WO2021187049A1 - Coil device - Google Patents

Coil device Download PDF

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Publication number
WO2021187049A1
WO2021187049A1 PCT/JP2021/007272 JP2021007272W WO2021187049A1 WO 2021187049 A1 WO2021187049 A1 WO 2021187049A1 JP 2021007272 W JP2021007272 W JP 2021007272W WO 2021187049 A1 WO2021187049 A1 WO 2021187049A1
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WIPO (PCT)
Prior art keywords
coil
coil winding
winding
magnetic core
coil device
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PCT/JP2021/007272
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French (fr)
Japanese (ja)
Inventor
弘文 仲澤
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ソニーグループ株式会社
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Application filed by ソニーグループ株式会社 filed Critical ソニーグループ株式会社
Priority to CN202180020284.9A priority Critical patent/CN115280440A/en
Priority to JP2022508167A priority patent/JPWO2021187049A1/ja
Publication of WO2021187049A1 publication Critical patent/WO2021187049A1/en

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/29Terminals; Tapping arrangements for signal inductances
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00Fixed inductances not covered by group H01F17/00

Definitions

  • This technology relates to a coil device that is mounted on a power supply unit or the like and is mainly applied to a common mode coil or a choke coil used for EMC (Electro-Magnetic Compatibility) countermeasures.
  • EMC Electro-Magnetic Compatibility
  • Patent Document 1 describes an invention relating to a common choke coil.
  • This common choke coil eliminates common mode noise.
  • the common choke coil for example, two conducting wires are wound around a toroidal core to form two coils. The winding directions of the coils are opposite to each other, and when a common mode current flows through the coil, magnetic fluxes are generated in the same direction, and the magnetic fluxes strengthen each other to block the passage of the common mode current, thereby blocking the inductor. Functions as.
  • the filter does not function as an inductor for the current in the differential mode, but acts as an inductor only in the common mode.
  • the coil device is vertically placed in order to reduce the installation space of the coil device on the substrate. In this case, the configuration of the coil and the connection terminal is devised.
  • Conductor loss (W) I 2 x R I (A): Effective current value, R ( ⁇ ): Conductor resistance value
  • the purpose of this technology is to provide a coil device that can easily cope with high power consumption.
  • This technology uses magnetic core and A plurality of coil winding bodies wound around a magnetic core so that the surfaces forming the long sides of the cross section of the flat wire are laminated.
  • a base that supports a magnetic core with a coil winding body, and It is provided on the base and has a connection terminal to be connected to the end of the coil winding body.
  • This is a coil device in which a connection terminal has a plate-shaped electrode that sandwiches an end surface derived from a coil winding body.
  • FIG. 1 is an external perspective view of a conventional common mode coil.
  • FIG. 2 is an exploded perspective view of a conventional common mode coil.
  • FIG. 3 is a perspective view of an embodiment of the present technology.
  • FIG. 4 is an exploded perspective view of an embodiment of the present technology.
  • FIG. 5 is a perspective view of a modified example of the embodiment of the present technology.
  • FIG. 6 is an exploded perspective view of a modified example of the embodiment of the present technology.
  • FIG. 7 is a partial perspective view of a modified example of the embodiment of the present technology.
  • FIG. 8 is a perspective view for explaining a process of winding an electric wire.
  • FIG. 9 is a perspective view for explaining the assembly process.
  • FIG. 10 is a perspective view of the coil device after assembly.
  • FIG. 10 is a perspective view of the coil device after assembly.
  • FIG. 11 is a front view of the coil device.
  • FIG. 12 is an enlarged perspective view of a part of FIG. 10.
  • FIG. 13 is an enlarged perspective view of a part of FIG. 10.
  • FIG. 14 is a perspective view used for explaining a modified example of the connection terminal.
  • FIG. 15 is an enlarged perspective view used for explaining a modified example of the connection terminal.
  • FIG. 16 is an enlarged perspective view used for explaining a modified example of the connection terminal.
  • FIG. 17 is a partial perspective view of another embodiment of the present technology.
  • FIG. 18 is a schematic diagram used for explaining the bending process of the winding start end portion.
  • FIG. 1 is an external perspective view of a conventional common mode coil
  • FIG. 2 is an exploded perspective view thereof.
  • a ring-shaped magnetic core 1 made of a magnetic material (iron core) having a main composition of Mn—Zn ferrite, iron amorphous, or the like is incorporated into a resin lower case 2 and a resin upper case 3.
  • An electric wire is wound around the lower case 2 and the upper case 3 in which the ring-shaped magnetic core 1 is incorporated, and the coil winding body 4a and the coil winding body 4b are formed.
  • the coil winding bodies 4a and 4b are provided by winding an electric wire having various insulating films on the surface, which is generally called an enamel electric wire and has a circular conductor cross-sectional shape.
  • the lower case 2 and the upper case 3 provided with the coil winding bodies 4a and 4b are incorporated into the resin pedestal 5.
  • the conductor diameter and number of turns of the wires can be easily selected according to the required electrical characteristics of the coil, the applied current value, the operating temperature environment, etc. It is said to be adjustable.
  • the first method is a method of reducing the resistance value by reducing the number of turns and shortening the total length of the conductor.
  • the inductance value is lowered at the same time, which means that the electromagnetic filter performance of the common mode coil is lowered, and the loss reduction and the filter performance are in a trade-off relationship.
  • the second method is to reduce the resistance value by increasing the diameter of the electric wire and increasing the conductor area.
  • the coil winding space occupancy rate decreases, which is specified. Since the number of turns cannot be rotated, the relationship is the same as that of the first method as a result.
  • productivity As the wire diameter increases, the bending strength of the wire becomes higher (difficult to bend), which makes the work itself extremely hard work, which significantly deteriorates productivity, and in recent years it has become extremely difficult to secure workers. There is a concern that the cost of parts will rise due to the fact that it has been increasing.
  • Edgewise winding is a winding method in which the edge side (short side side of the cross section) of the flat wire is wound in a direction in which it is difficult to bend, and the surfaces forming the long side side thereof are laminated.
  • the various insulating film layers (thickness) added to the flat wire are very thin, and according to JIS C3215-01: 2014, the minimum thickness is 0.06 mm to the maximum of 0.17 mm.
  • the insulating film layer (thickness) inside the center of the long side of the flat wire shrinks, and the outer diameter (outer diameter of the coil winding body) is It will be a growing situation. If it is forcibly stretched from this state, it can be easily imagined that the damage to the already stretched insulating film layer (thickness) will increase and the insulation performance will deteriorate, resulting in long-term component reliability (life). May affect.
  • the terminal pin entanglement / solder joining method which is a general joining method, can be used for both ends of the coil winding body.
  • the conductor cross-sectional area is expanded to reduce the conductor resistance value in order to reduce the loss, so the bending strength also increases and the terminal pin entanglement explained for low current is used.
  • the solder bonding method cannot be used. Therefore, it is not possible to perform the substrate bonding portion forming work in consideration of long-term reliability (life) by simply winding the flat wire edgewise, and it is not possible to improve the work process.
  • FIG. 3 is an external perspective view of an embodiment of the present technology
  • FIG. 4 is an exploded perspective view thereof.
  • the two perspective views of FIG. 3 are perspective views viewed from different directions.
  • the magnetic core 11 in one embodiment is a frame type composed of four sides, and a first coil winding body 13a and a second coil winding body 13b are provided on the left side 12a and the right side 12b, respectively.
  • the magnetic core 11 is an integrally shaped magnetic core having no portion such as a division or a notch, and its surface is insulatingly coated.
  • the coil winding bodies 13a and 13b are flat (copper) wires having various enamel insulating (coating) layers such as polyurethane.
  • the coil winding body 13a is formed by winding an electric wire from the side of the upper side 12c toward the lower side 12d with respect to the left side 12a of the magnetic core 11 by a winding device.
  • the coil winding body 13b is formed by winding an electric wire from the side of the upper side 12c toward the lower side 12d with respect to the right side 12b of the magnetic core 11 by a winding device.
  • the electric wire is a flat wire having a rectangular cross section, and is wound (that is, edgewise wound) so that the surfaces forming the long sides of the cross section are laminated.
  • the thickness (short side) of the conductor of the flat wire is 0.4 mm or more
  • the width (long side) of the flat wire is three times or more the thickness.
  • the magnetic core 11 provided with the coil winding bodies 13a and 13b is supported by the resin base portion 14.
  • the base portion 14 is insulated from the four sides 15a, 15b, 15c, 15d on which the magnetic core 11 around which the first coil winding body 13a and the second coil winding body 13b are wound is placed, and the central portion. It is a resin frame made of a separator 16.
  • the first and second coil winding bodies 13a and 13b are arranged in the left and right openings 17a and 17b of the base portion 14.
