JP2009105158A - Coil structure for inductor, and the inductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a coil structure for inductor which can eliminate the step of winding for a straight-angle copper wire, as well as, can have bend for the wire to be in a fixed direction, and can reduce the cost through easy processing. <P>SOLUTION: The center line S along the lengthwise direction of one band-like conductive plate 21 is used as a reference, and a plurality of circular arc parts 22a, 22b and 22c are provided in a planar staggered fashion, in the band-like conductive plate 21. The circular arc parts 22a, 22b and 22c are connected at joints 23a and 23b, to form a coil formation member 24. Bending portions 25a and 25b are formed at the joints 23a and 23b of the coil-formingmember 24, and the coil-forming member 24 is alternately trough-folded and crest-folded in repeated manner at the bending portions 25a and 25b. Then, the circular arc parts 22a, 22b and 22c are overlaid to form circular-arc coils 27 and 28, and a mounting terminal 26 is formed at both ends of the coil-forming member 24. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a coil structure for an inductor and an inductor used as a choke coil and other coil components that can be suitably used even at high currents and high frequencies.

  For example, a rectangular coil shown in FIGS. 8A and 8B is conventionally known as an inductor coil used as a choke coil. The flat coil 11 is formed by winding a flat copper wire 12 made of a strip-shaped conductive plate to form a flat coil portion 13 and mounting terminals 14 at both ends of the coil portion 13.

As shown in FIG. 9, the rectangular coil 11 is embedded with a core material 17 composed of a magnetic rivet core 15 made of a ferrite core and a magnetic pot core 16 made of a ferrite core. Bending and solder plating are performed so as to be exposed on the lower surface at both ends of the core material 17.

Also, in continuous bending coils used for electrical elements such as high-frequency transformers and high-frequency reactors, foil-shaped conductors with the same shape and continuous waveform that are alternately reversed in a staggered manner are folded back in a direction deviated by a specific angle each time from a predetermined folded portion. A high-frequency transformer and a high-frequency reactor formed as an annular continuous winding coil are known (for example, see Patent Document 1).

Also, in a plurality of ring portions made of metal flat plates arranged in a planar shape, an angle formed by a center line connecting the centers of adjacent ring portions connected by the ring connecting portion and a ring connected to the terminal portion A coil component is known in which the sum of the angles of the center line of the part and the extension line extending from the center of the ring part toward the end part forming the terminal part is 180 degrees (see, for example, Patent Document 2) .)
JP-A-9-275023 JP 2004-111457 A

  The flat coil 11 shown in FIGS. 8 and 9 is formed by winding a flat copper wire 12 made of a strip-shaped conductive plate with a dedicated winding machine to form a planar coil portion 13. Difficult, causing increased processing costs.

  In Patent Document 1, since the foil-shaped conductors having the same shape and continuous waveform that are alternately reversed in a staggered manner are folded back in a direction deviated by a specific angle from a predetermined folded portion each time, an annular continuous winding coil is formed. The direction of is not constant, and even if the crease part is slightly displaced, the annular coil part is displaced, which makes machining difficult and causes an increase in machining cost.

In Patent Document 2, a plurality of ring portions arranged in a plane are connected by a ring connecting portion, and a crease portion is formed in the ring connecting portion, but the direction of the fold portion is not constant, and the crease portion is slightly Even if they are displaced, the annular coil portion is displaced, so that processing is difficult and causes an increase in processing costs, as in Patent Document 1.

  The present invention has been made paying attention to the above circumstances, and the purpose thereof is that a winding process of a flat copper wire can be omitted, and a crease portion is formed at a connecting portion of the coil forming member, thereby forming the coil forming member. It is possible to form an annular coil part by alternately repeating valley folds and mountain folds at the crease part to overlap the arcuate part, and the bending direction is constant, making the processing easy and reducing costs. An object is to provide a coil structure for an inductor and an inductor.

  In order to solve the above-mentioned object, the present invention provides a plurality of arc-shaped portions 22a and 22b on the strip-shaped conductive plate 21 with reference to a center line S along the longitudinal direction of the single strip-shaped conductive plate 21. , 22c are provided in a zigzag shape in plan view, and the arc-shaped portions 22a, 22b, 22c are connected by connecting portions 23a, 23b to form a coil forming member 24. The connecting portions 23a, 23b of the coil forming member 24 Folded portions 25a and 25b are formed on the coil, and the coil-forming member 24 is repeatedly folded and folded at the fold portions 25a and 25b to overlap the arc-shaped portions 22a, 22b and 22c. In the inductor coil structure, the portions 27 and 28 are formed, and the mounting terminals 26 are formed at both ends of the coil forming member 24.

