JP2010251364A - Bobbin for coil, winding component, coil component, switching power supply unit, and method of manufacturing coil component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inter-core gap of magnetic core members with high precision through easy assembling operation. <P>SOLUTION: Bobbins 40 of a winding component 1 are bobbins for coils which electrically insulate a pair of magnetic core members at least one of which has leg parts, from coil windings 2 sandwiched between the pair of magnetic core members with the leg parts being inserted in the coil windings 2, respectively. The bobbins 40 of the winding component 1 include cylindrical parts 40a each provided on an inner peripheral side of the each coil winding 2 along the each center axis direction of the coil winding, spacer parts 61 each provided in the each cylindrical part 40a so as to provide the gap between the paired magnetic core members, and support pieces 63 each coupling an inner wall of the each cylindrical part 40a to the each spacer part 61 and supporting the spacer part 61, wherein the spacer part 61 is pressed by the leg part of the magnetic core member to draw or cut the support piece 63. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a coil bobbin, a winding component, a coil component, a switching power supply device, and a method for manufacturing the coil component.

  2. Description of the Related Art A switching power supply device such as a DC-DC converter that converts a high voltage into a low voltage or converts a low voltage into a high voltage is known as a vehicle-mounted component. As a coil component used for a transformer or the like of this switching power supply device, one having a coil winding and a cylindrical insulating coil bobbin is known. The coil bobbin of this coil component is inserted into the coil winding, and the coil component is inserted into the coil bobbin opening by a pair of magnetic core members along the axial direction of the coil winding. It is sandwiched with the part inserted.

  In the coil component described above, generally, the AL value (inductance coefficient) of the coil component is adjusted by providing a gap (gap) between the end surfaces of the leg portions of the pair of magnetic core members. An insulating gap spacer having a predetermined thickness is provided between the end surfaces of the leg portions of the pair of magnetic core members for the purpose of reducing loss due to leakage magnetic flux and making the AL value constant. Conventionally, the coil bobbin and the gap spacer have been used as separate members. For example, Patent Document 1 discloses an inner wall of a cylindrical coil bobbin for the purpose of simplifying the assembly work of the coil component. FIG. 2 shows a structure in which a gap spacer and a coil bobbin are integrally formed by providing a gap spacer for the coil.

Utility Model Registration No. 3054397

  However, in the configuration described in Patent Document 1, since the gap spacer is fixed to the coil bobbin, the core between the pair of magnetic core members is affected by the accumulated dimensional tolerances of the coil bobbin and the gap spacer. In some cases, the gap cannot be maintained at a predetermined interval, and the AL value fluctuates, which may cause problems such as failure to obtain the characteristics of the coil component as designed.

  The present invention has been made in view of the above, and a bobbin for a coil, a winding component, a coil component, a switching power supply device capable of providing a gap between cores of a magnetic core member with high accuracy and easy assembly work, And it aims at providing the manufacturing method of coil components.

  In order to achieve the above object, a coil bobbin according to the present invention includes a pair of magnetic core members, at least one of which has legs, and is sandwiched between the pair of magnetic core members in a state where the legs are inserted. A coil bobbin for electrically insulating the coil winding, the cylindrical portion provided along the axial direction around which the coil winding is wound on the inner peripheral side of the coil winding; A spacer portion provided in the cylindrical portion for providing a gap between the pair of magnetic core members, a support portion for connecting the inner wall of the cylindrical portion and the spacer portion, and supporting the spacer portion; And the support part is stretched or cut by pressing the spacer part with the leg part.

  According to said structure, since a support part is extended | stretched or cut | disconnected by the press of the spacer part by a leg part, in a position where the spacer part moved in the opening along the axial direction around which a coil winding winds, a pair A gap between the magnetic core members is provided. Thus, in the above-described coil bobbin, the spacer portion can be moved to a position different from the position supported by the coil bobbin, so the dimensional tolerances of the coil bobbin and the gap spacer do not accumulate, and the inter-core The size of the gap is adjusted with higher accuracy. Further, in the above-described coil bobbin, since the spacer portion is provided integrally, the assembly work becomes easier as compared with the case where a separate gap spacer is inserted between the pair of magnetic core members. .

  The winding component according to the present invention includes a coil winding that is sandwiched between a pair of magnetic core members, at least one of which has a leg portion, and the leg portion is inserted, the coil winding, and the pair And a coil bobbin for electrically insulating the magnetic core member.

  The coil component according to the present invention includes a pair of magnetic core members, at least one of which has legs, and a coil winding that is sandwiched between the pair of magnetic core members in a state where the legs are inserted. The coil bobbin according to claim 1, wherein the coil bobbin and the pair of magnetic core members are electrically insulated from each other.

And the manufacturing method of said coil components inserts the said leg part of the said magnetic body core member in the said cylindrical part of the said bobbin for coils, and extends or cuts the said support part by pressing the said spacer part. It is characterized by making it.

  According to the above-described winding component and coil component, the leg portion of the magnetic core member is inserted into the cylindrical portion of the coil bobbin, and the support portion is extended or cut by pressing the spacer portion. A gap between the cores is provided at a position where the spacer portion moves in the opening along the axial direction. For this reason, according to the winding component and the coil component described above, since the inter-core gap is provided at a position different from the position where the spacer portion is supported by the coil bobbin, the dimensional tolerances of the coil bobbin and the gap spacer are accumulated. Without this, the size of the gap between the cores is adjusted with higher accuracy.

