WO2015079869A1 - Noyau magnétique sans espace, dispositif de bobine l'utilisant et procédé de fabrication de dispositif de bobine - Google Patents

Noyau magnétique sans espace, dispositif de bobine l'utilisant et procédé de fabrication de dispositif de bobine Download PDF

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Publication number
WO2015079869A1
WO2015079869A1 PCT/JP2014/079209 JP2014079209W WO2015079869A1 WO 2015079869 A1 WO2015079869 A1 WO 2015079869A1 JP 2014079209 W JP2014079209 W JP 2014079209W WO 2015079869 A1 WO2015079869 A1 WO 2015079869A1
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WO
WIPO (PCT)
Prior art keywords
segment
main body
end surface
cutting
cut
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Application number
PCT/JP2014/079209
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English (en)
Japanese (ja)
Inventor
今西　恒次
康臣 ▲高▼橋
吉森　平
Original Assignee
株式会社エス・エッチ・ティ
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Publication of WO2015079869A1 publication Critical patent/WO2015079869A1/fr

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F17/06—Fixed inductances of the signal type  with magnetic core with core substantially closed in itself, e.g. toroid
    • H01F17/062—Toroidal core with turns of coil around it
    • 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
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/263—Fastening parts of the core together
    • 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
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits

Definitions

  • the present invention relates to a magnetic core used in a coil device installed in a rectifier circuit, a noise prevention circuit, a resonance circuit, etc. in an AC device such as a power supply circuit and an inverter, a coil device using the same, and a method of manufacturing the coil device. is there.
  • Coil devices mounted on circuits of various AC devices are configured by winding a coil around an annular magnetic core.
  • a magnetic core having a gap formed in part is formed, an air core coil wound in advance is inserted from this gap, and then the gap is filled with a magnetic or non-magnetic filler.
  • a gap is formed between one end face of the magnetic core forming the air gap and the filler, and between the filler and the other end face of the magnetic core.
  • interval of the gaps formed on both sides of a filler is not constant. For this reason, in a coil device using such a magnetic core, variations in quality such as magnetic characteristics occur, such as a decrease in inductance characteristics.
  • the filler and the magnetic core have different magnetic characteristics and the like, the magnetic characteristics and the like are deteriorated.
  • An object of the present invention is to provide a gapless magnetic core that is excellent in quality such as magnetic characteristics, has small variations in these characteristics, and has excellent manufacturing efficiency, a coil device using the same, and a manufacturing method of the coil device. is there.
  • the gapless magnetic core according to the present invention is An annular member including an annular magnetic body made of a magnetic material is cut at a first cutting portion and a second cutting portion that cross the outer peripheral surface and the inner peripheral surface and approach each other toward the inner peripheral direction of the annular member; A main body having a main body side first end surface cut by the first cutting portion and a main body side second end surface cut by the second cutting portion; Obtaining a segment having a segment-side first end face cut by the first cutting part and a segment-side second end face cut by the second cutting part; In the notch formed between the main body side first end surface and the main body side second end surface, the main body side first end surface and the segment side first end surface, the main body side second end surface and the segment side first It is formed by pushing the segment so that the two end faces abut.
  • the inner peripheral end surface of the segment protrudes inward from the inner peripheral surface of the main body.
  • an angle formed by the first cutting portion and the second cutting portion is preferably 90 ° or less, and is preferably 75 ° or less.
  • an angle formed by the first cutting portion and the second cutting portion is 20 ° or more.
  • the main body side first end face and the segment side first end face, and the main body side second end face and the segment side second end face can be fixed by bonding or clamping.
  • the annular member may include an annular magnetic body and an insulating resin coating that covers the magnetic body.
  • the magnetic body is preferably a compacted body of magnetic material
  • the resin coating is preferably formed by an insert molding method or a resin powder coating method.
  • the coil device of the present invention comprises: The gapless magnetic core body described above is configured by inserting an air core coil pre-wound from the notch portion and then pushing the segment into the notch portion.
  • the manufacturing method of the coil device of the present invention includes: An annular member including an annular magnetic body made of a magnetic material is cut at a first cutting portion and a second cutting portion that cross the outer peripheral surface and the inner peripheral surface and approach each other toward the inner peripheral direction of the annular member; A main body having a main body side first end surface cut by the first cutting portion and a main body side second end surface cut by the second cutting portion; Obtaining a segment having a segment-side first end face cut by the first cutting part and a segment-side second end face cut by the second cutting part; An air core coil wound in advance is inserted into a notch formed between the main body side first end surface and the main body side second end surface, and the main body side first end surface and the segment side first end surface, The segment is pushed in so that the main body side second end surface and the segment side second end surface are in contact with each other, thereby forming a coil device.
  • the main body and the segment are in close contact with each other without having a gap just by pushing the segment into the notch of the main body, so that there is no leakage of magnetic flux due to the gap, and there is no magnetism due to the size of the gap. Since there is no variation in characteristics and the like, it is possible to provide an excellent gapless magnetic core with stable magnetic characteristics and a coil device using the same.
  • the gapless magnetic core of the present invention is made of the same annular member and the main body and the segment, these magnetic characteristics and the like are the same, and the manufactured gapless magnetic core and the coil device using the same are: Stable magnetic properties can be exhibited.
  • FIG. 1 is a plan view (angle ⁇ is 60 °) showing an embodiment of a gapless magnetic core of the present invention.
  • FIG. 2 is an enlarged cross-sectional view of a gapless magnetic core obtained by cutting the circled portion of FIG. 1 in the height direction.
  • FIG. 3 is a plan view of the annular member according to the embodiment of the present invention before cutting.
  • FIG. 4 is a cross-sectional view taken along line AA in FIG.
