JP7148356B2 - coil - Google Patents

Description

TECHNICAL FIELD The present invention relates to coils for vehicles and the like that are applied to noise filters.

Various types of coils for vehicles are known. For example, as a coil for a noise filter that removes radio noise, etc., a coil in which a linear bus bar coated with an insulation is wound around a core with two turns of alpha winding has been proposed. A coil consisting of a core and a busbar requires a structure for fixing the core and the busbar. As a fixing structure for the core and busbar, for example, there is a structure in which the busbar side or the core side is provided with a retaining shape.

JP 2005-236026 A

The following problems have been pointed out in conventional coils. That is, a coil having a retainer shape for fixing the busbar and the core tends to have a complicated configuration and a tendency to increase the size of the coil. In addition, in the coil with the retainer shape, there is a concern that the insulating material, which is a flexible material, may be damaged or the core may be damaged due to external force being applied to the retainer shape portion. Furthermore, the coil for retaining the coil requires a large number of man-hours and increases the cost.

Therefore, it is conceivable to fix the bus bar and the core by using an adhesive such as a thermosetting adhesive, omitting the retaining shape. However, when using adhesive, the curing of the adhesive takes a long time. In addition, jigs for fixing the busbars and cores and facilities for curing the adhesive are required. As a result, even coils that use an adhesive to fix the busbar and the core have the drawback of increasing the cost.

The present invention has been proposed to solve the above problems, and its object is to achieve a one-turn penetration shape by inserting the bus bar into the core and fixing it with a belt-shaped member, and to make it easy to manufacture at low cost. It is to provide a coil of structure.

In order to achieve the above object, the coil of the present invention comprises the following components (a) to (f) .
(a) A core with two through holes.
(b) A U-shaped bus bar having long side portions facing each other and a connecting portion connecting the long side portions.
(c) a bobbin that insulates the core and the busbar;
(d) A belt-shaped member for fixing the busbar, with the long side portion inserted into the through-hole of the core, to the core together with the bobbin.
(e) A portion of the bobbin that covers the connecting portion of the busbar is a protruding portion that protrudes toward the outside of the core.
(f) The protruding portion protrudes from the bobbin so that at least a portion around which the belt-like member is wound has the same outer shape as the core.

The busbar may be a U-shaped member formed by bending a metal plate flatwise. The core may have a planar portion with which the belt-shaped member is in contact. The bobbin may include a sleeve portion that can be inserted into the through-hole of the core and that can accommodate the plate-like portion of the busbar.

The bobbin may be made of mold resin integrally molded with the bus bar. A portion of the bobbin that covers the connection portion of the busbar and faces the core includes a portion that covers the connection portion of the busbar of the bobbin when the long side portion of the busbar is inserted into the through hole of the core. may be provided with an abutment surface that abuts against the core.

The bobbin may have a hole through which the connecting portion of the bus bar is exposed. The bobbin may form a groove into which the belt-like member is fitted. The groove may have a curved surface at the end. The strip member may be an adhesive tape. A heat radiating member may be provided so as to be in contact with the bus bar.

According to the present invention, a one-turn penetrating shape is realized by inserting the bus bar into the core and fixing it with a belt-shaped member, and a coil having a structure that is easy to manufacture at low cost can be obtained.

1 is an exploded perspective view of the first embodiment; FIG. 1 is a perspective view of the first embodiment; FIG. 1 is a perspective view of the first embodiment; FIG. FIG. 2 is an exploded perspective view of essential parts of the first embodiment; FIG. 2 is an exploded side view of the essential parts of the first embodiment; FIG. 2 is an exploded side view of the essential parts of the first embodiment; FIG. 2 is an exploded side view of the essential parts of the first embodiment; A perspective view of another embodiment.

[First embodiment]
(Constitution)
The configuration of the first embodiment will be specifically described with reference to FIGS. 1 to 6. FIG. 1 is an exploded perspective view of the first embodiment, FIGS. 2 and 3 are perspective views of the first embodiment, and FIGS. 4 to 7 are exploded perspective views of essential parts of the first embodiment. In the description of the members shown in each figure, the surface located on the upper side of the figure is called a top surface portion, and the surface on the lower side of the figure is called a bottom surface portion. However, the top surface portion and the bottom surface portion described here do not reflect the positional relationship when the coil is mounted on the actual machine.