  • a first connection terminal 18, a second connection terminal 19, a third connection terminal 20, and a fourth connection terminal 21 are provided at each corner of the base portion 14 by press fitting or the like.
  • These connection terminals 18 to 21 are formed by molding a metal such as copper, and a portion protruding from the upper surface of the base portion 14 is a portion to which the terminal lead portion of the electric wire is connected. The portion protruding from the lower surface is the portion connected to the substrate.
  • the winding end ends 22a and 22b of the coil winding bodies 13a and 13b are bent at substantially right angles to the end faces, respectively.
  • FIG. 5 is an external perspective view of a modified example
  • FIG. 6 is an exploded perspective view
  • FIG. 7 is a perspective view showing a state in which the magnetic core 11 is wrapped by the upper case 31a and the lower case 31b.
  • the two perspective views of FIG. 5 are perspective views viewed from different directions.
  • the magnetic core 11 has no insulating coating.
  • the upper cover 31a and the lower cover 31b have a structure in which the required creepage distance is secured and the upper cover 31a and the lower cover 31b are fitted to each other.
  • the difference from the configurations shown in FIGS. 3 and 4 described above is whether an insulating coating or a resin cover is used to insulate the closed magnetic circuit magnetic core 11, which is the requirement of various safety standards in each country and the quality of the customer. It can be selected based on the request.
  • the manufacturing process of the coil device will be described by taking as an example the one using the resin cover described with reference to FIGS. 5, 6 and 7.
  • a winding facility is used to push the flat wire in the direction of the arrow to bend the flat wire. It passes through the tool (not shown), draws a spiral along the peripheral surface of the resin cover composed of the upper cover 31a and the lower cover 31b, and winds the edgewise coil.
  • the winding equipment for example, those described in JP-A-2017-130506 can be used.
  • the electric wire of the coil winding body 13a is wound from the winding start end (starting end) 23a toward the winding end end (end) 22a, and the electric wire of the coil winding body 13b is wound from the winding start end (starting end) 23b. It is wound from the winding end toward the end (end) 22b.
  • both ends of the electric wire are further processed to provide a substrate bonding (lead) portion that can be directly bonded to the circuit board, or copper is used as the main material.
  • a method is adopted in which soldering is performed via a connection terminal that has been surface-treated (plated, etc.). Connection terminals are often used to ensure stable quality.
  • the present technology can be applied to any case.
  • connection terminals 18, 19, 20 and 21 are press-fitted into the four corners of the resin base portion 14.
  • the parts provided with the coil winding bodies 13a and 13b are vertically moved and incorporated along the insulating separator 16 provided at the center of the base portion 14.
  • guide grooves are provided in the inner portions of the upper cover 31a and the lower cover 31b so that stable assembly is performed, and the side surface portions of the insulating separator 16 slide along the guide grooves and are incorporated.
  • work is performed to electrically connect the terminal lead portion of the coil winding body and various connection terminals.
  • FIG. 10 is a perspective view of the coil device viewed from different directions.
  • FIG. 11 is a view taken along the line CC of FIG.
  • connection terminals 18 to 20 will be described.
  • the connection terminals 18 and 20 to which the winding start ends 23a and 23b are connected have the same structure, and the connection terminals 19 and 21 to which the winding end ends 22a and 22b are connected have the same structure.
  • FIG. 12 shows an enlarged portion A (connection terminal 20) in FIG. 10
  • FIG. 13 shows an enlarged portion B (connection terminal 19) in FIG.
  • connection terminal 20 is bent so as to have two surfaces (plate-shaped electrodes) having a surface substantially parallel to the surface of the electric wire (flat wire) of the winding start end 23b of the coil winding body 13b.
  • the tip of the winding start end 23b is inserted and arranged in the facing gap (groove) of the surface of the winding.
  • the connection terminal 19 is bent in a U shape so as to be substantially parallel to the surface of the winding end end 22a of the bent coil winding body 13a and to have two opposing surfaces (plate-shaped electrodes). ..
  • the winding end end 22a is inserted so that the winding end end 22a of the coil winding body 13a abuts on the inner side surface on the back side of the two plate-shaped electrodes. After that, by bending one of the two plate-shaped electrodes, the winding end end 22a is sandwiched by the connection terminal 19.
  • the winding start ends 23a and 23b of the coil winding bodies 13a and 13b are fitted in the grooves of the connection terminals 18 and 20, and the substrate is not bent again in the edgewise direction.
  • a joint (lead) portion can be formed, and the winding end ends 22a and 22b are made to abut on the inner side surface on the back side of the terminal bent in a U shape of the connection terminals 19 and 21.
  • the positions of the winding end ends 22a and 22b are arranged so as to be horizontal to the connection fixing surface of the connection terminals 19 and 21. That is, the positions of the winding end ends 22a and 22b are regulated so as to be perpendicular to the base portion 14. By doing so, the winding end ends 22a and 22b can be easily bent, and flatwise bending that can be easily connected to the connection terminal can be performed.
  • the rotational motion of the coil winding body 13a is fixed by sandwiching the winding end end portion 22a between the upper surface portions of the connection terminals 19, and in that state, the connection terminal portions are soldered or the like. It is electrically joined.
  • solder bonding by providing through holes on the upper surface of the connection terminal, the solder bonding area between the winding start end and winding end end and the connection terminal is expanded, and the mechanical bonding strength is improved. It is possible to improve the solder joining workability.
  • bonding using spot welding or the like may be performed. In this case, it is preferable to emboss a cylinder or an arc so that the welding current is concentrated and flows at the welding point instead of the terminal through hole. It is desirable that this series of work is automatically performed by equipment or the like.
  • connection terminals 19a and 21a in which the shape of the terminal lead portion sandwiching portion on the upper surface of the terminal of the connection terminals 19 and 21 in the above-described embodiment is displaced by 90 ° are provided on the base portion 14. It is a thing. With such a configuration, the flatwise bending workability of the winding end ends 22a and 22b can be improved, so that automation by equipment or the like can be further facilitated.
  • FIGS. 17A and 17B are perspective views showing connection terminals of other embodiments of the present technology.
  • connection terminals 31, 32, 33 and 34 are provided at each corner of the base portion 14.
  • connection terminals 31a, 32a, 33a and 34a in which the shape of the terminal lead portion sandwiching portion of these connection terminals is displaced by 90 ° are provided on the base portion 14.
  • the coil winding bodies 13a and 13b are bent at approximately right angles (flatwise bending) so that they can be joined to the connection terminals.
  • Each end portion bent at a substantially right angle to the end faces of the coil winding bodies 13a and 13b is sandwiched by the sandwiching portions of the connection terminals 31 to 34 (or 31a to 34a). Then, as in the above-described embodiment, it is electrically joined by solder joining or the like.
  • FIG. 18 shows a side view of a flat wire wound in an annular shape, and when the bending position of the winding start end is changed from A (winding center position) to bending position B and bending position C, bending is performed. It can be seen that the length of the long side of the cross section becomes longer. This means that when the conductor thickness is unchanged, the area of the bent cross section increases as the length of the long side of the bent cross section increases, and the load required for bending also increases. Bending is performed at the center position where the length of the long side of the bent cross section is minimized.
  • the coil device according to the present technology described above has the following effects. It is possible to realize an inexpensive high power common mode winding. Longer life by reducing damage to the insulating film layer It is possible to reduce component costs by reducing the number of workers by automating the work process. The number of workers can be significantly reduced. The price of production equipment can be reduced.
  • the present technology is not limited to the above-mentioned one embodiment, and various modifications based on the technical idea of the present technology are possible. .. Further, the configurations, methods, processes, shapes, materials, numerical values, etc. mentioned in the above-described embodiments are merely examples, and different configurations, methods, processes, shapes, materials, numerical values, etc. may be used as necessary. May be good.
  • the present technology can also have the following configurations.
  • the coil device according to any one of (1) to (3), wherein the magnetic core is an integral shape.
  • the magnetic core is a frame type composed of four sides, and first and second coil winding bodies are provided on the left and right sides, respectively, and the first and second coil windings are provided in the vicinity of the upper and lower sides.
  • the coil device wherein the end portion of the body is led out.
  • the base portion is a frame type composed of four sides on which the magnetic core having the first and second coil winding bodies is placed and an insulating separator in the central portion, and is inside the left and right openings of the base portion.
  • the first and second coil winding bodies are arranged in the base portion, and the first connection terminal, the second connection terminal, the third connection terminal, and the fourth connection terminal are respectively arranged at each corner of the base portion.
  • the two opposing surfaces of the first and second connection terminals provided on the base portion are made substantially parallel to the surfaces of the coil winding body, and the first surface is in the facing gap between the two surfaces.