  In addition, another configuration of the winding component according to the present invention includes a plurality of coil windings sandwiched between a pair of magnetic core members, at least one of which has a leg portion, and the leg portion is inserted, A plurality of coil bobbins for electrically insulating the plurality of coil windings and the pair of magnetic core members, wherein the plurality of coil windings are axially wound around the coil windings. Are arranged side by side so as to follow.

  In another configuration of the coil component according to the present invention, at least one of the pair of magnetic core members having leg portions and the pair of magnetic core members are sandwiched between the leg portions. A plurality of coil windings, and a plurality of coil bobbins according to claim 1 that electrically insulate the plurality of coil windings from the pair of magnetic core members. The coil windings are arranged side by side so as to be along the axial direction around which the coil windings are wound.

  And the manufacturing method of said coil components inserts the said leg part of the said magnetic body core member in the said cylindrical part of each of these coil bobbins, respectively, and presses the said spacer part, respectively, The said support part Is stretched or cut.

  As described above, in the winding component and the coil component arranged in parallel so that the axial direction along which the plurality of coil windings are wound, the leg portion of the magnetic core member is inserted into the cylindrical portion of the coil bobbin. Since the support portion is extended or cut by pressing the spacer portion, the gap between the cores corresponds to the plurality of coil bobbins at the position where the spacer portion moves in the opening along the axial direction. Each is provided. As described above, according to the winding component and the coil component described above, the gap between the cores is provided at a position different from the position where the spacer portion is supported by the coil bobbin. Without accumulating, the size of the gap between the cores is adjusted with higher accuracy. Further, in the above-described coil component, since the spacer portion is provided in an integrated manner, a separate gap spacer is inserted into the cylindrical portion of the plurality of coil bobbins provided for the plurality of coil windings. In comparison, the assembly work of the coil component is facilitated.

  In the winding component and the coil component, the coil bobbin and the coil winding can be integrally formed by insert molding.

  When the coil bobbin and the coil winding are integrally formed as described above, the work of winding the coil winding around the coil bobbin can be omitted, so that the assembly work of the coil parts is further facilitated. It can be. Then, when the spacer portion is pressed by the leg portion, the support portion is extended or cut, and the inter-core gap is provided at the position where the spacer portion has moved, so the inter-core gap is adjusted with high accuracy.

  Moreover, the switching power supply device according to the present invention includes the coil component described above. In this case, it is possible to obtain a switching power supply device in which the gap between the cores of the magnetic core member is provided with high accuracy and easy assembling work.

  According to the present invention, there is provided a coil bobbin, a winding component, a coil component, a switching power supply device, and a method for manufacturing a coil component, which can provide a gap between cores of a magnetic core member with high accuracy and an easy assembly operation. Provided.

It is a perspective view which shows the coil | winding components which concern on 1st Embodiment of this invention. It is a perspective view from the bottom face side of the winding component of FIG. (A) is a top view of the coil | winding component of FIG. 1, (b) is a bottom view of a coil | winding component. (A) is a figure which shows the end surface in the IVA-IVA line of the coil | winding component of Fig.3 (a), (b) is a figure which shows the end surface in the IVB-IVB line of the coil | winding component of Fig.3 (a). is there. It is a perspective view which shows the coil winding and connection member which comprise the coil | winding components of FIG. (A) is a top view of a coil winding, (b) is a bottom view of the coil winding. It is a side view of a coil winding. It is a disassembled perspective view of the coil component which concerns on 1st Embodiment. It is a figure which shows the end surface in the IX-IX line of the coil components shown in FIG. 1 is a circuit diagram of a switching power supply device according to a first embodiment. 1 is a perspective view of a switching power supply device according to a first embodiment. It is a figure explaining the coil components which concern on 2nd Embodiment. It is a figure explaining the bobbin for coils which concerns on 3rd Embodiment.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted.

(First embodiment)
First, with reference to FIGS. 1-7, the structure of the coil | winding components containing the bobbin for coils which concerns on 1st Embodiment is demonstrated. FIG. 1 is a perspective view showing a winding component including a coil bobbin according to the present embodiment. FIG. 2 is a perspective view from the bottom side of the winding component of FIG. 3A is a plan view of the winding component of FIG. 1, and FIG. 3B is a bottom view of the winding component of FIG. 4A is a view showing an end face of the winding component IVA-IVA line of FIG. 3A, and FIG. 4B is an IVB-IVB line of the winding component of FIG. 3A. (The connection member 3 is omitted with respect to the winding component 1 in FIG. 4B). FIG. 5 is a perspective view showing a coil winding and a connecting member constituting the winding component of FIG. FIG. 6A is a plan view of the coil winding, and FIG. 6B is a bottom view of the coil winding. FIG. 7 is a side view of the coil winding.

  A winding component 1 shown in FIG. 1 is used for an inductance element, a switching power supply device such as a converter and an inverter, a noise filter, and the like. The winding component 1 includes two coil windings 2 made of a conductor plate, a bobbin 40 provided on the inner peripheral side of the two coil windings, and a connecting member 3 that electrically connects the two coil windings 2. And comprising. That is, the winding component 1 includes two winding components 5 (5A, 5B) each including a coil winding 2 made of a conductor plate and a bobbin 40, and these are electrically connected by the connecting member 3. Connected to each other. The bobbin (coil bobbin) 40 is made of an electrically insulating insulating member, is provided on the inner peripheral side of the coil winding 2, and has a cylindrical portion 40 a around which the coil winding 2 is wound. A covering portion 40b covering the periphery, a spacer portion 61 provided in the openings 52 and 54 of the cylindrical portion 40a, and a support provided on the inner walls of the openings 52 and 54 to support the spacer portion 61 in the openings 52 and 54 It is comprised from the piece (support part) 63 (63a, 63b). The connecting member 3 connects the coil windings 2 included in the winding component 5 respectively. Hereinafter, the coil winding 2 constituting the winding component 1 will be described first, then the configuration 4 in which the two coil windings 2 are connected by the connecting member 3 will be described, and finally the bobbin 40 covered with an insulating member. The winding component 1 in which the coil winding 2 is integrated (that is, the two winding components 5 are connected by the connecting member 3) will be described.