A coil 1 according to the first embodiment is applied to a coil for an in-vehicle noise filter or the like. As shown in FIGS. 1 to 3, the coil 1 is composed of a substantially rectangular parallelepiped core 2, a U-shaped bus bar 3, a bobbin 4, and a tape 5 which is a band-shaped member. The bobbin 4 is integrally molded with the busbar 3, but is shown in an exploded state in FIG. 2 and 3 show these members assembled.

(Core 2)
The core 2 is composed of a substantially rectangular parallelepiped dust core. The substantially rectangular parallelepiped core 2 is provided with a top surface portion 21 and a bottom surface portion 22 parallel to each other, and a side surface portion 23 is provided as a flat surface portion perpendicular to the top surface portion 21 and the bottom surface portion 22 . The top surface portion 21 and the bottom surface portion 22 are horizontal surfaces, and the side surface portion 23 is a surface with rounded corners. Although the surface of the core 2 is not provided with an insulating coating such as polyamide or polyester, the surface of the core 2 may be provided with an insulating coating.

The core 2 has two through holes 24 , 24 passing through the top surface portion 21 and the bottom surface portion 22 . The through holes 24, 24 are parallel to each other and are rectangular holes with rounded corners. By opening these through-holes 24, 24, the core 2 when viewed from above has the shape of the letter "H". A bus bar 3 integrally formed with the bobbin 4 is inserted into the through holes 24 from below the core 2 .

(Busbar 3)
When the busbar 3 is inserted into the through holes 24, 24 of the core 2, the upper half of the busbar 3 protrudes upward from the upper surface portion 21 of the core 2 (see FIGS. 2 and 3). As shown in FIGS. 1, 4 and 5, the bus bar 3 is a U-shaped member formed by flatwise bending, and is made of a single thin copper plate that is not coated with insulation. As described above, the bobbin 4 is molded integrally with the busbar 3, but the exploded views of FIGS. ing. In FIG. 4, the busbar 3 and the core 2 are shown.

The U-shaped bus bar 3 is provided with two parallel plate-like portions 31 and a connecting portion 32 connecting the plate-like portions 31 to each other. The plate-like portion 31 becomes the U-shaped long side portion. When the busbar 3 is inserted into the through-holes 24 , 24 of the core 2 , the upper half of the plate-like portion 31 of the busbar 3 protrudes from the upper surface portion 21 of the core 2 .

The upper half of the plate-like portion 31 is exposed to the copper plate without being covered with insulation. The plate-like portion 31 of the bus bar 3 has its end pulled out to be connected to wiring (not shown) of an external device such as an external power source. When power is supplied from an external power supply to the busbar 3, a current (indicated by a dotted arrow) flows through the U-shaped busbar 3, forming a one-turn coil, and as shown in FIG. A magnetic flux (indicated by solid arrows) is generated in the core 2 between the holes 24 , 24 . As a result, the generated magnetic flux passes through the core 2 to form an annular closed magnetic circuit.

(Bobbin 4)
The bobbin 4 is a member that insulates the core 2 and the busbar 3 and is made of molded resin that is integrally formed with the lower half of the busbar 3 . As shown in exploded views of FIGS. 1 and 5 to 7, the bobbin 4 includes two parallel sleeve portions 41, 41 protruding upward, and a table portion for vertically raising the sleeve portions 41, 41. 42 are provided. As shown in the lower side of FIG. 5 , when the bobbin 4 is integrally formed with the lower half of the busbar 3 , the lower half of the plate-like portion 31 of the busbar 3 is accommodated inside the sleeve portion 41 . That is, the sleeve portion 41 of the bobbin 4 covers the lower half of the plate-like portion 31 of the busbar 3 with insulation.

Since the sleeve portion 41 of the bobbin 4 covers the plate-like portion 31 of the busbar 3 , the sleeve portion 41 has a plate-like shape that is slightly thicker than the plate-like portion 31 . The shape of the square holes of the through holes 24, 24 of the core 2 is formed so that the sleeve portions 41, 41 having such a shape can be inserted. Further, as shown in FIG. 2, when the busbar 3 is inserted into the through holes 24 of the core 2, the tip of the sleeve portion 41 slightly protrudes from the upper surface portion 21 of the core 2. As shown in FIG.

The table portion 42 of the bobbin 4 covers the connecting portion 32 of the busbar 3 with an insulating coating. The upper surface side of the table portion 42 is an abutting surface 43 . The abutment surface 43 is a surface of the bobbin 4 that covers the connecting portion 32 of the busbar 3 and faces the core 2 . 2 is a surface that abuts on the entire bottom surface portion 22 of FIG.