  • FIG. 5 is a plan view of a main body and a segment obtained by cutting the annular member of FIG.
  • FIG. 6 is a plan view showing a state in which a segment is taken out from the main body of FIG.
  • FIG. 7 is a perspective view showing a process of inserting the air-core coil into the main body of FIG.
  • FIG. 8 is a perspective view showing a process of inserting the air-core coil into the main body, following FIG. FIG. 9 is a perspective view showing a process of attaching the segment to the main body in which the air-core coil is inserted.
  • FIG. 10 is a plan view of FIG.
  • FIG. 11 is a perspective view of a coil device obtained by attaching segments.
  • FIG. 12 is a plan view of the coil device of FIG.
  • FIG. 13 is a plan view of a gapless magnetic core having an angle ⁇ of 75 °.
  • FIG. 14 is a plan view of a gapless magnetic core having an angle ⁇ of 45 °.
  • FIG. 15 is a plan view of a gapless magnetic core having an angle ⁇ of 30 °.
  • FIG. 16 is a plan view of a gapless magnetic core having an angle ⁇ of 20 °.
  • FIG. 17 is a plan view of a gapless magnetic core having an angle ⁇ of 60 ° and shows an embodiment in which the retaining shape of the resin coating layer is changed.
  • FIG. 18 is a plan view of a gapless magnetic core having an angle ⁇ of 80 °, and shows an embodiment in which the retaining shape of the resin coating layer is changed.
  • FIG. 19 is a graph showing the DC superposition characteristics of the first embodiment.
  • FIG. 20 is a graph showing a comparison result between the angle ⁇ and the initial inductance value in the second embodiment.
  • FIG. 21 is a graph showing a comparison result between the opposing area P of the main body and the segment of the third embodiment and the initial inductance value.
  • FIG. 22 is an explanatory diagram (a) and (b) for comparing the opening widths of teardrop-shaped and annular annular members, and a table (c) for comparing the characteristics.
  • gapless magnetic core 10 according to the present invention will be described with reference to the drawings, and then an embodiment of the coil device 50 using the gapless magnetic core 10 will be described.
  • FIG. 1 is a plan view of a gapless magnetic core 10 according to an embodiment of the present invention.
  • the gapless magnetic core 10 includes a main body 30 with a notch 31 formed in part and a segment 40 that fits into the notch 31 of the main body 30.
  • the segment 40 and the cutout portion 31 of the main body 30 from which the segment 40 is cut out have shapes in which the contact surfaces approach the inner peripheral surface of the main body 30, that is, approximately
  • the inner peripheral surface of the segment 40 has a fan shape, and the magnetic body 21 protrudes inward (protrusion amount S) from the inner peripheral surface of the main body 30.
  • the gapless magnetic core 10 having the above-described configuration can be manufactured in the following manner.
  • the cross section of the magnetic body 21 may be circular, elliptical, or the like.
  • the shape of the annular member 20 may be a teardrop shape, an annular shape, an elliptical shape, an oval shape, a rectangular shape, or the like.
  • FIG. 3 shows a teardrop-shaped annular member 20, and the annular member 20 connects one end of the linear first straight portion 23 and the second straight portion 24 at a substantially right angle with a curved portion 25 having a small curvature radius, These other ends are connected by an arc portion 26 having a large curvature radius.
  • Examples of magnetic materials used for the magnetic body 21 include iron-based, iron-silicon-based, iron-aluminum-silicon-based, iron-nickel-based materials, iron-based and Co-based amorphous materials, and the like.
  • the magnetic body 21 is formed by pressing or compacting a powder made of a magnetic material, a ferrite core formed by sintering a powder made of a magnetic material, and a thin plate made of a magnetic material.
  • the laminated magnetic core can be made.
  • the peripheral surface may collapse when the cutting blade is applied. Accordingly, it is preferable to obtain the annular member 20 by insert-molding the magnetic body 21 made of a compacted body with an insulating resin and forming the resin coating 22 on the outer periphery of the magnetic body 21. Thereby, it can prevent that the magnetic body 21 collapse
  • the annular member 20 can also be produced by a resin powder coating method.
  • the produced annular member 20 crosses the inner circumferential surface and the outer circumferential surface and approaches the inner circumferential direction of the annular member 20 and the second cutting portion 27 and the second cutting portion 27.
  • Cutting is performed by the cutting unit 28.
  • the 1st cutting part 27 and the 2nd cutting part 28 implement a cutting
  • the cutting of the annular member 20 can be performed with a rotating cutting blade or the like.
  • a metal-bonded diamond grindstone can be exemplified.
  • the annular member 20 is preferably cut by the straight portions 23 and 24 in order to prevent the cutting blade from escaping.
  • a cutting allowance 29 corresponding to the thickness of the cutting blade is required. That is, the segment 40 becomes smaller by the cutting allowances 29 and 29 than the cutout portion 31 of the main body 30 where the annular member 20 is cut and the segment 40 is cut.
  • it is desirable to reduce the thickness of the cutting blade For example, it is preferable to use a cutting blade having a blade thickness of 0.5 mm to 1.2 mm or a blade thickness thinner than 0.7 mm.
  • the first straight portion 23 or the second straight portion 24 is cut at least one of the first cut portion 27 or the second cut portion 28.
  • the other cutting of the first cutting portion 27 or the second cutting portion 28 is preferably performed between the bent portion 25 and the end of the first straight portion 23 or the second straight portion 24.
  • a wide opening width 36 for inserting the air-core coil 51 (FIG. 7, etc., which will be described later) can be secured in the cutout portion 31 of the main body 30 from which the segment 40 is cut out. it can.
  • the opening width 36 will be described in detail in the fourth embodiment.
  • an end face for example, a first end face on the main body side
  • the end surface opposite to the end surface has the notch 31 in FIG. It is desirable to form it in parallel to (indicated by an arrow in FIG. 7).
  • the obtained segment 40 is pushed into the notch 31 of the main body 30 from the outer peripheral side and fixed, so that the notch 31 is backfilled and the gapless magnetic core 10 can be obtained.
  • the cutting allowance 29 is required. Therefore, the segment 40 is pushed into the cutout portion 31 of the main body 30, and the main body side first end face 32 and the segment side first end face 42 are When the main body side second end surface 33 and the segment side second end surface 43 are brought into close contact with each other, the segment 40 is cut out by the thickness of the cutting allowances 29 and 29 as shown in FIG. 1 and the enlarged sectional view 2. It enters the inside of the portion 31 and protrudes by an amount of protrusion S toward the inner peripheral side of the main body 30.