  As shown in FIGS. 5 to 7, the coil winding 2 is a ring-shaped end and ring-shaped first and second coil members 10, 12 arranged in parallel with a predetermined interval. It is connected so as to be continuous in the direction.

  Ended ring-shaped first and second coil members 10 and 12 are so-called C-shaped, and have circular openings 14 and 16 in the center. Further, between one end and the other end of the first and second coil members 10 and 12 are slits 20 and 22 extending from the inner periphery to the outer periphery. The first coil member 10 and the second coil member 12 are coaxially overlapped so that the openings 14 and 16 communicate with each other. In addition, the 1st coil member 10 and the 2nd coil member 12 have overlapped in the state which shifted the position of the slit 20 and the slit 22 (that is, these do not communicate). Therefore, the other end portion of the first coil member 10 overlaps with one end portion of the second coil member 12. The shape of the first and second coil members 10 and 12 is not limited to the C-shaped end ring shape, and may be another shape such as an elliptical shape or a square shape.

  One end of the first coil member 10 is integrally provided with a first terminal portion 24 projecting outward with respect to the central axis of the opening 14, and the other end of the first coil member 10. The part is connected to one end of the second coil member 12 via a U-shaped connecting part 18. The other end of the second coil member 12 is integrally provided with a second terminal portion 26 that protrudes outward with respect to the central axis of the opening 16.

  In the coil winding 2 having such a configuration, the first terminal portion 24 is the starting end of the coil winding 2, and the second terminal portion 26 is the end of the coil winding 2. The electric power input to the first terminal portion 24 flows in the order of the first coil member 10, the connecting portion 18, and the second coil member 12, and is output from the second terminal portion 26.

  On the inner peripheral edge of the first coil member 10, a cut portion 30 cut outward is formed. Further, in the outer peripheral edge of the first coil member 10, the outer peripheral edge of the first coil member 10 is increased in the radial direction in a region where a line connecting the central axis of the opening 14 and the cut portion 30 is extended. As described above, a protrusion 34 bulging outward is provided.

  On the other hand, a cut portion 32 cut outward is formed on the inner peripheral edge of the second coil member 12. Further, in the outer peripheral edge of the second coil member 12, the outer peripheral edge of the second coil member 12 is increased in the radial direction in a region where a line connecting the central axis of the opening 16 and the notch 32 is extended. As described above, a protruding portion 36 bulging outward is provided.

  The notches 30 and 32 penetrate through the first and second coil members 10 and 12 in the thickness direction. When viewed from the central axis direction of the openings 14 and 16, the notches 30 and 32 have a predetermined width along the periphery of the openings 14 and 16, and have a predetermined depth in the radial direction of the openings 14 and 16. Have. Moreover, the notch part 30 provided in the 1st coil member 10 and the notch part 32 provided in the 2nd coil member 12 are mutually different positions when it sees from the center axis line direction of the openings 14 and 16. Is provided. Moreover, the protrusion part 34 provided in the 1st coil member 10 and the protrusion part 36 provided in the 2nd coil member 12 are predetermined along the outer periphery of the 1st and 2nd coil members 10 and 12, respectively. The outer peripheral edge protrudes outward by a predetermined width.

  Further, the protrusions 34 and 36 are provided on the outer peripheral edge obtained by extending a straight line connecting the central axes of the openings 14 and 16 and the cut portions 30 and 32, respectively. Thereby, the width (width of the conductor plate) of the first and second coil members 10 and 12 in the formation region of the cut portions 30 and 32 is ensured, and the first and second around the cut portions 30 and 32. This prevents the coil members 10 and 12 from becoming thinner and increasing the electrical resistance that causes heat generation and the like. As described above, in the present embodiment, the width of the first and second coil members 10 and 12 in the formation region of the notches 30 and 32 is ensured by providing the protruding portions 34 and 36, and the width of the conductor plate. And an increase in electrical resistance due to a decrease in the cross-sectional area of each of the coil members 10 and 12 determined by the thickness. The protrusions 34 and 36 are provided at different positions when viewed from the central axis direction of the openings 14 and 16.

  Further, the first and second coil members 10 and 12 include projecting portions 33 and 35 different from the projecting portions 34 and 36, respectively. The protrusion 33 has a position different from the above-described protrusion 34 on the outer periphery of the first coil member 10 (for example, as shown in FIG. 6A, the axis around which the coil winding 2 is wound is used as a reference). (Position at 90 degrees with respect to the connecting portion 18). Further, the protrusion 35 has a position different from the protrusion 36 described above on the outer periphery of the second coil member 12 (for example, as shown in FIG. 6B, the axis around which the coil winding 2 is wound). As a reference, it is provided at a position of −90 degrees with respect to the connecting portion 18. Thus, the 1st and 2nd coil members 10 and 12 may be provided with a plurality of projection parts.