The second aspect provides a plurality of arc-shaped portions 22a, 22b, and 22c in a zigzag pattern on the belt-like conductive plate 21, with reference to the center line S along the longitudinal direction of one belt-like conductive plate 21. These arc-shaped portions 22a, 22b, and 22c are connected by connecting portions 23a and 23b to form a coil forming member 24. Folded portions 25a and 25b are formed in the connecting portions 23a and 23b of the coil forming member 24, and the coil The forming member 24 is alternately and repeatedly folded at the crease portions 25a and 25b to form the annular coil portions 27 and 28 by superimposing the arc-shaped portions 22a, 22b and 22c, and the coil forming member. An inductor coil 29 having mounting terminals 26 formed at both ends of 24, and coil portions 27 and 28 of the inductor coil 29 are embedded with a core material 32 made of a magnetic material. Certain Sotanshi 26 to the inductor, characterized in that provided exposed from the core material 32.

  According to the present invention, the winding process of the flat copper wire can be omitted, and a fold portion is formed at the coupling portion of the coil forming member, and the coil forming member is alternately arc-folded by repeatedly performing valley fold and mountain fold at the fold portion. An annular coil portion can be formed by overlapping the portions, the bending direction is constant, and there is an effect that processing is easy and cost can be reduced.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  1 to 4 show a first embodiment, FIGS. 1 to 3 show a manufacturing process of an inductor coil for 1.5T, and FIG. 4 is a perspective view of the inductor. A reference numeral 21 shown in FIG. 1 is a thin strip-shaped conductive plate formed by punching one copper plate, and S is a center line along the longitudinal direction of the strip-shaped conductive plate 21. The strip-shaped conductive plate 21 is provided with a plurality of arc-shaped portions 22 a, 22 b, and 22 c in a zigzag shape on a plane from one end side to the other end side of the strip-shaped conductive plate 21 with the center line S as a reference. These arc-shaped portions 22a, 22b, and 22c are semicircular in the same shape, and the arc-shaped portions 22a and 22b are integrally connected by a connecting portion 23a, and the arc-shaped portions 22b and 22c are integrally connected by a connecting portion 23b. The coil forming member 24 is configured by being connected.

The connecting portions 23a and 23b have the same width as the arc-shaped portions 22a, 22b, and 22c, are linear in the extending direction of the center line S, and the connecting portions 23a and 23b are formed to have the same length. Furthermore, a first fold portion 25a and a second fold portion 25b are formed in a direction perpendicular to the center line S at the intermediate portion in the longitudinal direction of the coupling portions 23a and 23b of the coil forming member 24. In addition, mounting terminals 26 are integrally provided in both ends of the coil forming member 24 in the extending direction of the center line S, and these mounting terminals 26 are formed slightly wider than the connecting portions 23a and 23b.

When the coil forming member 24 configured in this way is valley-folded at the first fold portion 25a, the coil-forming member 24 is folded in two at the connecting portion 23a, and the arc-shaped portions 22a and 22b face each other across the center line S, and the annular coil A portion 27 is formed. Next, when the second fold portion 25b is mountain-folded, it is folded in two at the connecting portion 23b, and the arc-shaped portions 22b and 22c face each other across the center line S to form an annular coil portion 28. And the arc-shaped part 22c overlaps with the upper surface of the arc-shaped part 22a. Accordingly, the coil portions 27 and 28 are concentrically overlapped with each other, and mounting terminals 26 are formed at both ends of the coil forming member 24 so as to protrude from the coil portions 27 and 28. As shown in FIGS. The coil 29 is completed.

  Next, as shown in FIG. 4, the inductor coil 29 is embedded with a core material 32 composed of a magnetic rivet core 30 composed of a ferrite core and a magnetic pot core 31 composed of a ferrite core, thereby producing a choke coil or the like. Inductor 33 is obtained. Finally, the mounting terminal 26 is fixed in an exposed state on the lower surfaces at both ends of the bent core material 32. The core material 32 can be a Ni-based material, a Mn-based ferrite material, an amorphous material, or a metal dust material, and the inductor coil 29 may be molded with the core material.

  5 to 7 show a second embodiment, and FIGS. 5 to 7 show a manufacturing process of a 3.5T inductor coil. A reference numeral 41 shown in FIG. 5 is a thin strip-shaped conductive plate formed by punching one copper plate, and S is a center line along the longitudinal direction of the strip-shaped conductive plate 41. The strip-shaped conductive plate 41 is provided with a plurality of arc-shaped portions 42 a to 42 g in a zigzag manner on a plane from one end side to the other end side of the strip-shaped conductive plate 41 with the center line S as a reference. These arc-shaped portions 42 a to 42 g are semicircular in the same shape, and are integrally connected by connecting portions 43 a to 43 f to constitute a coil forming member 44.

The connecting parts 43a to 43f have the same width as the arcuate parts 42a to 42g, are linear in the extending direction of the center line S, and the connecting parts 43a to 43f are formed to have the same length. Furthermore, first fold portions 45a to sixth fold portions 45f are formed in the direction perpendicular to the center line S at intermediate portions in the longitudinal direction of the connecting portions 43a to 43f of the coil forming member 44. Moreover, the terminal part 46 is integrally provided in the extension direction of the center line S in the both ends of the longitudinal direction of the coil formation member 44, and these terminal parts 46 are formed a little wider than the connection parts 43a-43f.