  • the ends of the first and second coil winding bodies on the winding end side are bent at substantially right angles so that the surfaces are substantially horizontal, and the two opposing pieces of the third and fourth connection terminals are opposed to each other.
  • the coil device according to (6) wherein the surface of the coil device is substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in an opposing gap between the surfaces.
  • the winding start side and winding end side ends of the first and second coil winding bodies are bent at substantially right angles so that the surfaces are substantially horizontal, and the first to fourth connection terminals of the first to fourth connection terminals are bent.
  • the coil device according to (6) wherein the two opposing surfaces are substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in the facing gap of the plate-shaped electrode.

Abstract

Provided is a coil device comprising: a magnetic core; a plurality of coil wound bodies wound onto the magnetic core such that surfaces forming the long side of a cross-section of a flat wire are stacked; a base stand part that supports the magnetic core having the coil wound bodies; and connection terminals that are provided on the base stand part and that respectively connect to end parts of the coil wound bodies. The connection terminals include plate-shaped electrodes that sandwich surfaces of the end parts led out from the coil wound bodies.

Description

コイル装置Coil device
 本技術は、電源ユニット等に搭載され主にEMC(Electro-Magnetic Compatibility)対策などに用いられるコモンモードコイルやチョークコイルに対して適用されるコイル装置に関する。 This technology relates to a coil device that is mounted on a power supply unit or the like and is mainly applied to a common mode coil or a choke coil used for EMC (Electro-Magnetic Compatibility) countermeasures.
 例えばテレビジョン受像機の大型化やプロジェクターの高輝度化等に伴い、コイル装置も大電力化に対応することが要請されている。例えば特許文献1には、コモンチョークコイルに関する発明が記載されている。このコモンチョークコイルは、コモンモードのノイズを除去する。コモンチョークコイルは、トロイダルコアに、例えば2本の導線が巻かれて2つのコイルを構成している。コイルの巻方向は互いに逆になっており、コイルにコモンモードの電流が流れると、同じ方向に磁束が発生し、互いの磁束が強め合ってコモンモードの電流の通過を阻止することで、インダクタとして機能する。一方、コイルにディファレンシャルモードの電流が流れると、発生した磁束の方向が逆方向になり磁束が打ち消し合ってディファレンシャルモードの電流がスムーズに流れる。このように、ディファレンシャルモードの電流に対してはインダクタとして機能せず、コモンモードに対してだけインダクタとして働くフィルタとなる。特許文献1に記載の発明は、基板上のコイル装置の設置スペースを小さくするために、コイル装置を縦置きするものである。この場合にコイルと接続端子の構成を工夫したものである。 For example, with the increase in size of television receivers and the increase in brightness of projectors, coil devices are also required to support higher power consumption. For example, Patent Document 1 describes an invention relating to a common choke coil. This common choke coil eliminates common mode noise. In the common choke coil, for example, two conducting wires are wound around a toroidal core to form two coils. The winding directions of the coils are opposite to each other, and when a common mode current flows through the coil, magnetic fluxes are generated in the same direction, and the magnetic fluxes strengthen each other to block the passage of the common mode current, thereby blocking the inductor. Functions as. On the other hand, when a current in the differential mode flows through the coil, the directions of the generated magnetic fluxes are opposite, and the magnetic fluxes cancel each other out, so that the current in the differential mode flows smoothly. In this way, the filter does not function as an inductor for the current in the differential mode, but acts as an inductor only in the common mode. In the invention described in Patent Document 1, the coil device is vertically placed in order to reduce the installation space of the coil device on the substrate. In this case, the configuration of the coil and the connection terminal is devised.
特開2019-165219号公報JP-A-2019-165219
 特許文献1に記載されているようなコモンモードコイルの構造及びコイル方法によって大電力化を図る場合の問題点としては、以下のようなことがある。
・電流量の増加に従い導体(コイル)部の損失が増大
・導体径増加による最大巻数減少に伴うフィルタ性能劣化
・占積率低下に伴う部品の大型化
・生産性悪化に伴うコスト上昇
The problems in increasing the power by the structure and coil method of the common mode coil as described in Patent Document 1 are as follows.
・ The loss of the conductor (coil) increases as the amount of current increases. ・ The filter performance deteriorates due to the decrease in the maximum number of turns due to the increase in the conductor diameter.
 導体損失については次式により導かれる。
 導体損失(W)=I2×R
 I(A):実効電流値、R(Ω):導体の抵抗値
The conductor loss is derived by the following equation.
Conductor loss (W) = I 2 x R
I (A): Effective current value, R (Ω): Conductor resistance value
 この式を基に放熱可能な面積を一定とした場合、損失増加に伴い導体(コイル)部の発熱が大きくなる、つまり大電力化を図るためには、導体(コイル)部の抵抗値低減を図ると共に導体断面積の増加に伴う基板接合(リード)部形成の容易化が非常に重要な課題となってくる。しかしながら、特許文献1では一体形状の鉄心(ケース付き等も含む)に平角線を巻回し後、必ず巻線開始部をなんらかの方法により基板接合部の形成作業を行う必要があるが、これらを容易に解決する方法については記載されていない。 If the area where heat can be dissipated is constant based on this formula, the heat generated by the conductor (coil) increases as the loss increases. In other words, in order to increase the power, the resistance value of the conductor (coil) should be reduced. At the same time, facilitation of forming a substrate bonding (lead) portion with an increase in the cross-sectional area of the conductor becomes a very important issue. However, in Patent Document 1, after winding a flat wire around an integrally shaped iron core (including a case), it is necessary to always form a wafer bonding portion at the winding start portion by some method, which is easy. There is no description on how to solve it.
 したがって、本技術の目的は、大電力化に容易に対応することができるコイル装置を提供することにある。 Therefore, the purpose of this technology is to provide a coil device that can easily cope with high power consumption.
 本技術は、磁心と、
 平角線の断面の長辺を形成する面同士が積層されるように、磁心に巻回された複数のコイル巻回体と、
 コイル巻回体を有する磁心を支持する基台部と、
 基台部に設けられ、コイル巻回体の端部と接続される接続端子とを備え、
 コイル巻回体から導出された端部の面を挟持する板状電極を接続端子が有するコイル装置である。
This technology uses magnetic core and
A plurality of coil winding bodies wound around a magnetic core so that the surfaces forming the long sides of the cross section of the flat wire are laminated.
A base that supports a magnetic core with a coil winding body, and
It is provided on the base and has a connection terminal to be connected to the end of the coil winding body.
This is a coil device in which a connection terminal has a plate-shaped electrode that sandwiches an end surface derived from a coil winding body.
図1は、従来のコモンモードコイルの外観斜視図である。FIG. 1 is an external perspective view of a conventional common mode coil. 図2は、従来のコモンモードコイルの分解斜視図である。FIG. 2 is an exploded perspective view of a conventional common mode coil. 図3は、本技術の一実施形態の斜視図である。FIG. 3 is a perspective view of an embodiment of the present technology. 図4は、本技術の一実施形態の分解斜視図である。FIG. 4 is an exploded perspective view of an embodiment of the present technology. 図5は、本技術の一実施形態の変形例の斜視図である。FIG. 5 is a perspective view of a modified example of the embodiment of the present technology. 図6は、本技術の一実施形態の変形例の分解斜視図である。FIG. 6 is an exploded perspective view of a modified example of the embodiment of the present technology. 図7は、本技術の一実施形態の変形例の一部の斜視図である。FIG. 7 is a partial perspective view of a modified example of the embodiment of the present technology. 図8は、電線を巻回する工程を説明するための斜視図である。FIG. 8 is a perspective view for explaining a process of winding an electric wire. 図9は、組み立て工程を説明するための斜視図である。FIG. 9 is a perspective view for explaining the assembly process. 図10は、組み立て後のコイル装置の斜視図である。FIG. 10 is a perspective view of the coil device after assembly. 図11は、コイル装置の正面図である。FIG. 11 is a front view of the coil device. 図12は、図10の一部の拡大斜視図である。FIG. 12 is an enlarged perspective view of a part of FIG. 10. 図13は、図10の一部の拡大斜視図である。FIG. 13 is an enlarged perspective view of a part of FIG. 10. 図14は、接続端子の変形例の説明に用いる斜視図である。FIG. 14 is a perspective view used for explaining a modified example of the connection terminal. 図15は、接続端子の変形例の説明に用いる拡大斜視図である。FIG. 15 is an enlarged perspective view used for explaining a modified example of the connection terminal. 図16は、接続端子の変形例の説明に用いる拡大斜視図である。FIG. 16 is an enlarged perspective view used for explaining a modified example of the connection terminal. 図17は、本技術の他の実施形態の一部斜視図である。FIG. 17 is a partial perspective view of another embodiment of the present technology. 図18は、巻き始め端部の折り曲げ加工の説明に使用する略線図である。FIG. 18 is a schematic diagram used for explaining the bending process of the winding start end portion.