  The coil winding 2 having the above configuration can be formed by punching a single substrate having high electrical conductivity. More specifically, from a substrate such as a copper plate or an aluminum plate, the first terminal portion 24, the first coil member 10 continuous to the first terminal portion 24, the second coil member 12, and the second The second terminal portion 26 that is continuous to the coil member 12 and the I-shaped connecting portion 18 that connects the first and second coil members 10 and 12 are obtained by punching. Then, the first coil member 10 and the second coil member 12 are overlapped with a predetermined gap by bending the connecting portion 18 in a U shape. Thereby, the coil winding 2 made of a conductor plate is completed. Note that the coil winding 2 is not limited to such a bending coil, and may be, for example, a coil member and a connection portion that are screwed together or may be welded. Moreover, you may fix with a rivet.

  In the winding component 1 according to the present embodiment, as shown in FIG. 5, the second terminal portions 26 of the two coil windings 2 (2A, 2B) arranged in parallel are connected via the connection member 3. Connected configuration 4 is used. The connection member 3 and the second terminal portions 26 of the two coil windings 2 are fixed by screws 38, respectively. Thereby, the current input to the first terminal portion 24 of the coil winding 2A flows in the order of the first coil member 10, the connecting portion 18, and the second coil member 12, and the second of the coil winding 2A. Is then input to the second terminal portion 26 of the coil winding 2 </ b> B via the connection member 3. And it flows in order of the 2nd coil member 12, the connection part 18, and the 1st coil member 10 of the coil winding 2B, and is output from the 1st terminal 24 of the coil winding 2B.

  Next, the winding component 1 in which an insulating member is integrally formed with the two coil windings 2 connected by the connection member 3 will be described.

  As shown in FIG. 1, the winding component 1 includes a bobbin 40 made of an insulating material so as to cover partial regions of the first and second coil members 10 and 12 of the two coil windings 2. Provided. Specifically, the bobbin 40 includes a cylindrical portion 40a that covers the inner peripheral edges of the first and second coil members, and the outermost of the first and second coil members 10 and 12 that face a magnetic core member described later. In order to provide a gap between the cores on the outer plate surface and a covering portion 40b extending so as to cover between the adjacent first and second coil members 10 and 12, and a pair of magnetic core members described later. It includes a spacer portion 61 provided in the openings 52 and 54 of the cylindrical portion 40a and a support piece 63 (63a and 63b) for supporting the spacer portion 61 in the openings 52 and 54. In the winding component 1 shown in the present embodiment, the outer peripheral edges of the first and second coil members 10 and 12 are also covered with the covering portion 40 b of the bobbin 40. As an insulating material used for the bobbin 40, for example, PBT (Poly Butylene Terephthalate) resin, PPS (Poly Phenylene Sulfide) resin, etc. are excellent in characteristics such as heat resistance, chemical resistance, flame resistance, and dimensional stability. Therefore, it is preferably used.

  The covering portion 40 b of the bobbin 40 covers the surfaces of the first and second coil members 10 and 12 except for the first terminal portion 24 and the second terminal portion 26 of the two coil windings 2. Further, openings 52 and 54 are formed in the cylindrical portion 40 a of the bobbin 40 along the axial direction of the coil winding 2. That is, the winding component 1 is hollow like the coil members 10 and 12. The openings 52 and 54 are provided so that legs of a magnetic core member described later can be inserted.

  In the openings 52 and 54 of the cylindrical portion 40a of the bobbin 40, as shown in FIGS. 3 and 4, etc., spacers are provided for providing a gap between a pair of magnetic core members described later. The part 61 and support pieces 63a and 63b that connect the inner wall of the tubular part 40a and the spacer part 61 and support the spacer part 61 in the openings 52 and 54, respectively, are provided.

  The spacer portion 61 is formed of a substantially disk-shaped flat plate, and the diameter thereof is smaller than the inner diameter of the tubular portion 40a of the bobbin 40 in the openings 52 and 54, but in the axial direction in which the openings 52 and 54 of the tubular portion 40a extend. It is preferable to have a size that substantially closes the cross section. The spacer 61 is provided with a notch 65 for the purpose of adjusting a magnetic flux by a magnetic core member, which will be described later, but this notch 65 may not be provided. Further, the shape of the spacer portion 61 may be changed to an ellipse, a triangle, a square, or the like. The spacer portion 61 according to the present embodiment is provided apart from the inner wall of the tubular portion 40a so that the substantially circular surface is perpendicular to the axial direction in which the openings 52 and 54 of the tubular portion 40a extend. The thickness of the spacer 61 is designed according to the gap between the cores of a pair of magnetic core members described later. The spacer portion 61 has a support piece so that the end surface thereof coincides with the end portions of the openings 52 and 54 of the tubular portion 40a in the axial direction in which the openings 52 and 54 extend, or is located inward of the end portions. It is supported by 63a, 63b.

  The support pieces 63a and 63b that connect the tubular portion 40a and the spacer portion 61 and support the spacer portion 61 in the openings 52 and 54 are at the same position as the spacer portion 61 in the axial direction in which the openings 52 and 54 extend. And it is provided so as to face each other through the center of the spacer portion 61. The support pieces 63a and 63b are formed in a thin columnar shape, and are easily cut when the spacer portion 61 is pressed in the axial direction in which the openings 52 and 54 extend. When at least a part of the support pieces 63a and 63b is cut by pressing the spacer portion 61, the spacer portion 61 can move in the openings 52 and 54. Further, when all of the support pieces 63a and 63b are cut, the spacer portion 61 is separated from the cylindrical portion 40a and can move within the openings 52 and 54.