Projecting portions 44 projecting outward from the core 2 are formed at the left and right end portions of the table portion 42 in the figure. The projecting portion 44 is provided on the abutment surface 43 that is the portion of the bobbin 4 that covers the connecting portion 32 of the busbar 3 . The protruding portion 44 protrudes from the bobbin 4 so that at least the portion around which the tape 5 is wound has the same outer shape as the core 2 . The projecting portion 44 is located outside the sleeve portion 41 and is provided integrally with the table portion 42 . As shown in FIGS. 3 and 7, a square hole 45 is formed in the center of the table portion 42 . The connecting portion 32 of the busbar 3 is exposed through the hole 45 .

Further, as shown in FIGS. 1 to 7, grooves 46 into which the tape 5 is fitted are formed in the side and bottom surfaces of the table portion 42 . The groove portion 46 is set to have a dimension slightly wider than the width dimension of the tape 5 . Further, the groove portion 46 is formed to have an R shape, which is a curved surface, at the end portion of the groove portion 46 corresponding to the side surface portion of the table portion 42 . The groove portion 46 is recessed in the table portion 42 and its depth is set deeper than the thickness dimension of the tape 5 .

(Tape 5)
The tape 5 is a non-conductive adhesive tape made of polyester film or the like. The tape 5 fixes the busbar 3 with the plate-like portion 31 inserted into the through hole 24 to the core 2 together with the bobbin 4 . The tape 5 is applied from the upper surface 21 of the core 2 through the side surface 23 and over the side and bottom surfaces of the table portion 42 of the bobbin 4. It is designed to be

(Assembly of Coil 1)
The first embodiment described above is assembled as follows. By molding the bobbin 4 on the bus bar 3, the bobbin 4 is integrally formed on the lower half of the bus bar 3. - 特許庁The sleeve portion 41 of the bobbin 4 is inserted into the through holes 24 of the core 2 from the bottom surface portion 22 side of the core 2 . By abutting the abutment surface 43 of the bobbin 4 against the bottom surface portion 22 of the core 2, the bobbin 4 and the core 2 are positioned. As a result, the bobbin 4 and the busbar 3 are inserted into the through holes 24, 24 of the core 2, and the coil 1 becomes a one-turn through coil.

After that, the tape 5 is pasted so as to go around the core 2 and the table portion 42 of the bobbin 4 from the upper surface portion 21 of the core 2 through the side portion 23 to the table portion 42 of the bobbin 4 . Thereby, the tape 5 fixes the busbar 3 and the bobbin 4 to the core 2 . When the tape 5 is wound around the table portion 42 of the bobbin 4, the tape 5 is fitted in the groove portion 46. As shown in FIG.

In this embodiment, the coil 1 is housed in a case (not shown) and filled with a filler for heat radiation. The case is a metallic container that houses the coil 1, and has a substantially rectangular parallelepiped shape with an open top and a hollow interior. The case is preferably made of metal such as aluminum, aluminum alloy, or the like, which has high thermal conductivity and is lightweight. A filling material is filled and solidified in the case to dissipate the heat generated by the coil 1 . That is, a filling molded portion formed by solidifying the filler is provided in the gap between the case and the coil 1 . A relatively soft resin with high thermal conductivity is suitable for the filler in order to ensure the heat radiation performance of the coil 1 .

(action and effect)
The actions and effects of the first embodiment are as follows.
(1) The coil 1 according to the first embodiment includes a core 2 provided with two through holes 24, 24, two plate-like portions 31 parallel to each other, and a connecting portion 32 connecting the plate-like portions 31. , a bobbin 4 for insulating the core 2 and the busbar 3, and a tape for fixing the busbar 3 with the plate-like portion 31 inserted into the through hole 24 of the core 2 to the core 2 together with the bobbin 4. 5 and .

According to the first embodiment, the plate-like portion 31 of the busbar 3 insulated by the bobbin 4 is inserted into the through holes 24, 24 of the core 2, and the core 2, the busbar 3 and the bobbin 4 are connected with the tape 5. The one-turn through-shaped coil 1 can be easily manufactured only by fixing the . Therefore, as a structure for fixing the busbar 3 and the core 2, a shape for preventing the busbar 3 from coming off is not required. As a result, the configuration can be simplified, and the size of the coil 1 can be reduced.