  • the segment 40 is pushed in until the main body side first end face 32 and the segment side first end face 42 and the main body side second end face 33 and the segment side second end face 43 are in close contact with each other in the pushing direction which is the width direction of the main body 30. Therefore, fine adjustment of the pushing amount of the segment 40 with respect to the notch 31 is unnecessary. That is, since it is only necessary to adjust the position of the segment 40 only in the height direction with respect to the notch 31, the gapless magnetic core 10 can be manufactured very easily.
  • the step of forming the segment from another member can be eliminated, and in addition, the loss of raw materials is almost all. Therefore, the production efficiency can be increased as much as possible.
  • a method for manufacturing the coil device 50 using the gapless magnetic core 10 will be described. First, after cutting out the segment 40 from the annular member 20 (FIG. 6), as shown in FIGS. 7 to 10, an air-core coil 51 in which a conducting wire is wound in advance from the notch 31 is inserted into the main body 30.
  • the air-core coil 51 is manufactured by winding in accordance with the outer peripheral shape of the main body 30. And after inserting the air-core coil 51 in the main body 30, as shown in FIG.11 and FIG.12, the segment 40 is pushed and fixed to the notch part 31 of the main body 30 in the same way as the above, and a coil apparatus is carried out. 50 is produced.
  • the manufactured coil device 50 has no gap, and since the inner circumferential side magnetic path M passing through the magnetic body 21 and a substantial cross-sectional area are secured, the coil device 50 is stable. Magnetic properties and the like. Moreover, it has the various effects mentioned above.
  • the cutting allowance 29 is thin.
  • the resin coating portion 22 is formed with one end face 28 of the main body 30 and protrusions 34 and 44 that are to be prevented from being removed from the segment 40, respectively.
  • the air-core coil 51 When the air-core coil 51 is inserted from the one end surface 27 of the main body 30, the air-core coil 51 hits the retaining member 34, so that it can be prevented from falling off. Further, after the coil device 50 is manufactured, the retaining cores 34 and 44 can prevent the air-core coil 51 from moving on the gapless magnetic core 10, and the lead terminal of the air-core coil 51 is positioned. be able to.
  • a plurality of green compacts were produced from Sendust powder (composition: Fe—Si—Al alloy) as the magnetic body 21, and an annular member 20 in which the resin coating portion 22 was formed by insert molding was obtained.
  • the magnetic body 21 has a teardrop shape having a cross section with a width of 9.8 mm and a height of 25 mm, an inner peripheral length of 84 mm, and an average magnetic path length of 114 mm.
  • the thickness of the resin coating part 22 is 0.6 mm.
  • the inventive example 4 in which the angle ⁇ is 75 ° exhibits the highest inductance value, and the inductance value decreases as the angle ⁇ decreases.
  • ⁇ Second embodiment Comparison of initial inductance values> Further, the angle ⁇ formed by the first cutting portion 27 and the second cutting portion 28 from the annular member 20 is 0 ° (comparative example: the first cutting portion and the second cutting portion are parallel), 10 ° (Invention Example 21). ), 20 ° (Invention Example 22), 30 ° (Invention Example 23), 45 ° (Invention Example 24), and 75 ° (Invention Example 25). These initial inductance values were measured. The results are shown in FIG.
  • the invention example 22 in which the angle ⁇ is 20 ° has an initial inductance value improved by about 14% compared to the comparative example, and the angle ⁇ is 75.
  • Inventive Example 25 which is ° was able to improve the initial inductance value by about 29% compared to the comparative example.
  • Invention Example 21 in which the angle ⁇ is 10 ° has an initial inductance value substantially equal to that of the comparative example. This is because a sufficient magnetic path could not be secured as a result of an increase in the projecting amount S of the segment 40 toward the inner periphery.
  • a magnetic path M without a gap can be ensured simply by pushing the segment 40 into the notch 31, so that even when the angle ⁇ is 10 °, when the plurality of coil devices 50 are manufactured, There is an advantage that a certain inductance value can be secured.
  • since it is difficult to adjust the width of the two gaps in the comparative example it is difficult to obtain a constant inductance value when a plurality of coil devices are manufactured, and the invention example is superior.
  • the initial inductance value is linearly decreased in the range where the angle ⁇ is 75 ° to 30 °.
  • the angle ⁇ is changed from 30 ° to 20 °
  • the decrease amount of the initial inductance value is increased
  • the angle ⁇ is changed from 20 ° to 10 °
  • the initial inductance value is greatly reduced.
  • the lower limit of the angle ⁇ formed by the first cutting portion 27 and the second cutting portion 28 is preferably 20 ° or more, and more preferably 30 ° or more.
  • ⁇ Third embodiment Comparison of opposing area P of main body and segment and initial inductance value>
  • the angle ⁇ formed by the first cutting portion 27 and the second cutting portion 28 from the annular member 20 is 20 ° (invention).
  • segment 40 was cut out to be 30 ° (Invention Example 32), 45 ° (Invention Example 33), 60 ° (Invention Example 34), and 75 ° (Invention Example 25). They were prepared and their initial inductance values were measured. The results are shown in FIG.
  • the initial inductance value increases as the ratio of the opposed area P to the cross-sectional area C increases.
  • ⁇ Fourth embodiment Comparison of opening widths for inserting air-core coils> As shown in FIGS. 22A and 22B, the size of the segment 40 necessary for forming the notch 31 having the same opening width 36 in which the annular member 20 has a teardrop shape and an annular shape (toroidal core). Compared. The teardrop-shaped annular member 20 (FIG. 22A) was cut so that the first cutting portion 27 was positioned at the curved portion 25 and the second cutting portion 28 was positioned at the second straight portion 24.
  • the size of the segment 40 to be cut out is smaller than that of the annular annular member 20. This is because the notch 31 is formed so as to include the curved portion 25 having a small radius of curvature.
  • the teardrop-shaped annular member 20 needs to chuck the annular member 20 with a jig or the like at the time of cutting. Since a large area can be stably chucked with reference to 23 or 24 and cutting can be performed, positioning is easy. In addition, since the cutting portion 28 is positioned on the straight portion 24, the cutting blade can be orthogonally cut with respect to the straight portion 28, so that the cutting blade can be cut off easily and the cutting operation can be easily performed. .
  • the present invention is particularly suitable for application to the teardrop-shaped annular member 20.
  • the teardrop-shaped annular member 20 is superior in positioning accuracy and workability.
  • the segment 40 can be returned to another main body 30 without returning to the main body 30 from which the segment 40 is cut out.
  • the segment 40 can also be arranged such that the segment-side first end face 42 abuts on the main body-side second end face 33 and the segment-side second end face 43 abuts on the main body-side first end face 32.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