  Further, as shown in FIGS. 2 and 3B, the winding component 1 includes convex portions 50 a and 50 b that are made of the same insulating material as that of the bobbin 40 and project to the outside on the bottom surface side. This is provided in order to perform positioning with a magnetic core portion described later. Further, the bobbin 40 is configured to fill a space between the first coil member 10 and the second coil member 12 as shown in FIGS. However, in the partial area of the surface of the protrusions 34 and 36 of the coil winding 2 and the second coil member 12, it corresponds to the notch 30 of the first coil member 10 along the central axis of the openings 14 and 16. In the first coil member 10 and in a part of the region corresponding to the notch 32 of the second coil member 12 along the central axis of the openings 14 and 16 in the first coil member 10, the coil winding 2 The bobbin 40 does not cover the surface, but the coil winding 2 is exposed to the outside. Hereinafter, the region where the coil winding 2 is exposed will be described.

  First, the protrusions 34 and 36 of the coil winding 2 are surfaces perpendicular to the central axis of the openings 14 and 16 (that is, the surfaces 34a, 34b, 36a, FIGS. 3A and 3B). 36b) is exposed to the outside. And the outer periphery of the protrusion parts 34 and 36 is covered with the resin parts 44 and 46 extended from the coating | coated part 40b, respectively. In this way, by exposing a part of the surface of the protrusions 34 and 36 to the outside, the exposed part is electrically connected to a heat dissipating member provided outside through, for example, a heat conductive member. Can be radiated from the coil winding 2 by being insulated and connected. Moreover, the outer periphery of the protrusions 34 and 36 is covered with the resin parts 44 and 46, respectively, so that the insulation properties when contacting with other devices arranged around the winding component 1 can be maintained. In addition, the outer periphery of the coil winding 2 is covered with the bobbin 40, and the outer periphery of the projecting portions 34 and 36 is also covered with the resin portions 44 and 46, so that the winding component 1 is formed in the bobbin as in this embodiment. In the case where two coil windings 2 integrated with 40 are arranged side by side, the insulation between the two coil windings 2 of the winding component 1 can be maintained.

  Furthermore, in the winding component 1, as described above, in the second coil member 12, a part of the region corresponding to the cut portion 30 of the first coil member 10 along the central axis of the openings 14 and 16, In the first coil member 10, a part of the region corresponding to the cut portion 32 of the second coil member 12 is exposed to the outside along the central axis of the openings 14 and 16. Specifically, as shown in FIGS. 1, 3, and 4, the cylindrical portion 40 a of the bobbin 40 having the same thickness as that of the other inner peripheral edge is provided to the cut portion 30. As a result, as shown in FIG. 4A, in the second coil member 12, the region corresponding to the cut portion 30 of the first coil member 10 along the central axis of the openings 14 and 16 is the bobbin 40. Compared with the notch 30 provided on the inner side, the inner peripheral edge projects inward. And the surface 43a which is a part of this protrusion area | region (area | region of the 2nd coil member 12 corresponding to the cutting part 30 of the 1st coil member 10), and the back surface 43b are exposed outside. As shown in FIG. 4A, the surface 43a exposed to the outside and the inner side (inner peripheral portion) of the back surface 43b are different from the other inner peripheral portions of the first and second coil members 10 and 12, respectively. Similarly, a cylindrical portion 40a of the bobbin 40 is provided. As a result, the bobbin 40 made of an insulating material is provided at the inner peripheral edges of the openings 52 and 54 of the winding component 1, and the gap between the magnetic core member inserted into the openings 52 and 54 and the coil winding 2 is set. Insulation can be maintained.

  In the first coil member 10, the region corresponding to the cut portion 32 of the second coil member 12 has the same shape along the central axis of the openings 14 and 16. That is, similarly to the region of the second coil member 12 corresponding to the cut portion 30 of the first coil member 10 described above, the cut portion 32 of the second coil member 12 as shown in FIG. The region of the first coil member 10 corresponding to the region corresponding to is configured to protrude inward of the inner peripheral edge as compared with the cut portion 32. And the surface 41a which is a part of this protrusion area | region, and its back surface 41b are exposed outside. In addition, as shown in FIG.4 (b), the surface 41a exposed outside and the inner side (inner peripheral part) of the back surface 41b are the other inner peripheral parts of the 1st and 2nd coil members 10 and 12. Similarly, the bobbin 40 is provided.

  Furthermore, in the winding component 1, the protrusions 33 and 35 provided on the first and second coil members 10 and 12 constituting the coil winding 2 are completely exposed to the outside (that is, the winding component 1 is exposed to the outside) (that is, The outer periphery of the protrusion is not covered by the bobbin 40). Like these protrusion parts 33 and 35, the outer periphery of the area exposed to the outside without being covered by the covering part 40b of the bobbin 40 is not necessarily covered by the insulating member.

  As described above, the areas exposed to the outside (the surfaces 41a, 34b, 36a, and 36b of the protrusions 33 and 35 and the protrusions 34 and 36, and the surface 41a that corresponds to the notches 30 and 32). , 41b, 43a, 43b), the heat of the coil winding 2 can be efficiently released to the outside as compared with the case where the region is covered with an insulating member.

