JP2000348951A - Laminated coil unit and transformer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To decrease the number of part items and the number of assembling processes used to produce a laminated coil unit, even when laminated coils with two or more turns are used. SOLUTION: Because the end of a conductor pattern 11A in each of laminated coils 9 and 10 extends to form an electrical connection portion 16A, conductor patterns 11A in the laminated coils 9 and 10 are integrated, and electrical connection between the laminated coils 9 and 10 can be serially established through the electrical connection portion 16A without the need for soldering via a fitting, etc. Because the electrical connection portion 16A can be bent so that the laminated coils 9 and 10 are opposite to each other, a secondary coil unit is held by bending the electrical connection portion 16A of a primary laminated coil unit 3 at the positions of the laminated coils 9 and 10, and these are held by cores, so as to facilitate the installation of the transformer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a laminated coil unit, and more particularly, to a laminated coil unit incorporated in a transformer.

[0002]

2. Description of the Related Art As a coil unit provided in a transformer, for example, a coil unit shown in FIG. 6 is disclosed in Japanese Patent Application No. 10-351261.

[0003] The transformer has a structure in which primary side coil units 23 and 24 and a secondary side coil unit 25 whose outer surface is covered with an insulating material are sandwiched between a pair of PQ cores 21 and 22. The secondary coil unit 25 is sandwiched between the primary coil units 23 and 24. Each of the primary side coil units 23 and 24 is formed of a multilayer laminate in which a plurality of insulating materials provided with coil patterns on both surfaces are laminated, and provided with protrusions 26 to 29. Projecting part 26,
27 electrically connects the primary side coil units 23 and 24 in series, respectively, and projections 28 and 29 electrically connect the primary side coil units 23 and 24 in series and also serves as external connection terminals. The secondary-side coil unit 25 is resin-molded by injection molding and is integrated with two copper-side secondary coils sandwiching an insulating spacer.

[0004] As another winding structure of a transformer, for example, Japanese Patent Application Laid-Open No. Hei 10-12454 discloses FIG.
The one shown in (b) is disclosed.

[0005] A thin plate-shaped metal conductor 31 which becomes a square shape when unfolded in a plane is placed at a predetermined position A at the center of a vertical side.
Fold in. Then, the metal conductor 31 is bent at predetermined positions B and C on the vertical side so that the two sides in the horizontal direction face each other and are in parallel. By this step, a winding 36 in which the terminal portions 32 and 33 and the coil portions 34 and 35 are formed is obtained. Another winding is sandwiched between the coil portions 34 and 35, and in this state, the winding 36 and another winding are incorporated in a transformer core to constitute a transformer.

[0006]

However, in the coil unit disclosed in Japanese Patent Application No. 10-351261, when the primary side coil units 23 and 24 are electrically connected in series, the primary side coil unit 23 , 24 are soldered via connection joints or the like.
Therefore, there is a problem that the number of assembling steps is increased and the reliability of the solder portion is reduced.

In the winding structure of a transformer disclosed in Japanese Patent Application Laid-Open No. 10-12454, coil portions 34 and 35
Are formed integrally, there is no need to make electrical connection by soldering the coil portions 34, 35 via joints or the like. However, the use of a multi-turn laminated coil is not considered.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the present invention is to reduce the number of parts and the number of assembling steps of a laminated coil unit even when a laminated coil having a plurality of turns is used. It is to provide a laminated coil unit and a transformer.

[0009]

In order to achieve the above object, according to the present invention, a plurality of conductor patterns are laminated while ensuring electrical insulation from each other, and a space between terminals of each conductor pattern is formed. In a laminated coil unit having a plurality of laminated coil portions electrically connected in series, a lead terminal is provided at one end of at least one conductor pattern in each of the laminated coil portions, and at least one of the at least one of the laminated coil portions in each of the laminated coil portions is provided. One end of each of the conductor patterns is formed to extend, and the extended conductor patterns are connected to each other to form an electrical connection portion, whereby the conductor patterns are integrally formed, and the laminated coil portion is formed. Are electrically connected in series.

According to a second aspect of the present invention, in the first aspect of the present invention, the electrical connection portion is formed so as to be bendable so that the laminated coil portions connected to each other face each other.

According to a third aspect of the present invention, one end of each of the pair of conductor patterns is formed so as to extend, and is connected to each other to form an electrical connection portion. And a pair of conductor patterns, one or a plurality of conductor patterns are respectively laminated while ensuring electrical insulation from each other, and terminals of the conductor patterns are electrically connected in series. And a coil layer to be formed.

According to a fourth aspect of the present invention, in the third aspect of the invention, the connection layer and the coil layer according to the third aspect are formed by bending an electrical connection portion such that a pair of conductor patterns face each other. A primary side laminated coil unit, a secondary side coil unit formed of a plurality of coils and having an outer surface covered with an insulating material is sandwiched by the primary side laminated coil unit, and in this state, sandwiched by a pair of cores. Have been.