 以下、本技術の実施形態等について図面を参照しながら説明する。以下に説明する実施の形態等は本技術の好適な具体例であり、本技術の内容がこれらの実施形態等に限定されるものではない。 Hereinafter, embodiments of the present technology will be described with reference to the drawings. The embodiments described below are suitable specific examples of the present technology, and the contents of the present technology are not limited to these embodiments.
 本技術の説明に先立って、従来のトロイダルタイプのコモンモードコイルについて説明する。図1は、従来のコモンモードコイルの外観斜視図であり、図2はその分解斜視図である。Mn-Znフェライトや、鉄アモルファスなどを主組成とする磁性材(鉄芯)からなるリング状磁心1が樹脂製の下ケース2及び樹脂製の上ケース3に組み込まれる。 Prior to the explanation of this technology, the conventional toroidal type common mode coil will be described. FIG. 1 is an external perspective view of a conventional common mode coil, and FIG. 2 is an exploded perspective view thereof. A ring-shaped magnetic core 1 made of a magnetic material (iron core) having a main composition of Mn—Zn ferrite, iron amorphous, or the like is incorporated into a resin lower case 2 and a resin upper case 3.
 リング状磁心1が組み込まれた下ケース2及び上ケース3の周囲に電線が巻回され、コイル巻回体4a及びコイル巻回体4bが形成される。円形の導体断面形状を持つ一般的にはエナメル電線と呼ばれる表面に各種の絶縁皮膜を施した電線を巻回することによって、コイル巻回体4a及び4bが設けられる。コイル巻回体4a及び4bが設けられた下ケース2及び上ケース3が樹脂製の台座5に組み込まれる。 An electric wire is wound around the lower case 2 and the upper case 3 in which the ring-shaped magnetic core 1 is incorporated, and the coil winding body 4a and the coil winding body 4b are formed. The coil winding bodies 4a and 4b are provided by winding an electric wire having various insulating films on the surface, which is generally called an enamel electric wire and has a circular conductor cross-sectional shape. The lower case 2 and the upper case 3 provided with the coil winding bodies 4a and 4b are incorporated into the resin pedestal 5.
 図1に示すように、台座5の形成された4個の孔6に対してコイル巻回体4aの巻き始め端末及び巻き終わり端末が挿入されることによって、基板と接合されるリード部分の位置が固定される構造となっている。また、コイル巻回体4a及び4bに使用されるエナメル電線は、必要とするコイルの電気特性、印加される電流値や使用温度環境等に合わせ、その電線の導体径や巻数が容易に選択・調整可能とされている。 As shown in FIG. 1, the position of the lead portion joined to the substrate by inserting the winding start terminal and the winding end terminal of the coil winding body 4a into the four holes 6 formed in the pedestal 5. Has a fixed structure. For the enamel wires used for the coil winding bodies 4a and 4b, the conductor diameter and number of turns of the wires can be easily selected according to the required electrical characteristics of the coil, the applied current value, the operating temperature environment, etc. It is said to be adjustable.
 このような構造のコモンモードコイルの構造及び巻回方法によって大電力化を図る場合、上述したように、導体部(コイル巻回体)の抵抗値低減を図ることが非常に重要である。この導体部の抵抗値低減を図るには二つの方法をとることが可能である。第1の方法は、巻数を減少させ導体全長を短くすることで、抵抗値低減を図る方法である。しかしながら、この方法では同時にインダクタンス値の低下が起きるためコモンモードコイルの電磁フィルタ性能が低下することを意味し、損失低減とフィルタ性能が二律背反の関係となる。 When increasing the power by the structure and winding method of the common mode coil having such a structure, it is very important to reduce the resistance value of the conductor portion (coil winding body) as described above. Two methods can be taken to reduce the resistance value of the conductor portion. The first method is a method of reducing the resistance value by reducing the number of turns and shortening the total length of the conductor. However, in this method, the inductance value is lowered at the same time, which means that the electromagnetic filter performance of the common mode coil is lowered, and the loss reduction and the filter performance are in a trade-off relationship.
 第2の方法としては、電線の径を太くし導体面積を増加させることで、抵抗値低減を図る方法であるが、電線径の増加に伴いコイル巻回体占積率の低下が起こり規定の巻数を巻回することができなくなるため、結果的に第1の方法と同様な関係となってしまう。生産性についても電線径拡大により電線の曲げ強度が高く(曲げ難く)なることで、作業自体が非常に重労働となるため生産性が著しく悪化するため、近年では作業人員の確保も非常に難しくなってきていることも重なり部品コスト上昇が懸念されている。 The second method is to reduce the resistance value by increasing the diameter of the electric wire and increasing the conductor area. However, as the electric wire diameter increases, the coil winding space occupancy rate decreases, which is specified. Since the number of turns cannot be rotated, the relationship is the same as that of the first method as a result. In terms of productivity, as the wire diameter increases, the bending strength of the wire becomes higher (difficult to bend), which makes the work itself extremely hard work, which significantly deteriorates productivity, and in recent years it has become extremely difficult to secure workers. There is a concern that the cost of parts will rise due to the fact that it has been increasing.
 そのため導体面積を拡大させても極端な占積率の低下が起こらない平角線を用いたエッジワイズコイル巻回体が用いられ、平角線をエッジワイズ巻回後その一端を引き延ばして基板接続部とする提案がなされている。エッジワイズ巻きは、平角線のエッジ側(断面の短辺側)の曲がりにくい方向に巻き、その長辺側を形成する面が積層される巻回方法である。 Therefore, an edgewise coil winding body using a flat wire that does not cause an extreme decrease in space factor even if the conductor area is expanded is used. Proposals have been made. Edgewise winding is a winding method in which the edge side (short side side of the cross section) of the flat wire is wound in a direction in which it is difficult to bend, and the surfaces forming the long side side thereof are laminated.
 品質面でも平角線に付加されている各種の絶縁皮膜層(厚)自体は非常に薄く、JISC3215-01:2014によれば、その厚み最小0.06mm~最大0.17mmとなっている。この平角線をエッジワイズコイル巻回する場合、平角線の長辺中心より内側(コイル巻回体内径)部にある絶縁皮膜層(厚)は縮み、外径(コイル巻回体外径)部は伸びる状況となる。この状態から更に強制的に引き延ばした場合、既に伸縮している絶縁皮膜層(厚)に対するダメージが増え、絶縁性能の劣化が起こることが容易に想像でき、長期的な部品信頼性(寿命)に影響を及ぼす恐れがある。 In terms of quality, the various insulating film layers (thickness) added to the flat wire are very thin, and according to JIS C3215-01: 2014, the minimum thickness is 0.06 mm to the maximum of 0.17 mm. When this flat wire is wound with an edgewise coil, the insulating film layer (thickness) inside the center of the long side of the flat wire (inner diameter of the coil winding body) shrinks, and the outer diameter (outer diameter of the coil winding body) is It will be a growing situation. If it is forcibly stretched from this state, it can be easily imagined that the damage to the already stretched insulating film layer (thickness) will increase and the insulation performance will deteriorate, resulting in long-term component reliability (life). May affect.
 例えば低電力用のエッジワイズコイル巻回体ではコイル巻回体に加わる電流も小さく導体断面積を大きくする必要がないので、作業者の手作業(または機械的な作業でも可能)対応可能な範囲に留まる。したがって、コイル巻回体両端は一般的な接合方法である端子ピン絡げ・はんだ接合方法が使用できる。これに対し、大電力用は当然ながら損失を低減させるため導体断面積を拡大させ導体抵抗値の低減を図っているため、曲げ強度も上昇してしまい低電流用で説明した端子ピン絡げによるはんだ接合方法は用いることができない。従って平角線をエッジワイズ巻きするだけでは、長期的な信頼性(寿命)を考慮した基板接合部形成作業を行うことが出来ず、作業工程の改善もできない。 For example, in an edgewise coil winding body for low power, the current applied to the coil winding body is small and it is not necessary to increase the conductor cross-sectional area. Stay in. Therefore, the terminal pin entanglement / solder joining method, which is a general joining method, can be used for both ends of the coil winding body. On the other hand, for high power, the conductor cross-sectional area is expanded to reduce the conductor resistance value in order to reduce the loss, so the bending strength also increases and the terminal pin entanglement explained for low current is used. The solder bonding method cannot be used. Therefore, it is not possible to perform the substrate bonding portion forming work in consideration of long-term reliability (life) by simply winding the flat wire edgewise, and it is not possible to improve the work process.