  The winding component 1 described above is manufactured by, for example, the following method. First, the coil winding 2 in which the first coil member 10 and the second coil member 12 are connected by the connecting portion 18 is prepared. Next, the coil winding 2 is placed in a mold configured in the shape of the bobbin 40 to be used as an insert part, and the resin constituting the bobbin 40 is molded into the mold to be molded, and the first coil The winding component 5 in which the bobbin 40 is integrally formed on a part of the periphery of the member 10 and the second coil member 12 can be obtained. Next, the winding terminal 1 is obtained by fixing the second terminal portions 26 included in the coil winding 2 of the winding part 5 to the conductive connecting member 3 with the screw 38.

  The coil winding 2 may be deformed and a short circuit may occur due to the molding pressure at the time of molding the winding component 5 (that is, the pressure when the resin is injected into the mold). However, even if the coil winding 2 is deformed during molding, it is difficult to confirm whether a short circuit has occurred in the coil winding 2 after the integral molding. For this reason, at the time of molding of the winding component 1 of the present embodiment, the protrusions 34 and 36 provided on the first and second coil members 10 and 12 are used for the purpose of preventing deformation of the coil winding 2 due to molding pressure. In the second coil member 12, a part of a region corresponding to the cut portion 30 of the first coil member 10 along the central axis of the openings 14 and 16, and the openings 14 and 16 in the first coil member 10. A part of the region corresponding to the cut portion 32 of the second coil member 12 is mechanically fixed along the central axis of the second coil member 12 by a molding die. Thereby, generation | occurrence | production of the deformation | transformation of the coil winding 2 at the time of shaping | molding is suppressed. The region to be mechanically fixed is not covered with the resin and is exposed to the outside (that is, the region corresponding to the surfaces 34a, 34b, 36a, 36b of the protruding portions 34, 36 and the cut portions 30, 32). The surfaces 41a, 41b, 43a, 43b).

  Next, the coil component 70 will be described. In the coil component 70, the winding component 1 further includes a magnetic core member. That is, the pair of magnetic core members 8 and 9, the two coil windings 2 sandwiched between the leg portions 81 and 82 of the pair of magnetic core members 8 and 9, and the coil windings. Two coil bobbins 40 that electrically insulate the wire 2 from the pair of magnetic core members 8 and 9 are provided, and the two coil windings 2 are arranged in parallel so that the axial direction along which the coil windings are wound. It is set as the configuration. The coil component 70 functions as, for example, a choke coil of a switching power supply device described later. FIG. 8 is an exploded perspective view of the coil component 70 according to the present embodiment, and FIG. 9 is a diagram illustrating an end surface taken along line IX-IX of the coil component 70 illustrated in FIG.

  As shown in FIGS. 8 and 9, the coil component 70 in which the winding component 1 is preferably used includes a winding component 1 in which the surface of the coil winding 2 is covered with a bobbin 40, a pair of magnetic core members 8, 9. The magnetic core members 8 and 9 are arranged so as to sandwich the winding component 1 along the central axes of the openings 14 and 16 of the coil winding 2 of the winding component 1. In a state sandwiched between the pair of magnetic core members 8 and 9, the first and second terminal portions 24 and 26 and the connection member 3 are configured to protrude from the magnetic core members 8 and 9.

  The magnetic core members 8 and 9 are a so-called U-type core and I-type core obtained by compacting ferrite powder. More specifically, the magnetic core member 8 includes a flat plate-like base portion 80 having a longitudinal direction and two columnar leg portions 81 and 82 projecting from one main surface of the base portion 80. The leg portion 81 and the leg portion 82 are connected to the base portion 80 so as to be spatially separated. On the other hand, the magnetic core member 9 is composed of a flat base 90 having a longitudinal direction. The thickness of the leg portions 81 and 82 (the length in the vertical direction in FIG. 8) is designed according to the gap between the cores of the magnetic core member 8, but the thickness of the spacer portion 61 and the thickness of the leg portions 81 and 82. The sum is designed so as to be equal to the thickness of the winding component 1. The leg portions 81 and 82 of the magnetic core member 8 are inserted into the openings 52 and 54 provided in the cylindrical portion 40a of the bobbin 40 included in the winding component 1, respectively.

  Further, one main surface of the base portion 80 of the magnetic core member 8 contacts the bobbin 40 on one main surface (upper surface side shown in FIG. 1) of the winding component 1. Further, one main surface of the base portion 90 of the magnetic core member 9 contacts the bobbin 40 on the other main surface (the bottom surface shown in FIG. 2) of the winding component 1. At this time, the convex portions 50 a and 50 b provided on the bobbin 40 come into contact with the two side surfaces facing each other in the longitudinal direction of the base portion 90, so that the width direction between the magnetic core member 9 and the winding component 1 is increased. Generation of misalignment is suppressed. In addition, although the convex parts 50a and 50b provided in the bobbin 40 of the winding component 1 according to the present embodiment are formed in a rib shape along the outer periphery in the longitudinal direction of the base part 90, the shape of the convex part is The present invention is not limited to the above, and for example, it may be provided in several places including the short direction along the outer periphery of the base 90, or a recess is provided in the base 90, and a protrusion is formed at a position corresponding thereto. Accordingly, the position of the winding component 1 and the magnetic core member 9 can be set to determine the contact position.