In addition, in the first embodiment, since it is not necessary to provide a shape to prevent the busbar 3 from coming off, even if the busbar 3 is pulled by an external force, the insulating coating of the bobbin 4 integrally formed with the busbar 3 is maintained. There is no fear that the part will be damaged or the core 2 will be damaged. Therefore, the coil 1 can obtain excellent reliability.

Furthermore, in the first embodiment, the busbar 3 and the core 2 are fixed simply by winding the tape 5 around the busbar 3, so there is no need to use an adhesive to fix the busbar 3 and the core 2 together. Therefore, the time required for fixing the busbar 3 and the core 2 can be shortened. Moreover, neither a jig for fixing the busbar 3 and the core 2 nor equipment for curing the adhesive is required. Therefore, the assembly work is facilitated, the cost is reduced, and the inexpensive coil 1 can be provided.

(2) In the first embodiment, the busbar 3 is a U-shaped member formed by flatwise bending a copper plate. can be inserted smoothly. Therefore, the coil 1 is easy to assemble. Moreover, since the bus bar 3 is a member formed by flatwise bending a copper plate, the production cost is low and the size can be easily reduced. Therefore, the size and cost of the coil 1 can be reduced.

(3) In the core 2 of the first embodiment, since the side surface portion 23 is provided as the flat surface portion with which the tape 5 is in contact, adhesion of the tape 5 to the side surface portion 23 is greater than when the surface with which the tape 5 is in contact is a curved surface. power increases. Therefore, the tape 5 can exhibit a high fixing force. Therefore, the tape 5 reliably fixes the busbar 3 and the bobbin 4 to the core 2, and the assembly reliability of the coil 1 is improved.

(4) In the bobbin 4 of the first embodiment, the sleeve portion 41 can be inserted into the through hole 24 of the core 2 and accommodate the plate-like portion 31 of the busbar 3. The operation of inserting the plate-like portion 31 of the busbar 3 insulated by the bobbin 4 into the 24 is easy. Therefore, the coil 1 having a one-turn penetrating shape can be manufactured more easily.

(5) In the first embodiment, the bobbin 4 made of mold resin is formed integrally with the U-shaped bus bar 3, so that the dimensional tolerance can be reduced as a whole. Therefore, the assemblability of the coil 1 is further improved.

(6) In the first embodiment, when the plate-like portion 31 of the busbar 3 is inserted into the through-hole 24 of the core 2, the abutment surface 43 of the bobbin 4 is simply abutted against the entire bottom surface portion 22 of the core 2. Positioning of the core 2 and the bus bar 3 can be easily performed. Therefore, it is possible to improve the assembly work efficiency of the coil 1 .

(7) In the first embodiment, in the table portion 42 of the bobbin 4, the portion of the bobbin 4 that covers the connection portion 32 of the busbar 3 has the projecting portion 44 that projects outward from the core 2. can be stably placed on a flat surface. Such a stable arrangement of the bobbin 4 improves the work environment for assembling the coil 1 . Moreover, since the protruding portion 44 is provided outside the sleeve portion 41, the dead space formed inside the side surface of the core 2 can be effectively utilized. Therefore, in the first embodiment, even if the overhanging portion 44 is provided, the coil 1 does not increase in size, and only the advantage of improved stability due to the overhanging portion 44 can be obtained.

(8) The protruding portion 44 protrudes from the bobbin 4 so that at least the portion around which the tape 5 is wound has the same outer shape as the core 2. Intrusion of foreign matter into the gap between the tape 5, the core 2 and the bobbin 4 can be suppressed by closely contacting. In particular, when the tape 5 is an adhesive tape, foreign matter tends to adhere to the adhesive tape. Therefore, the adhesion of the tape 5 to the side surface of the core 2 and the bobbin 4 is effective in preventing foreign matter from entering.

(9) In the first embodiment, since the hole 45 of the bobbin 4 exposes the connection portion 32 of the busbar 3, the heat of the busbar 3 can be efficiently dissipated. Therefore, the coil 1 can stably exhibit predetermined characteristics.

(10) In the first embodiment, the groove portion 46 provided in the table portion 42 of the bobbin 4 serves as a guide, and the tape 5 can be easily wound on the lower surface side of the table portion 42 of the bobbin 4 . Further, since the groove portion 46 is formed to have an R shape, which is a curved surface, at the end portion, the tape 5 can be more easily wound around the table portion 42 of the bobbin 4 . Furthermore, since the position where the tape 5 is wound is inside the side surface of the bobbin 4 by providing the groove 46 on the bobbin 4, the size of the coil 1 can be reduced. Furthermore, when the bobbin 4 is positioned on the bottom side of the coil 1, the bobbin 4 faces the heat dissipation surface, so heat dissipation is further improved.