La présente invention concerne ce qui suit : un noyau magnétique sans espace dont la qualité est excellente par rapport aux caractéristiques magnétiques et analogues, avec lequel les variations de telles caractéristiques sont faibles et dont l'efficacité de fabrication est excellente ; un dispositif de bobine l'utilisant ; et un procédé de fabrication du dispositif de bobine. Le noyau magnétique sans espace (10) est formé de la façon suivante : un élément annulaire (20) qui comprend un corps magnétique annulaire (21) fait d'un matériau magnétique est découpé par une première partie de découpe (27) et une seconde partie de découpe (28) qui traversent une surface circonférentielle externe et une surface circonférentielle interne et s'approchent l'une de l'autre en allant vers la circonférence interne de l'élément annulaire ; un corps principal (30) est obtenu et comprend une première surface d'extrémité (32) qui est découpée par la première partie de découpe (27) et une seconde surface d'extrémité (33) qui est découpée par la seconde partie de découpe ; un segment (40) est obtenu et comprend une première surface d'extrémité (43) découpée par la première partie de découpe et une seconde surface d'extrémité (44) découpée par la seconde partie de découpe ; et le segment est appuyé dans une section encoche (31) formée entre la première surface d'extrémité et la seconde surface d'extrémité du corps principal, de sorte que les premières surfaces d'extrémité (33, 42) viennent buter l'une contre l'autre et que les secondes surfaces d'extrémité (33, 43) viennent buter l'une contre l'autre.
PCT/JP2014/079209 2013-11-26 2014-11-04 Noyau magnétique sans espace, dispositif de bobine l'utilisant et procédé de fabrication de dispositif de bobine WO2015079869A1 (fr)