When the coil forming member 44 configured in this way is valley-folded at the first fold portion 45a, the coil-forming member 44 is folded in two at the connecting portion 43a, and the arc-shaped portions 42a and 42b face each other across the center line S so as to form an annular coil. A portion 47a is formed. Next, when the second fold part 45b is folded in a mountain, the connecting part 43b is folded in half, and the arcuate parts 42b and 42c face each other across the center line S to form an annular coil part 47b. Similarly, when the third fold portion 45c is valley-folded, it is folded in two at the connecting portion 43c, and the arc-shaped portions 42c and 42d face each other across the center line S to form an annular coil portion 47c. Next, when the fourth fold portion 45d is mountain-folded, it is folded in two at the connecting portion 43d, and the arc-shaped portions 42d and 42e face each other across the center line S to form an annular coil portion 47d. Similarly, when the valley is folded at the fifth fold portion 45e, it is folded in two at the connecting portion 43e, and the arc-shaped portions 42f and 42e face each other across the center line S to form an annular coil portion 47e. Next, when the mountain is folded at the sixth fold portion 45f, it is folded in half at the connecting portion 43f, and the arc-shaped portions 42f and 42g face each other across the center line S to form an annular coil portion 47f.

The arc-shaped portion 42c overlaps the upper surface of the arc-shaped portion 42a, the arc-shaped portion 42d overlaps the upper surface of the arc-shaped portion 42b, and the arc-shaped portion 42e overlaps the upper surface of the arc-shaped portion 42c. Overlaps the upper surface of the arc-shaped portion 42d, and the arc-shaped portion 42g overlaps the upper surface of the arc-shaped portion 42e. Accordingly, the coil portions 47a to 47f are concentrically overlapped, and terminal portions 46 are formed at both ends of the coil forming member 44 so as to protrude from the coil portions 47a to 47f, and the inductor coil as shown in FIGS. 49 is completed.

  As in the first embodiment, the inductor coil 49 is embedded with a core material consisting of a magnetic rivet core made of a ferrite core and a magnetic pot core made of a ferrite core so that an inductor such as a choke coil can be obtained. can get.

  As described above, the present invention can form a coil portion by connecting a plurality of arc-shaped portions at a connecting portion, repeating a valley fold at a fold portion provided at the connecting portion, and repeating a mountain fold. Because it is in the same direction, it can be easily manufactured simply by repeating valley folding and mountain folding.

  In addition, according to the said embodiment, although the copper plate was used as a thin strip | belt-shaped electroconductive board, oxygen free copper and phosphor bronze may be sufficient as long as it is a conductive material.

  Note that the present invention is not limited to the above-described embodiment as it is, and can be embodied by modifying constituent elements without departing from the scope of the invention in the implementation stage. Moreover, various inventions can be formed by appropriately combining a plurality of constituent elements disclosed in the embodiment. For example, some components may be deleted from all the components shown in the embodiment. Furthermore, you may combine the component covering different embodiment suitably.

The top view of the strip | belt-shaped electroconductive board which shows the manufacturing process of the coil for inductors for 1.5T of the 1st Embodiment of this invention. The top view of the coil for inductors of the embodiment. The perspective view of the coil for inductors of the embodiment. The perspective view of the inductor of the embodiment. The top view of the strip | belt-shaped electroconductive board which shows the manufacturing process of the coil for inductors for 3.5T of the 2nd Embodiment of this invention. The top view of the coil for inductors of the embodiment. The perspective view of the coil for inductors of the embodiment. A prior art example is shown, (a) is a perspective view of the coil for inductors, (b) is a top view similarly. The perspective view of an inductor which shows a prior art example.

Explanation of symbols

  21 ... Strip-shaped conductive plate, 22a, 22b, 22c ... Arc-shaped part, 23a, 23b ... Connection part, 24 ... Coil forming member, 25a, 25b ... Crease part, 26 ... Mounting terminal, 27, 28 ... Coil part, 29 ... Coil for inductor, 32 ... core material.

Claims (2)

  A plurality of arc-shaped portions are provided in a zigzag pattern on the strip-shaped conductive plate with a center line along the longitudinal direction of one strip-shaped conductive plate as a reference, and a coil is formed by connecting these arc-shaped portions with connecting portions. An annular coil is formed by configuring a member, forming a crease portion at a connecting portion of the coil forming member, and alternately repeating the valley fold and the mountain fold at the crease portion to overlap the arc-shaped portion. A coil structure for an inductor, wherein a terminal portion is formed at both ends of the coil forming member. A plurality of arc-shaped portions are provided in a zigzag pattern on the strip-shaped conductive plate with a center line along the longitudinal direction of one strip-shaped conductive plate as a reference, and a coil is formed by connecting these arc-shaped portions with connecting portions. An annular coil is formed by configuring a member, forming a crease portion at a connecting portion of the coil forming member, and alternately repeating the valley fold and the mountain fold at the crease portion to overlap the arc-shaped portion. An inductor coil in which a terminal portion is formed on both ends of the coil forming member,
An inductor, wherein a coil portion of the inductor coil is embedded with a core material made of a magnetic material, and the terminal portion is exposed from the core material.

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