 本技術の一実施形態は、上述した従来のコイル巻回体装置の問題点を解決するものである。図3は、本技術の一実施形態の外観斜視図であり、図4は、その分解斜視図である。図3の二つの斜視図は、異なる方向から見た斜視図である。一実施形態における磁心11は、4辺からなる枠型であり、左辺12a及び右辺12bのそれぞれに第1のコイル巻回体13a及び第2のコイル巻回体13bがそれぞれ設けられている。磁心11は、分割または切り欠き等の部分が無い一体形状磁心であり、その表面が絶縁塗装されている。 One embodiment of the present technology solves the above-mentioned problems of the conventional coil winding device. FIG. 3 is an external perspective view of an embodiment of the present technology, and FIG. 4 is an exploded perspective view thereof. The two perspective views of FIG. 3 are perspective views viewed from different directions. The magnetic core 11 in one embodiment is a frame type composed of four sides, and a first coil winding body 13a and a second coil winding body 13b are provided on the left side 12a and the right side 12b, respectively. The magnetic core 11 is an integrally shaped magnetic core having no portion such as a division or a notch, and its surface is insulatingly coated.
 コイル巻回体13a及び13bは、ポリウレタンなどの各種エナメル絶縁(皮膜)層を有した平角(銅)線である。コイル巻回体13aは、磁心11の左辺12aに対して上辺12cの側から下辺12dに向かって電線が巻回装置によって巻回されることによって形成されている。コイル巻回体13bは、磁心11の右辺12bに対して上辺12cの側から下辺12dに向かって電線が巻回装置によって巻回されることによって形成されている。電線は、断面が矩形の平角線であり、断面の長辺を形成する面同士が積層されるように、巻回(すなわち、エッジワイズ巻き)されている。大電力に対応するために、平角線の導体の厚み(短辺)が0.4mm以上で、且つ平角線の幅(長辺)が厚みの3倍以上とされている。 The coil winding bodies 13a and 13b are flat (copper) wires having various enamel insulating (coating) layers such as polyurethane. The coil winding body 13a is formed by winding an electric wire from the side of the upper side 12c toward the lower side 12d with respect to the left side 12a of the magnetic core 11 by a winding device. The coil winding body 13b is formed by winding an electric wire from the side of the upper side 12c toward the lower side 12d with respect to the right side 12b of the magnetic core 11 by a winding device. The electric wire is a flat wire having a rectangular cross section, and is wound (that is, edgewise wound) so that the surfaces forming the long sides of the cross section are laminated. In order to cope with high power, the thickness (short side) of the conductor of the flat wire is 0.4 mm or more, and the width (long side) of the flat wire is three times or more the thickness.
 コイル巻回体13a及び13bが設けられている磁心11が樹脂製の基台部14によって支持されている。基台部14は、第1のコイル巻回体13a及び第2のコイル巻回体13bが巻回された磁心11が載置される4辺15a、15b、15c、15dと、中央部の絶縁セパレータ16からなる樹脂製の枠である。基台部14の左右の開口17a及び17b内に第1及び第2のコイル巻回体13a及び13bが配置されている。 The magnetic core 11 provided with the coil winding bodies 13a and 13b is supported by the resin base portion 14. The base portion 14 is insulated from the four sides 15a, 15b, 15c, 15d on which the magnetic core 11 around which the first coil winding body 13a and the second coil winding body 13b are wound is placed, and the central portion. It is a resin frame made of a separator 16. The first and second coil winding bodies 13a and 13b are arranged in the left and right openings 17a and 17b of the base portion 14.
 基台部14の各コーナー部に第1の接続端子18、第2の接続端子19、第3の接続端子20及び第4の接続端子21がそれぞれ圧入などによって設けられている。これらの接続端子18~21は、銅等の金属を成形したものであり、基台部14の上面から突出している部分が電線の端末リード部が接続される部分であり、基台部14の下面から突出している部分が基板に接続される部分である。なお、コイル巻回体13a及び13bのそれぞれの巻き終わり端部22a及び22bが端面に対してほぼ直角に折り曲げられている。 A first connection terminal 18, a second connection terminal 19, a third connection terminal 20, and a fourth connection terminal 21 are provided at each corner of the base portion 14 by press fitting or the like. These connection terminals 18 to 21 are formed by molding a metal such as copper, and a portion protruding from the upper surface of the base portion 14 is a portion to which the terminal lead portion of the electric wire is connected. The portion protruding from the lower surface is the portion connected to the substrate. The winding end ends 22a and 22b of the coil winding bodies 13a and 13b are bent at substantially right angles to the end faces, respectively.
 図5、図6及び図7は、本技術の一実施形態の変形例を示している。図5は、変形例の外観斜視図であり、図6は、分解斜視図であり、図7は、上ケース31a及び下ケース31bによって磁心11が包まれている状態を示す斜視図である。図5の二つの斜視図は、異なる方向から見た斜視図である。磁心11は、絶縁塗装無しのものである。上カバー31a及び下カバー31bは必要な沿面距離を確保し、互いに嵌合する構造となっている。上述した図3及び図4に示す構成と異なる点は、閉磁路磁心11の絶縁を行うために絶縁塗装或いは樹脂カバーを用いるかの違いであり、これは各国各種の安全規格要求及び顧客の品質要求に基づき選択することができる。 5, 6 and 7 show a modified example of one embodiment of the present technology. 5 is an external perspective view of a modified example, FIG. 6 is an exploded perspective view, and FIG. 7 is a perspective view showing a state in which the magnetic core 11 is wrapped by the upper case 31a and the lower case 31b. The two perspective views of FIG. 5 are perspective views viewed from different directions. The magnetic core 11 has no insulating coating. The upper cover 31a and the lower cover 31b have a structure in which the required creepage distance is secured and the upper cover 31a and the lower cover 31b are fitted to each other. The difference from the configurations shown in FIGS. 3 and 4 described above is whether an insulating coating or a resin cover is used to insulate the closed magnetic circuit magnetic core 11, which is the requirement of various safety standards in each country and the quality of the customer. It can be selected based on the request.
 コイル装置の製造工程について、図5、図6及び図7にて説明した樹脂製カバーを用いたものを例に説明する。磁心11を上カバー31a及び下カバー31bに組み込んだ状態(図7参照)で、図8に示すように、巻線設備を使用し、矢印の方向から平角線を押し込み、平角線を湾曲させる治具(図示しない)内を通過し、上カバー31a及び下カバー31bからなる樹脂カバーの周面に沿って螺旋を描き、エッジワイズコイル巻きをする。巻線設備としては、例えば特開2017-130506号公報に記載されているものを使用できる。 The manufacturing process of the coil device will be described by taking as an example the one using the resin cover described with reference to FIGS. 5, 6 and 7. With the magnetic core 11 incorporated in the upper cover 31a and the lower cover 31b (see FIG. 7), as shown in FIG. 8, a winding facility is used to push the flat wire in the direction of the arrow to bend the flat wire. It passes through the tool (not shown), draws a spiral along the peripheral surface of the resin cover composed of the upper cover 31a and the lower cover 31b, and winds the edgewise coil. As the winding equipment, for example, those described in JP-A-2017-130506 can be used.
 コイル巻回体13aの電線は、巻き始め端部(始端)23aから巻き終わり端部(終端)22aに向かって巻回され、コイル巻回体13bの電線は、巻き始め端部(始端)23bから巻き終わり端部(終端)22bに向かって巻回される。なお、この左右に電線を巻回する場合、片側ずつ電線を巻回することも可能であるが、一般的には生産性を考慮し2つ同時に電線を巻回するようになされる。この場合、巻回時のスペースはあまり広くないので、巻き始め端部23a及び23bがコイル巻回体13a及び13bの外周より外側に飛び出さないか、又は飛び出し量が小さいものとされている。 The electric wire of the coil winding body 13a is wound from the winding start end (starting end) 23a toward the winding end end (end) 22a, and the electric wire of the coil winding body 13b is wound from the winding start end (starting end) 23b. It is wound from the winding end toward the end (end) 22b. When winding the electric wires to the left and right, it is possible to wind the electric wires one side at a time, but in general, two electric wires are wound at the same time in consideration of productivity. In this case, since the space at the time of winding is not so wide, it is assumed that the winding start ends 23a and 23b do not protrude outside the outer circumference of the coil winding bodies 13a and 13b, or the amount of protrusion is small.
 電線の巻回が終了すると、次に、回路基板と接合させるためには、電線の両端部を更に加工し回路基板と直接接合可能とする基板接合(リード)部を設けるか或いは銅を主素材に表面処理(メッキ等)を施した接続端子を介しはんだ接合される方法がとられる。安定した品質を確保する場合は接続端子を用いることが多い。本技術では、いずれの場合に対しても適用できる。 After the winding of the electric wire is completed, next, in order to join with the circuit board, both ends of the electric wire are further processed to provide a substrate bonding (lead) portion that can be directly bonded to the circuit board, or copper is used as the main material. A method is adopted in which soldering is performed via a connection terminal that has been surface-treated (plated, etc.). Connection terminals are often used to ensure stable quality. The present technology can be applied to any case.