Moreover, in the first embodiment, since the depth of the groove portion 46 is set to the depth at which the tape 5 is fitted, the tape 5 does not protrude from the bottom surface of the table portion 42 . Therefore, the assembled coil 1 can be stably placed on a flat surface, and the efficiency of assembling the coil 1 can be further improved.

(11) In the first embodiment, since the tape 5 is an adhesive tape, it is possible to easily and quickly fix the busbar 3 and the core 2 together. Therefore, the assembling work of the coil 1 is further improved.

[Other embodiments]
The present invention is not limited to the above embodiments. It can be embodied in various other forms, and various omissions, replacements, and modifications can be made without departing from the scope of the invention. These embodiments and modifications thereof are included within the scope, gist, and equivalents of the invention.

For example, a heat radiating member may be provided so as to be in contact with the busbar 3 . Specifically, as shown in FIG. 7 , the heat radiation sheet 6 may be crimped onto the entire lower surface of the table portion 42 of the bobbin 4 . The heat dissipation sheet 6 is in contact with the connecting portion 32 of the busbar 3 through the hole 45 . According to such an embodiment, the heat dissipation sheet 6 can efficiently dissipate heat from the busbar 3, and the coil 1 can more stably exhibit predetermined characteristics.

Further, the outer shape of the core 2 may not be a rectangular parallelepiped shape, and may be an outer shape including a curved surface, or may be a combination of two E-shaped cores. Further, although the core 2 in the above embodiment is a dust core, a magnetic material such as a ferrite core or a laminated steel plate may be used. Further, in the above embodiment, the bobbin 4 is formed integrally with the busbar 3, but the bobbin 4 may be formed integrally with the core 2 side.

The bobbin 4 may be a member that insulates the core 2 and the bus bar 3, and the type of the insulating resin includes, for example, epoxy resin, unsaturated polyester resin, urethane resin, and the like, and can be appropriately selected. Also, the bobbin 4 may be separate from the busbar 3 . In the embodiment in which the bobbin 4 and the busbar 3 are separate bodies, the bobbin 4 can be manufactured at low cost.

DESCRIPTION OF SYMBOLS 1... Coil 2... Core 21... Upper surface part 22... Bottom part 23... Side part 24... Through hole 3... Bus bar 31... Plate-like part 32... Connecting part 4... Bobbin 41... Sleeve part 42... Table part 43... Abutment surface 44 Overhang 45 Hole 46 Groove 5 Tape 6 Heat dissipation sheet

Claims (11)

a core provided with two through holes;
a U-shaped bus bar having long side portions facing each other and a connecting portion connecting the long side portions;
a bobbin that insulates the core and the busbar;
a band-shaped member that fixes the busbar, the long side portion of which is inserted into the through-hole of the core, to the core together with the bobbin ;
a portion of the bobbin that covers the connecting portion of the busbar has an overhanging portion that overhangs the core,
The coil , wherein the projecting portion projects from the bobbin so that at least a portion around which the belt-like member is wound has the same outer shape as the core . 2. The coil according to claim 1, wherein the bus bar is a U-shaped member formed by flatwise bending a metal plate. 3. The coil according to claim 1, wherein the core has a planar portion with which the belt-shaped member is in contact. The coil according to any one of claims 1 to 3, wherein the bobbin has a sleeve portion that can be inserted into the through-hole of the core and that can accommodate the plate-like portion of the bus bar. The coil according to any one of claims 1 to 4, wherein the bobbin is made of molded resin integrally molded with the bus bar. A portion of the bobbin that covers the connection portion of the busbar and faces the core has a portion that covers the connection portion of the busbar of the bobbin when the long side portion of the busbar is inserted into the through hole of the core. 6. The coil according to any one of claims 1 to 5, further comprising an abutment surface that abuts against said core. The coil according to any one of claims 1 to 6 , wherein the bobbin has a hole through which the connecting portion of the bus bar is exposed. The coil according to any one of claims 1 to 7 , wherein the bobbin is formed with a groove into which the belt-like member is fitted. 9. The coil according to claim 8 , wherein said groove has a curved surface at its end. 10. The coil according to any one of claims 1 to 9 , wherein said belt-shaped member is an adhesive tape. 11. The coil according to any one of claims 1 to 10 , further comprising a heat radiating member in contact with said bus bar.

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