According to the first and second aspects of the present invention,
Since one end of at least one conductor pattern in each laminated coil portion is formed to extend and form an electrical connection portion, at least one conductor pattern in each laminated coil portion is integrally formed, and a plurality of laminated coil portions are formed. The electrical connection of the parts is performed in series by the electrical connection part without soldering or the like between the laminated coil parts via a joint or the like. Therefore, the necessity of assembling the laminated coil portions is eliminated,
Increases the reliability of electrical connections.

According to the second aspect of the present invention, since the electrical connection portion is formed so as to be bendable so that the laminated coil portions connected to each other are opposed to each other, for example, the electrical connection portion is formed by the laminated coil portions connected to each other. It is possible to sandwich a conductor pattern whose outer surface is covered with an insulating material.

According to the third and fourth aspects of the present invention, the laminated coil unit has a connection layer in which an electrical connection portion is formed and a pair of conductor patterns are integrally formed, and a connection layer formed in each of the conductor patterns. Since the electrical connection between the pair of conductor patterns is performed without being soldered to the pair of conductor patterns via a joint or the like, the electrical connection of the pair of conductor patterns is performed in series by the electrical connection portion. Therefore, it is easy to assemble the laminated coil units while being electrically connected in series.

According to the fourth aspect of the present invention, the secondary coil unit is sandwiched by bending the electrical connection portion of the primary laminated coil unit including the connection layer and the coil layer, and these are sandwiched by the core. In addition, the transformer can be easily assembled.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS.

As shown in FIGS. 1A and 1B, the transformer T of this embodiment includes a pair of PQ cores (hereinafter simply referred to as cores) 1 and 2 and primary-side laminated coil units 3 and 2. It is composed of a secondary coil unit 4. A secondary coil unit 4 is sandwiched between the cores 1 and 2 in a state sandwiched by the primary laminated coil unit 3.

The pair of cores 1 and 2 are made of ferrite and have the same shape, and are formed into a shape obtained by processing a rectangular parallelepiped object. A columnar projection is formed at the center of the cores 1 and 2, an arc-shaped storage section is formed around the projections, and both sides of the cores 1 and 2 are cut open. The depth of the storage portion is determined by the cores 1 and 2 in a state where the primary side coil unit 3 and the secondary side coil unit 4 are stored.
Are set so as to abut each other.

As shown in FIG. 2, the secondary coil unit 4 is composed of two spacers 5 made of an insulating material and two secondary coils 6 and 7 of the same shape made of a stamped copper plate. Have. The thicknesses of the spacer 5 and the secondary coils 6, 7 are formed to be the same. Terminals 6A and 7A for tapping and terminals 6B and 7B are formed at the ends of the secondary coils 6 and 7, respectively, and the terminals 6A and 7A for tapping are respectively formed by bending. In a state in which the two spacers 5 are sandwiched between the secondary coils 6, 7 and one of the secondary coils 6, 7 is inverted so that the tap terminals 6A, 7A contact each other,
The secondary coil unit 4 is formed integrally with a resin mold. That is, the outer surfaces of the secondary coils 6 and 7 are covered with the insulating material 8. The inner and outer diameters of the secondary coil are formed to be the same as the conductor pattern of the primary laminated coil unit 3 described later, and the secondary coil unit 4 has holes for inserting the protrusions of the cores 1 and 2. Is provided.

As shown in FIGS. 3 and 4A, the primary-side laminated coil unit 3 is constituted by a pair of laminated coil portions 9 and 10. The laminated coil portions 9 and 10 are formed in the same shape, and have conductor patterns 11A to 1
Plural insulating materials 12A to 12C provided with 1F
And a plurality of insulating materials 12D are alternately laminated. The laminated coil portions 9 and 10 are provided with holes 9A and 10A at the center where projections of the cores 1 and 2 are fitted, and protruding portions 13 and 14, respectively.

As shown in FIG. 3, a five-layer conductor pattern 1
1A to 11E, a pair of first conductor patterns 11A arranged at the top and a fifth conductor pattern 11E arranged at the bottom are formed shorter than one turn, and the other conductor patterns 11B to 11D are It is formed to be one turn. One end of the first conductor pattern 11A and one end of the second conductor pattern 11B, the other end of the second conductor pattern 11B and one end of the third conductor pattern 11C, the other end of the third conductor pattern 11C and the fourth One end of the conductor pattern 11D, the other end of the fourth conductor pattern 11D, and the fifth conductor pattern 1
One end of 1E is electrically connected in series by a plating layer provided in a through hole 15 formed in the protruding portion 13 to form a four-turn conductor. Each of the conductor patterns 11A to 11F has the same inner diameter and outer diameter,
Its thickness is formed, for example, in the range of 75 μm to 175 μm.