 図9に示すように、樹脂製の基台部14の四隅には、接続端子18,19,20及び21が圧入されている。基台部14の中心部に設けられた絶縁セパレータ16に沿ってコイル巻回体13a及び13bが設けられている部品が垂直方向に移動して組み込まれる。このとき、安定的な組み込みが行われるように、上カバー31a及び下カバー31bの内側部にガイド溝が設けられ、ガイド溝に絶縁セパレータ16の側面部が沿ってスライドしながら組み込まれて行く。組み込み後、コイル巻回体の端末リード部と各種接続端子を電気的に接続するための作業が行われる。このようにして図10に示すような本技術によるコイル装置が完成する。図10は、異なる方向からコイル装置を見た斜視図である。また、図11は、図10のC-C矢視図である。 As shown in FIG. 9, connection terminals 18, 19, 20 and 21 are press-fitted into the four corners of the resin base portion 14. The parts provided with the coil winding bodies 13a and 13b are vertically moved and incorporated along the insulating separator 16 provided at the center of the base portion 14. At this time, guide grooves are provided in the inner portions of the upper cover 31a and the lower cover 31b so that stable assembly is performed, and the side surface portions of the insulating separator 16 slide along the guide grooves and are incorporated. After assembly, work is performed to electrically connect the terminal lead portion of the coil winding body and various connection terminals. In this way, the coil device according to the present technology as shown in FIG. 10 is completed. FIG. 10 is a perspective view of the coil device viewed from different directions. Further, FIG. 11 is a view taken along the line CC of FIG.
 接続端子18~20について説明する。巻き始め端部23a及び23bが接続される接続端子18及び20は、同一構造を有し、巻き終わり端部22a及び22bが接続される接続端子19及び21は、同一構造を有する。図12は、図10中のA部(接続端子20)を拡大して示し、図13は、図10中のB部(接続端子19)を拡大して示す。 The connection terminals 18 to 20 will be described. The connection terminals 18 and 20 to which the winding start ends 23a and 23b are connected have the same structure, and the connection terminals 19 and 21 to which the winding end ends 22a and 22b are connected have the same structure. FIG. 12 shows an enlarged portion A (connection terminal 20) in FIG. 10, and FIG. 13 shows an enlarged portion B (connection terminal 19) in FIG.
 接続端子20は、コイル巻回体13bの巻き始め端部23bの電線(平角線)の面とほぼ平行な面を持つ2枚の面(板状電極)を持つように折り曲げ加工され、2枚の面の対向間隙(溝)に、巻き始め端部23bの先端が挿入されて配置される。接続端子19は、折り曲げられたコイル巻回体13aの巻き終わり端部22aの面とほぼ平行となり、対向する2枚の面(板状電極)を持つように、コ字状に折り曲げられている。2枚の板状電極の奥側内側面にコイル巻回体13aの巻き終わり端部22aが突き当たるように、巻き終わり端部22aが挿入される。その後2枚の板状電極の一方を折り曲げることによって巻き終わり端部22aが接続端子19によって挟持される。 The connection terminal 20 is bent so as to have two surfaces (plate-shaped electrodes) having a surface substantially parallel to the surface of the electric wire (flat wire) of the winding start end 23b of the coil winding body 13b. The tip of the winding start end 23b is inserted and arranged in the facing gap (groove) of the surface of the winding. The connection terminal 19 is bent in a U shape so as to be substantially parallel to the surface of the winding end end 22a of the bent coil winding body 13a and to have two opposing surfaces (plate-shaped electrodes). .. The winding end end 22a is inserted so that the winding end end 22a of the coil winding body 13a abuts on the inner side surface on the back side of the two plate-shaped electrodes. After that, by bending one of the two plate-shaped electrodes, the winding end end 22a is sandwiched by the connection terminal 19.
 このように、コイル巻回体13a及び13bの巻き始め端部23a及び23bが接続端子18及び20の溝内に嵌まる構造とされ、再度エッジワイズ方向にコイル巻き始め部を曲げ直すこと無く基板接合(リード)部を形成が可能となり、巻き終わり端部22a及び22bが接続端子19及び21のコの字に折り曲げられた端子奥側内側面に突き当たるようになされる。その結果、巻き終わり端部22a及び22bの位置が接続端子19及び21の接続固定面と水平となるように配置される。すなわち、巻き終わり端部22a及び22bの位置が基台部14に対して垂直位置となるように規制配置される。こうすることで、巻き終わり端部22a及び22bの曲げ加工が容易に行え、また接続端子とも容易に接続可能なフラットワイズ曲げを行えるようになる。 In this way, the winding start ends 23a and 23b of the coil winding bodies 13a and 13b are fitted in the grooves of the connection terminals 18 and 20, and the substrate is not bent again in the edgewise direction. A joint (lead) portion can be formed, and the winding end ends 22a and 22b are made to abut on the inner side surface on the back side of the terminal bent in a U shape of the connection terminals 19 and 21. As a result, the positions of the winding end ends 22a and 22b are arranged so as to be horizontal to the connection fixing surface of the connection terminals 19 and 21. That is, the positions of the winding end ends 22a and 22b are regulated so as to be perpendicular to the base portion 14. By doing so, the winding end ends 22a and 22b can be easily bent, and flatwise bending that can be easily connected to the connection terminal can be performed.
 その後、図13に示すように、接続端子19の上面部で巻き終わり端部22aを挟み込むことで、コイル巻回体13aの回転運動が固定され、その状態で各接続端子部をはんだ接合等により電気的な接合される。はんだ接合を行う場合には、接続端子の上面部に貫通穴を設けることで、巻き始め端部及び巻き終わり端部と接続端子のはんだ接合面積が拡大し、機械的な接合強度を向上することができ、なおかつはんだ接合作業性を改善することが可能となる。なお、はんだ接合の代わりにスポット溶接等を用いた接合を行っても良い。この場合には端子部貫通穴では無く、溶接個所に溶接電流が集中して流れるよう円筒や円弧状などの打出しを行うのが良い。なお、この一連の作業は設備等によって自動的行われるのが望ましい。 After that, as shown in FIG. 13, the rotational motion of the coil winding body 13a is fixed by sandwiching the winding end end portion 22a between the upper surface portions of the connection terminals 19, and in that state, the connection terminal portions are soldered or the like. It is electrically joined. When performing solder bonding, by providing through holes on the upper surface of the connection terminal, the solder bonding area between the winding start end and winding end end and the connection terminal is expanded, and the mechanical bonding strength is improved. It is possible to improve the solder joining workability. In addition, instead of solder bonding, bonding using spot welding or the like may be performed. In this case, it is preferable to emboss a cylinder or an arc so that the welding current is concentrated and flows at the welding point instead of the terminal through hole. It is desirable that this series of work is automatically performed by equipment or the like.
 図14、図15及び図16は、本技術の一実施形態における接続端子の変形例を示している。図14及び図15の構成は、上述した一実施形態における接続端子19及び21の端子上面の端末リード部挟み込み部の形状を90°変位させた接続端子19a及び21aを基台部14に設けたものである。このような構成とすると、巻き終わり端部22a及び22bのフラットワイズ曲げ加工性は高くすることができるため、設備等による自動化を更に容易にすることが可能となる。 14, 15, and 16 show a modified example of the connection terminal in one embodiment of the present technology. In the configuration of FIGS. 14 and 15, connection terminals 19a and 21a in which the shape of the terminal lead portion sandwiching portion on the upper surface of the terminal of the connection terminals 19 and 21 in the above-described embodiment is displaced by 90 ° are provided on the base portion 14. It is a thing. With such a configuration, the flatwise bending workability of the winding end ends 22a and 22b can be improved, so that automation by equipment or the like can be further facilitated.
 また、上述した説明では、巻き始め端部を基準位置とした形状の説明をしてきたが、反対に巻き終わり端部を基準位置としても同様の生産性が実現可能である。但し、巻き終わり端部を基準固定位置とする場合は、図16に示すように、接続端子20(18)と曲げ方向を逆転させるようにした接続端子20aが使用される。このことによって巻き始め端部の固定位置の自由度が上がり、巻き終わり端部の折り曲げ位置精度が緩和可能となる。 Also, in the above explanation, the shape with the winding start end as the reference position has been explained, but on the contrary, the same productivity can be realized even if the winding end end is used as the reference position. However, when the winding end end is set as the reference fixed position, as shown in FIG. 16, the connection terminal 20 (18) and the connection terminal 20a whose bending direction is reversed are used. As a result, the degree of freedom in the fixed position of the winding start end is increased, and the bending position accuracy of the winding end end can be relaxed.