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JP2013-244043 2013-11-26
JP2013244043A JP6039538B2 (ja) 2013-11-26 2013-11-26 ギャップレス磁芯、これを用いたコイル装置及びコイル装置の製造方法

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JP6055871B2 (ja) 2015-06-03 2016-12-27 株式会社エス・エッチ・ティ コイル部品に用いられるモールドコアの切断方法

Citations (5)

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Publication number Priority date Publication date Assignee Title
JPS63282667A (ja) * 1987-02-19 1988-11-18 イートン　コーポレイション 電流−電圧トランスデューサ
JP2003124015A (ja) * 2001-10-18 2003-04-25 Nec Tokin Corp 圧粉磁心、コイル部品、及びそれらを用いた電力変換装置
JP2006237030A (ja) * 2005-02-22 2006-09-07 Sht Corp Ltd 鉄心及びその製造方法
JP2011181869A (ja) * 2010-03-04 2011-09-15 Sht Corp Ltd 磁性コア
JP5509267B2 (ja) * 2012-07-13 2014-06-04 株式会社エス・エッチ・ティ 涙滴状磁芯及びこれを用いたコイル装置

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH07120593B2 (ja) * 1987-02-12 1995-12-20 サンケン電気株式会社 直流変流器
JP2013149801A (ja) * 2012-01-19 2013-08-01 Takanari Terakawa ノイズ減衰器用可変インダクター

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS63282667A (ja) * 1987-02-19 1988-11-18 イートン　コーポレイション 電流−電圧トランスデューサ
JP2003124015A (ja) * 2001-10-18 2003-04-25 Nec Tokin Corp 圧粉磁心、コイル部品、及びそれらを用いた電力変換装置
JP2006237030A (ja) * 2005-02-22 2006-09-07 Sht Corp Ltd 鉄心及びその製造方法
JP2011181869A (ja) * 2010-03-04 2011-09-15 Sht Corp Ltd 磁性コア
JP5509267B2 (ja) * 2012-07-13 2014-06-04 株式会社エス・エッチ・ティ 涙滴状磁芯及びこれを用いたコイル装置

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