A lead terminal 16E is formed at the other end of the fifth conductor pattern 11E so as to extend to a position corresponding to the protrusion 14 for the terminal. The projecting portion 14 is formed with a plated through hole 17 that forms a terminal together with the lead terminal 16E of the fifth conductor pattern 11E.

As shown in FIG. 4B, the insulating material 12A has a shape in which the insulating material 12B (12C) is connected by the protruding portion 14. A pair of first conductor patterns 11A is provided on one surface of the insulating material 12A. On one surface of the insulating material 12A, the other end of the first conductor pattern 11A of the laminated coil portion 9 and the other end of the first conductor pattern 11A of the laminated coil portion 10 are respectively formed to extend, and the extended conductor is formed. By electrically connecting the patterns 11A to each other, an electrical connection portion 16A is formed. That is, the electrical connection portion 16A
The conductor patterns 11A are integrally formed with each other via a point, and are formed point-symmetrically. Laminated coil part 9
The laminated coil portions 9 and 10 are electrically connected in series by integrally forming the conductor patterns 11A in the first and second conductor patterns 11 and 10. The electrical connection portion 16A and the insulating material 12A are each formed to be thin and have elasticity so that they can be bent, and when bent, have a length that can hold the secondary coil unit 4. Is formed. (In the present embodiment, the connection layer is the insulating layer 12A and the conductor pattern 11A provided on the insulating layer 12A, and the coil layer is the insulating layers 12B to 12D and the conductor patterns 11B to 11F.) When assembling the transformer T
First, the laminated coil unit 10 of the primary-side laminated coil unit 3 and the secondary-side coil unit 4 are stored in the storage part of the core 2 in this order. Next, the electrical connection portion 16A of the primary-side laminated coil unit 3 is arranged such that the hole 9A of the laminated coil 9 portion of the primary-side laminated coil unit 3 matches the hole of the secondary-side coil unit 4.
Is bent and brought into contact with the secondary coil unit 4. Finally, the protrusion of the core 1 is inserted into the hole 9A of the laminated coil unit 9 of the primary laminated coil unit 3 and the hole of the secondary coil unit 4. Then, the portions where the conductor patterns on the tap terminals 6A, 7A and the protrusions 14 are exposed are coated with solder by a solder leveler process so that the conductor patterns are not oxidized.

Next, the transformer T configured as described above is used.
Is used in a DC / DC converter circuit as a DC power supply circuit.

As shown in FIG. 5, the DC / DC converter circuit includes a battery E, a filter F, and a transistor Q1.
, A transformer T having a secondary coil having an intermediate tap, and a diode D.
1 and D2 and a secondary circuit having a capacitor C. Then, a load R is connected between the output terminals VO. In the inverter section I, the transistor Q
1, Q4 and the transistors Q2, Q3 are simultaneously turned on and off, respectively. When both transistors Q1 and Q4 are ON, both transistors Q2 and Q3 are simultaneously OFF, and when both transistors Q1 and Q4 are OFF, both transistors Q2 and Q3 are simultaneously ON. When both transistors Q1 and Q4 are ON, current flows in the direction of arrow A1 in the primary side laminated coil unit 3 of the transformer T. Then, in the secondary coil unit 4 of the transformer T, a current flows through the secondary coil 6 in the direction of arrow A3, and the diode D1,
A loop of current flowing through the load R and the intermediate tap is formed. On the other hand, when both transistors Q2 and Q3 are ON, a current flows in a direction opposite to arrow A1 in primary-side laminated coil unit 3. Then, in the secondary coil unit 4, a current flows in the secondary coil 7 in the direction of arrow B3, and a loop of a current flowing through the diode D2, the load R, and the intermediate tap is formed. And transistors Q1, Q2, Q
The DC voltage passing through the secondary coil 6 or 7 is always applied to the load R by the switching control of Q3 and Q4. Since the number of turns of the conductor of the primary-side laminated coil unit 3 is a total of eight turns, and the number of turns of the conductors of the secondary-side coils 6 and 7 is one, the voltage of 1/8 of the battery E is applied to the load R. You. This DC / DC converter circuit changes the voltage of a high-voltage battery E for a drive motor mounted on an automobile, for example, to a low voltage suitable for a power supply of an auxiliary machine.

Therefore, the present embodiment has the following effects.

(1) Since one end of one conductor pattern 11A in the laminated coil portions 9 and 10 is extended to form the electrical connection portion 16A, one conductor pattern in the laminated coil portions 9 and 10 is formed. 11A are integrally formed, and the electrical connection of the laminated coil portions 9 and 10 is performed by the electrical connection portion 16A without soldering between the laminated coil portions 9 and 10 via a joint or the like. They are connected in series, eliminating the need to assemble the laminated coil sections.