 さらに、図17A及び図17Bは、本技術の他の実施形態の接続端子を示す斜視図である。他の実施形態は、生産数量が少ない場合、手動(手)作業でも作業者へ極力負担をかけないようにできる。自動巻線機によるエッジワイズ巻線までには、第1の実施例と同一の工程であるため説明を省略する。他の実施形態では、図17Aに示すように、基台部14の各コーナー部に接続端子31、32、33及び34が設けられている。図17Bに示す構成は、これらの接続端子の端末リード部挟み込み部の形状を90°変位させた接続端子31a、32a、33a及び34aを基台部14に設けたものである。 Further, FIGS. 17A and 17B are perspective views showing connection terminals of other embodiments of the present technology. In another embodiment, when the production quantity is small, even manual (manual) work can minimize the burden on the operator. Since the process up to the edgewise winding by the automatic winding machine is the same as that of the first embodiment, the description thereof will be omitted. In another embodiment, as shown in FIG. 17A, connection terminals 31, 32, 33 and 34 are provided at each corner of the base portion 14. In the configuration shown in FIG. 17B, connection terminals 31a, 32a, 33a and 34a in which the shape of the terminal lead portion sandwiching portion of these connection terminals is displaced by 90 ° are provided on the base portion 14.
 エッジワイズ巻線後、コイル巻回体13a及び13bのそれぞれの巻き始め端部及び巻き始め端部をほぼ直角に折り曲げる加工(フラットワイズ曲げ加工)を施し、接続端子と接合できる状態とする。コイル巻回体13a及び13bの端面に対してほぼ直角に折り曲げられた各端部が接続端子31~34(又は31a~34a)の挟み込み部によって挟持される。そして、上述した一実施形態と同様にはんだ接合等により電気的な接合される。 After edgewise winding, the coil winding bodies 13a and 13b are bent at approximately right angles (flatwise bending) so that they can be joined to the connection terminals. Each end portion bent at a substantially right angle to the end faces of the coil winding bodies 13a and 13b is sandwiched by the sandwiching portions of the connection terminals 31 to 34 (or 31a to 34a). Then, as in the above-described embodiment, it is electrically joined by solder joining or the like.
 コイル巻回体13a及び13bのそれぞれの円環状に巻線された平角線に対し一番小さい荷重でフラットワイズ曲げ加工を施すことが非常に重要となる。図18は、円環状に巻回された平角線の側面図を示しており、巻き始め端部の曲げ位置をA(巻線中心位置)から曲げ位置B及び曲げ位置Cへ変化させると、曲げ断面の長辺の長さが長くなってくることが分かる。これはつまり、導体厚を不変とした場合、曲げ断面の長辺の長さが大きくなるに従い曲げ断面部面積が大きくなることを示し、同様に曲げるために必要な荷重も増加して行くため、曲げ断面の長辺の長さが最小となる中心位置にて曲げ加工を行うようになされる。 It is very important to perform flatwise bending with the smallest load on the rectangular wires wound in the annular shape of the coil winding bodies 13a and 13b. FIG. 18 shows a side view of a flat wire wound in an annular shape, and when the bending position of the winding start end is changed from A (winding center position) to bending position B and bending position C, bending is performed. It can be seen that the length of the long side of the cross section becomes longer. This means that when the conductor thickness is unchanged, the area of the bent cross section increases as the length of the long side of the bent cross section increases, and the load required for bending also increases. Bending is performed at the center position where the length of the long side of the bent cross section is minimized.
 一方、巻き終わり端部にはストレートな部分が残っているため、この場合はどの位置でフラットワイズ曲げを行っても必要な曲げ荷重に変化は無いが、ストレート部を超え円環状位置で曲げを行う場合は、上述した巻き始め端部と同様の結果となる。自動設備による曲げ加工においても当然ながら曲げ荷重が小さければ、小さな設備で済むため設備費用等の削減も可能となる。 On the other hand, since a straight part remains at the end of winding, in this case, the required bending load does not change regardless of the position where flatwise bending is performed, but bending is performed at an annular position beyond the straight part. If this is done, the result will be the same as the winding start end described above. As a matter of course, if the bending load is small even in the bending process by the automatic equipment, the equipment cost can be reduced because the equipment can be small.
 上述した本技術によるコイル装置は、以下のような効果を奏する。
 安価な大電力化コモンモード巻線を実現できる。
 絶縁皮膜層へのダメージ軽減による高寿命化
 作業工程自動化による作業員削減による部品コスト低減ができる。
 作業人員大幅削減ができる。
 生産設備価格を低減することができる。
The coil device according to the present technology described above has the following effects.
It is possible to realize an inexpensive high power common mode winding.
Longer life by reducing damage to the insulating film layer It is possible to reduce component costs by reducing the number of workers by automating the work process.
The number of workers can be significantly reduced.
The price of production equipment can be reduced.
 以上、本技術の一実施の形態について具体的に説明したが、本技術は、上述の一実施の形態に限定されるものではなく、本技術の技術的思想に基づく各種の変形が可能である。また、上述の実施形態において挙げた構成、方法、工程、形状、材料及び数値などはあくまでも例に過ぎず、必要に応じてこれと異なる構成、方法、工程、形状、材料及
び数値などを用いてもよい。
Although one embodiment of the present technology has been specifically described above, the present technology is not limited to the above-mentioned one embodiment, and various modifications based on the technical idea of the present technology are possible. .. Further, the configurations, methods, processes, shapes, materials, numerical values, etc. mentioned in the above-described embodiments are merely examples, and different configurations, methods, processes, shapes, materials, numerical values, etc. may be used as necessary. May be good.
 なお、本技術は、以下のような構成も取ることができる。
(1)
 磁心と、
 平角線の断面の長辺を形成する面同士が積層されるように、前記磁心に巻回された複数のコイル巻回体と、
 前記コイル巻回体を有する前記磁心を支持する基台部と、
 前記基台部に設けられ、前記コイル巻回体の端部と接続される接続端子とを備え、
 前記コイル巻回体から導出された前記端部の前記面を挟持する板状電極を前記接続端子が有するコイル装置。
(2)
 前記磁心及び前記複数のコイル巻回体間が絶縁された(1)に記載のコイル装置。
(3)
 前記平角線の導体の厚みが0.4mm以上で、且つ前記平角線の幅が前記厚みの3倍以上である(1)又は(2)に記載のコイル装置。
(4)
 前記磁心が一体形状となされた磁心である(1)から(3)のいずれかに記載のコイル装置。
(5)
 前記磁心が4辺からなる枠型であり、左右の辺のそれぞれに第1及び第2のコイル巻回体がそれぞれ設けられ、上下の辺の近傍において、前記第1及び第2のコイル巻回体の前記端部が導出されるようにした(4)に記載のコイル装置。
(6)
 前記基台部が前記第1及び第2のコイル巻回体を有する前記磁心が載置される4辺と、中央部の絶縁セパレータからなる枠型であり、前記基台部の左右の開口内に前記第1及び第2のコイル巻回体が配置され、前記基台部の各コーナー部に第1の接続端子、第2の接続端子、第3の接続端子及び第4の接続端子がそれぞれ設けられた(1)から(5)のいずれかに記載のコイル装置。
(7)
 前記基台部に設けられた前記第1及び第2の接続端子の対向する2枚の面が前記コイル巻回体の前記面とほぼ平行とされ、前記2枚の面の対向間隙に前記第1及び第2のコイル巻回体のそれぞれの巻き始め端部が配置された(6)に記載のコイル装置。
(8)
 前記面がほぼ水平となるように、前記第1及び第2のコイル巻回体の巻き終り側の端部がそれぞれほぼ直角に折り曲げられ、前記第3及び第4の接続端子の対向する2枚の面が前記折り曲げられた端部の前記面とほぼ平行とされ、前記面の対向間隙に前記折り曲げられた端部が配置された(6)に記載のコイル装置。
(9)
 前記面がほぼ水平となるように、前記第1及び第2のコイル巻回体の巻き始め側及び巻き終り側の端部がそれぞれほぼ直角に折り曲げられ、前記第1から第4の接続端子の対向する2枚の面が前記折り曲げられた端部の前記面とほぼ平行とされ、前記板状電極の対向間隙に前記折り曲げられた端部が配置された(6)に記載のコイル装置。
(10)
 前記第1及び第2のコイル巻回体の巻き始め端部の折り曲げ位置が前記第1及び第2のコイル巻回体の幅が最小となる位置付近とされた(9)に記載のコイル装置。
The present technology can also have the following configurations.
(1)
Magnetic core and
A plurality of coil winding bodies wound around the magnetic core so that the surfaces forming the long sides of the cross section of the flat wire are laminated.
A base portion that supports the magnetic core having the coil winding body and
A connection terminal provided on the base portion and connected to the end portion of the coil winding body is provided.