  Here, the manufacturing method of the coil component 70 provided with the magnetic body core members 8 and 9 is demonstrated. Specifically, the magnetic core member is located at a position corresponding to the convex portions 50a and 50b on one main surface (bottom surface shown in FIG. 2) of the winding component 1 in which the coil winding 2 and the bobbin 40 are integrated. 9 and the leg portions 81 and 82 of the magnetic core member 8 are respectively inserted into the openings 52 and 54 provided in the tubular portion 40a of the bobbin 40 included in the winding component 1, and the end surfaces of the leg portions 81 and 82 are inserted. Are arranged so as to face the main surface of the magnetic core member 9, respectively. At this time, the leg portions 81 and 82 of the magnetic core member 8 press the spacer portion 61 provided in the openings 52 and 54. By this pressing, a part or all of the support pieces 63a and 63b that support the spacer portion 61 are cut, and the inside of the openings 52 and 54 can be moved. As a result, as shown in FIG. 9, the spacer 61 moves to a position where it abuts on the main surface of the base 90 of the magnetic core member 9, and the main surface of the base 90 and the legs 81 and 82 of the magnetic core member 9. It becomes the structure clamped by the end surface of this. The thickness of the spacer portion 61 is an inter-core gap between the magnetic core member 8 and the magnetic core member 9.

  In the coil component 70 according to the present embodiment, the openings 52 and 54 provided in the cylindrical portion 40a of the bobbin 40 included in the two winding components 5A and 5B that are included in the winding component 1 and arranged in parallel. On the other hand, the leg portions 81 and 82 are simultaneously inserted. Therefore, the spacer part 61 of the winding part 5A and the spacer part 61 of the winding part 5B are moved simultaneously by the pressing of the leg parts 81 and 82 and come into contact with the magnetic core member 9, respectively.

  Next, a switching power supply device in which the coil component 70 is preferably used will be described. FIG. 10 is a circuit diagram of the switching power supply apparatus 100. FIG. 11 is a perspective view of the switching power supply device 100. The switching power supply device 100 according to the present embodiment functions as a DC-DC converter. For example, a high-voltage DC input voltage Vin supplied from a high-voltage battery or the like that stores a voltage of about 100 V to 500 V is used as a low-voltage DC output. The voltage is converted to a voltage Vout and supplied to a low voltage battery or the like that stores a voltage of about 12 to 16V.

  As shown in FIG. 11, the switching power supply device 100 includes a base plate 101 on which an input smoothing capacitor (input filter) 130, a switching circuit 120, a main transformer 140, a rectifier circuit 150, A smoothing circuit 160 including a choke coil (coil component) 70 and a smoothing capacitor 162 is fixed.

  More specifically, the switching power supply device 100 includes a switching circuit 120 and an input smoothing capacitor 130 provided between the primary high voltage line 121 and the primary low voltage line 122, and the primary side and secondary side. A main transformer 140 having transformer coil portions 141 and 142, a rectifier circuit 150 connected to the secondary transformer coil portion 142, and a smoothing circuit 160 connected to the rectifier circuit 150 are provided.

  The switching circuit 120 has a full-bridge circuit configuration including switching elements S1 to S4. The switching circuit 120 converts a DC input voltage Vin applied between the input terminals T1 and T2 into an input AC voltage, for example, according to a drive signal supplied from a drive circuit (not shown).

  The input smoothing capacitor 130 smoothes the DC input voltage Vin input from the input terminals T1 and T2. The transformer 140 transforms the input AC voltage generated by the switching circuit 120 and outputs an output AC voltage. The turns ratio of the primary and secondary transformer coils 141 and 142 is appropriately set according to the transformation ratio. Here, the number of turns of the primary transformer coil part 141 is made larger than the number of turns of the secondary transformer coil part 142. The secondary transformer coil part 142 is a center tap type, and is led to the output terminal T3 via the connection part C and the output line LO.

  The rectifier circuit 150 is a single-layer full-wave rectifier type composed of rectifier diodes 151A and 151B. The cathodes of the rectifier diodes 151A and 151B are connected to the secondary transformer coil section 142, while the anode is connected to the ground line LG and led to the output terminal T4. As a result, the rectifier circuit 150 individually rectifies each half-short wave period of the output AC voltage from the transformer 140 to generate a DC voltage.

  The smoothing circuit 160 includes a choke coil 70 and an output smoothing capacitor 162. The choke coil 70 is inserted into the output line LO. The output smoothing capacitor 162 is connected between the choke coil 70 and the ground line LG in the output line LO. As a result, the smoothing circuit 160 smoothes the DC voltage rectified by the rectifying circuit 150 to generate the DC output voltage Vout, and supplies the DC output voltage Vout from the output terminals T3 and T4 to a low-voltage battery or the like.

  In the switching power supply device 100 configured as described above, the DC input voltage Vin supplied from the input terminals T <b> 1 and T <b> 2 is switched to generate an input AC voltage, which is supplied to the primary-side transformer coil unit 141 of the transformer 140. Is done. Then, the generated input AC voltage is transformed and output from the secondary transformer coil unit 142 as an output AC voltage. The output AC voltage is rectified by the rectifier circuit 150 and smoothed by the smoothing circuit 160, and is output as the DC output voltage Vout from the output terminals T3 and T4.

  As described above, in the winding component 1 according to the present embodiment and the coil component 70 in which the winding component 1 further includes the pair of magnetic core members 8 and 9, the leg portions 81 and 82 of the magnetic core member 8. The support pieces 63a and 63b are cut by the pressure on the spacer part 61 by the spacer part 61, and the leg parts 81 and 82 of the magnetic core member 8 are moved by the spacer part 61 moved in the openings 52 and 54 provided in the cylindrical part 40a. An inter-core gap is formed between the end surface and the main surface of the other magnetic core member 9 facing the end surface. Therefore, the size of the gap between the cores is adjusted with higher accuracy according to the shape of the pair of magnetic core members 8 and 9. Further, in the above-described bobbin 40, since the spacer portion 61 is integrally provided by the support pieces 63a and 63b, the bobbin 40 is assembled as compared with the case where a separate gap spacer is inserted between the pair of magnetic core members. Work becomes easy.