(2) Since the thickness of the conductor pattern 11A is, for example, 75 μm to 175 μm, the electrical connection portion 16A can be easily bent so that the laminated coil portions 9 and 10 face each other. Therefore, the laminated coil portions 9 and 10 can sandwich, for example, a conductor pattern whose outer surface is covered with an insulating material.

(3) The secondary coil unit 4 is clamped by bending the electrical connection portion 16A of the primary laminated coil unit 3 composed of the connection layer and the coil layer. Transformer can be assembled.

The embodiments are not limited to those described above, and can be modified as appropriate, for example, as follows.

The laminated coil unit 3 does not need to be composed of the pair of laminated coil portions 9 and 10, but may be composed of, for example, three laminated coils. In this case, both ends of one conductor pattern in the first laminated coil are formed to extend, and one end of each conductor pattern in the second and third laminated coils is formed to extend. Then, the conductor patterns in the first laminated coil and the second laminated coil are connected to each other, and the conductor patterns in the first laminated coil and the third laminated coil are connected to each other. Therefore, the three laminated coils are electrically connected in series.

The electrical connection portion 16A does not need to be formed to be bendable so that the laminated coil portions 9 and 10 face each other, and may be formed in a state in which it is bent in advance.

The tap terminals 6A and 7A and the protrusion 1
When the solder is applied to the exposed portions of the conductor pattern on the solder connection by a solder develler process, the electrical connection portions 1
The surface which is not covered with the insulating material 12A of 6A may be covered with solder. In this case, the electrical connection 16A is strengthened.

Instead of using the laminated coil unit 3 as the primary side of the transformer, it may be used as the secondary side. When used as a secondary side, it is suitable for a step-up transformer.

The thickness and diameter of the conductor pattern may be appropriately changed in accordance with the power used in the transformer T.

The pair of conductor patterns 11A in the primary-side laminated coil unit 3 may not be formed in a point-symmetrical manner.

[0038]

As described above in detail, according to the first to fourth aspects of the present invention, the number of parts and the number of assembling steps of a laminated coil unit can be reduced even when a laminated coil having a plurality of turns is used. Can be.

According to the second aspect of the present invention, for example, a conductor pattern whose outer surface is covered with an insulating material can be sandwiched between the laminated coil portions connected to each other.

According to the fourth aspect of the present invention, the transformer can be easily assembled.

[Brief description of the drawings]

1A and 1B are perspective views of a transformer.

FIG. 2 is a schematic cross-sectional view of a secondary coil unit.

FIG. 3 is a schematic cross-sectional view of each conductor pattern of the laminated coil unit.

4A is a schematic sectional view of a primary-side laminated coil unit, and FIG. 4B is a schematic sectional view of a connection layer.

FIG. 5 is an electric circuit diagram of a DC / DC converter.

FIG. 6 is an exploded perspective view of a conventional transformer.

FIG. 7 (a) is an unformed developed state diagram of a conventional winding structure,
(B) is a winding formation state diagram.

[Explanation of symbols]

1, 2 ... core, 3 ... primary side laminated coil unit, 4 ... secondary side coil unit, 9, 10 ... laminated coil part, 11 ...
Conductor pattern, 12: insulating material, 16A: electrical connection,
16E: Lead-out terminal.

Claims (4)

[Claims] 1. A laminated coil unit having a plurality of laminated coil portions in which a plurality of conductor patterns are laminated while securing electrical insulation from each other and terminals of the conductor patterns are electrically connected in series. A lead terminal is provided at one end of at least one conductor pattern in the portion, and one end of at least one conductor pattern in each of the laminated coil portions is formed so as to extend, and the formed conductor patterns are mutually connected. A laminated coil unit in which conductor patterns are integrally formed by forming an electrical connection portion continuously with the laminated coil portion, and the laminated coil portions are electrically connected in series. 2. The laminated coil unit according to claim 1, wherein the electric connection portion is formed so as to be bent so that the laminated coil portions provided in series with each other are opposed to each other. 3. A connection layer in which one end of each of the pair of conductor patterns is formed so as to extend, and is connected to each other to form an electrical connection portion. A pair of conductor patterns, one or a plurality of conductor patterns are laminated while ensuring electrical insulation from each other,
And a coil layer formed by electrically connecting the terminals of the conductor patterns in series. 4. The connection layer and the coil layer according to claim 3, wherein the electrical connection portion is bent so that the pair of conductor patterns face each other to form a primary-side laminated coil unit.
A transformer comprising a secondary coil unit formed of a plurality of coils and having an outer surface covered with an insulating material sandwiched by the primary laminated coil unit, and sandwiched by a pair of cores in that state.