A coil device in which the connection terminal has a plate-shaped electrode that sandwiches the surface of the end portion derived from the coil winding body.
(2)
The coil device according to (1), wherein the magnetic core and the plurality of coil winding bodies are insulated from each other.
(3)
The coil device according to (1) or (2), wherein the conductor thickness of the flat wire is 0.4 mm or more, and the width of the flat wire is three times or more the thickness.
(4)
The coil device according to any one of (1) to (3), wherein the magnetic core is an integral shape.
(5)
The magnetic core is a frame type composed of four sides, and first and second coil winding bodies are provided on the left and right sides, respectively, and the first and second coil windings are provided in the vicinity of the upper and lower sides. The coil device according to (4), wherein the end portion of the body is led out.
(6)
The base portion is a frame type composed of four sides on which the magnetic core having the first and second coil winding bodies is placed and an insulating separator in the central portion, and is inside the left and right openings of the base portion. The first and second coil winding bodies are arranged in the base portion, and the first connection terminal, the second connection terminal, the third connection terminal, and the fourth connection terminal are respectively arranged at each corner of the base portion. The coil device according to any one of (1) to (5) provided.
(7)
The two opposing surfaces of the first and second connection terminals provided on the base portion are made substantially parallel to the surfaces of the coil winding body, and the first surface is in the facing gap between the two surfaces. The coil device according to (6), wherein the winding start ends of the first and second coil winding bodies are arranged.
(8)
The ends of the first and second coil winding bodies on the winding end side are bent at substantially right angles so that the surfaces are substantially horizontal, and the two opposing pieces of the third and fourth connection terminals are opposed to each other. The coil device according to (6), wherein the surface of the coil device is substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in an opposing gap between the surfaces.
(9)
The winding start side and winding end side ends of the first and second coil winding bodies are bent at substantially right angles so that the surfaces are substantially horizontal, and the first to fourth connection terminals of the first to fourth connection terminals are bent. The coil device according to (6), wherein the two opposing surfaces are substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in the facing gap of the plate-shaped electrode.
(10)
The coil device according to (9), wherein the bending position of the winding start end of the first and second coil winding bodies is near a position where the width of the first and second coil winding bodies is minimized. ..
11・・・磁心、13a,13b・・・コイル巻回体、14・・・基台部、
16・・・絶縁セパレータ、18,19,20,21・・・接続端子、
22a,22b・・・巻き終わり端部、23a,23b・・・巻き始め端部、
31a・・・上カバー、31b・・・下カバー
11 ... Magnetic core, 13a, 13b ... Coil winding body, 14 ... Base part,
16 ... Insulation separator, 18, 19, 20, 21 ... Connection terminal,
22a, 22b ... winding end end, 23a, 23b ... winding start end,
31a ... top cover, 31b ... bottom cover

Claims (10)

  1.  磁心と、
     平角線の断面の長辺を形成する面同士が積層されるように、前記磁心に巻回された複数のコイル巻回体と、
     前記コイル巻回体を有する前記磁心を支持する基台部と、
     前記基台部に設けられ、前記コイル巻回体の端部と接続される接続端子とを備え、
     前記コイル巻回体から導出された前記端部の前記面を挟持する板状電極を前記接続端子が有するコイル装置。
    Magnetic core and
    A plurality of coil winding bodies wound around the magnetic core so that the surfaces forming the long sides of the cross section of the flat wire are laminated.
    A base portion that supports the magnetic core having the coil winding body and
    A connection terminal provided on the base portion and connected to the end portion of the coil winding body is provided.
    A coil device in which the connection terminal has a plate-shaped electrode that sandwiches the surface of the end portion derived from the coil winding body.
  2.  前記磁心及び前記複数のコイル巻回体間が絶縁された請求項1に記載のコイル装置。 The coil device according to claim 1, wherein the magnetic core and the plurality of coil winding bodies are insulated from each other.
  3.  前記平角線の導体の厚みが0.4mm以上で、且つ前記平角線の幅が前記厚みの3倍以上である請求項1に記載のコイル装置。 The coil device according to claim 1, wherein the conductor thickness of the flat wire is 0.4 mm or more, and the width of the flat wire is three times or more the thickness.
  4.  前記磁心が一体形状となされた磁心である請求項1に記載のコイル装置。 The coil device according to claim 1, wherein the magnetic core is an integral shape.
  5.  前記磁心が4辺からなる枠型であり、左右の辺のそれぞれに第1及び第2のコイル巻回体がそれぞれ設けられ、上下の辺の近傍において、前記第1及び第2のコイル巻回体の前記端部が導出されるようにした請求項4に記載のコイル装置。 The magnetic core is a frame type composed of four sides, and first and second coil winding bodies are provided on the left and right sides, respectively, and the first and second coil windings are provided in the vicinity of the upper and lower sides. The coil device according to claim 4, wherein the end portion of the body is derived.
  6.  前記基台部が前記第1及び第2のコイル巻回体を有する前記磁心が載置される4辺と、中央部の絶縁セパレータからなる枠型であり、前記基台部の左右の開口内に前記第1及び第2のコイル巻回体が配置され、前記基台部の各コーナー部に第1の接続端子、第2の接続端子、第3の接続端子及び第4の接続端子がそれぞれ設けられた請求項1に記載のコイル装置。 The base portion is a frame type composed of four sides on which the magnetic core having the first and second coil winding bodies is placed and an insulating separator in the central portion, and is inside the left and right openings of the base portion. The first and second coil winding bodies are arranged in the base portion, and the first connection terminal, the second connection terminal, the third connection terminal, and the fourth connection terminal are respectively arranged at each corner of the base portion. The coil device according to claim 1.
  7.  前記基台部に設けられた前記第1及び第2の接続端子の対向する2枚の面が前記コイル巻回体の前記面とほぼ平行とされ、前記2枚の面の対向間隙に前記第1及び第2のコイル巻回体のそれぞれの巻き始め端部が配置された請求項6に記載のコイル装置。 The two opposing surfaces of the first and second connection terminals provided on the base portion are made substantially parallel to the surfaces of the coil winding body, and the first surface is in the facing gap between the two surfaces. The coil device according to claim 6, wherein the winding start ends of the first and second coil winding bodies are arranged.
  8.  前記面がほぼ水平となるように、前記第1及び第2のコイル巻回体の巻き終り側の端部がそれぞれほぼ直角に折り曲げられ、前記第3及び第4の接続端子の対向する2枚の面が前記折り曲げられた端部の前記面とほぼ平行とされ、前記面の対向間隙に前記折り曲げられた端部が配置された請求項6に記載のコイル装置。 The ends of the first and second coil winding bodies on the winding end side are bent at substantially right angles so that the surfaces are substantially horizontal, and the two opposing pieces of the third and fourth connection terminals are opposed to each other. The coil device according to claim 6, wherein the surface of the coil device is substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in an opposing gap between the surfaces.
  9.  前記面がほぼ水平となるように、前記第1及び第2のコイル巻回体の巻き始め側及び巻き終り側の端部がそれぞれほぼ直角に折り曲げられ、前記第1から第4の接続端子の対向する2枚の面が前記折り曲げられた端部の前記面とほぼ平行とされ、前記板状電極の対向間隙に前記折り曲げられた端部が配置された請求項6に記載のコイル装置。 The winding start side and winding end side ends of the first and second coil winding bodies are bent at substantially right angles so that the surfaces are substantially horizontal, and the first to fourth connection terminals of the first to fourth connection terminals are bent. The coil device according to claim 6, wherein the two opposing surfaces are substantially parallel to the surface of the bent end portion, and the bent end portion is arranged in the facing gap of the plate-shaped electrode.
  10.  前記第1及び第2のコイル巻回体の巻き始め端部の折り曲げ位置が前記第1及び第2のコイル巻回体の幅が最小となる位置付近とされた請求項9に記載のコイル装置。 The coil device according to claim 9, wherein the bending position of the winding start end of the first and second coil winding bodies is near a position where the width of the first and second coil winding bodies is minimized. ..
PCT/JP2021/007272 2020-03-19 2021-02-26 Coil device WO2021187049A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1174132A (en) * 1997-08-29 1999-03-16 Matsushita Electric Works Ltd Electromagnetic apparatus
JP2015053369A (en) * 2013-09-06 2015-03-19 日立金属株式会社 Coil component and power supply device using the same
JP2015133411A (en) * 2014-01-14 2015-07-23 北川工業株式会社 choke coil

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH1174132A (en) * 1997-08-29 1999-03-16 Matsushita Electric Works Ltd Electromagnetic apparatus
JP2015053369A (en) * 2013-09-06 2015-03-19 日立金属株式会社 Coil component and power supply device using the same
JP2015133411A (en) * 2014-01-14 2015-07-23 北川工業株式会社 choke coil

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