuit board |
US10405429B2 (en) | 2017-05-23 | 2019-09-03 | Omron Corporation | Transformer integrated type printed circuit board |
WO2021111566A1 (ja) * | 2019-12-04 | 2021-06-10 | 三菱電機株式会社 | スイッチング電源装置 |
WO2022064662A1 (ja) * | 2020-09-25 | 2022-03-31 | 住友電気工業株式会社 | トランス及びコンバータ |
Also Published As
Publication number | Publication date |
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CN103748776B (zh) | 2016-08-17 |
DE112011105682T5 (de) | 2014-07-17 |
JP5788012B2 (ja) | 2015-09-30 |
CN103748776A (zh) | 2014-04-23 |
JPWO2013046259A1 (ja) | 2015-03-26 |
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