  Further, in the winding component 1 of the present embodiment, two coil windings 2 are arranged side by side along the axial direction around which the coil winding 2 is wound, and a bobbin 40 is provided on the inner peripheral side of each coil winding 2. Cylindrical portions 40a, spacer portions 61 are provided in the openings 52 and 54 of the respective cylindrical portions 40a, and the respective spacer portions 61 are pressed by the magnetic core members 81 and 82. That is, in the winding component 1, two winding components 5 (5A, 5B) are arranged side by side along the axial direction around which the coil winding 2 is wound. The leg portions 81 and 82 of the member 8 are inserted respectively. In this case, since the gaps between the cores in the openings 52 and 54 can be provided at one time, separate gap spacers are respectively inserted into the cylindrical portions of the coil bobbins of the plurality of winding parts to form the gaps between the cores. Compared with the case of providing, the assembly work of the coil component 70 becomes easy.

  In addition, when the bobbin 40 and the coil winding 2 of the winding component 1 according to the present embodiment are integrally formed, the operation of winding the coil winding 2 around the bobbin 40 can be omitted. The assembly work of the winding component 1 can be further facilitated.

  Moreover, by using the winding component 1 for the switching power supply device 100, the switching power supply device 100 using the winding component 1 in which the gap between the cores of the magnetic core member is provided by high-precision and easy assembly work is provided. Obtainable. Even when the winding component 1 is used for the main transformer 140, similarly, switching using the winding component 1 in which the gap between the cores of the magnetic core member is provided by high-precision and easy assembly work is performed. The power supply device 100 can be obtained.

(Second Embodiment)
Next, a coil component 70A according to a second embodiment of the present invention will be described with reference to FIG. FIG. 12 is a diagram illustrating a coil component 70A according to the second embodiment. The coil component 70A according to the present embodiment is different from the coil component 70 according to the first embodiment in that the support pieces 63a and 63b are formed as support portions 64 formed of a stretchable material. In FIG. 12, for easy understanding, the mounting position of the support portion (support portion piece) 64 is set to a position different from that of the winding component 1 according to the first embodiment.

  By forming the support portion 64 from a stretchable material, when the spacer portion 61 is pressed by the leg portions 81 and 82 of the magnetic core member 8, the support portion 64 extends in response to the pressing, The spacer portion 61 can move without being separated from the cylindrical portion 40a. Therefore, as shown in FIG. 12, the spacer portion 61 moves in the openings 52 and 54 while being connected to the spacer portion 61 and the tubular portion 40 a by the support portion 64, and the leg portion of the magnetic core member 8 is moved. 81 and 82 and the main surface of the magnetic core member 9. Examples of the stretchable material that is preferably used for forming the support portion 64 include elastic materials such as rubber.

  Thus, also in the coil component 70A according to the second embodiment, the leg portions 81 and 82 of the magnetic core member 8 are respectively formed in the openings 52 and 54 of the bobbin 40, similarly to the coil component 70 according to the first embodiment. By inserting and moving the spacer portion 61 in the openings 52 and 54 along the axial direction, the spacer portion 61 becomes the other magnetic member whose end surfaces face the end surfaces of the leg portions 81 and 82 of the magnetic core member 8. It is clamped by the surface of the body core member 9. As described above, in this coil component 70, the magnetic core member is moved in a state in which the support portion 64 is extended by the pressure by the leg portions 81 and 82 against the spacer portion 61 and moved to a position different from the position supported by the bobbin 40. Since the gap between the cores is provided by being sandwiched between 8 and 9, the size of the gap between the cores is adjusted with higher accuracy according to the shape of the magnetic core member.

(Third embodiment)
Next, the bobbin 200 which concerns on 3rd Embodiment of this invention is demonstrated using FIG. FIG. 13 is a diagram illustrating a bobbin 200 according to the third embodiment.

  In the first and second embodiments described above, the configuration in which the bobbin 40 including the spacer portion 61 is integrally formed with the coil winding 2 has been described. However, the coil bobbin does not need to be integrally formed with the coil winding 2, and the above-described effects can be achieved with the coil bobbin alone.

  That is, the bobbin (coil bobbin) 200 shown in FIG. 13 has a conductive coil winding wound around it, an opening 201 in the center, a spacer portion 61 provided in the opening 201, and a cylindrical portion 40a. The inner wall and the spacer portion 61 are connected to the spacer portion 61, and support pieces (support portions) 63a and 63b (63b are not shown) that support the spacer portion 61 in the opening 101, and project from the outer peripheral surface of the cylindrical portion 40a. And a protrusion 202 that can be interposed between the windings. When the spacer portion 61 is pressed in the axial direction around which the coil winding is wound by the leg portion of the magnetic core member, at least a part of the support pieces 63a and 63b is cut, whereby the spacer portion 61 can be moved by pressing the leg.

  As described above, even in the configuration of the bobbin 200 according to this embodiment in which the cylindrical portion 40a is provided with the spacer portion 61 and the support pieces 63a and 63b, the spacer portion 61 moves in the opening 202, and the bobbin 200 Therefore, the size of the gap between the cores is adjusted with higher accuracy according to the shape of the pair of magnetic core members. Moreover, since the spacer part 61 is integrally provided with respect to the bobbin 200 similarly to other embodiment, compared with the case where a separate gap spacer is inserted between a pair of magnetic core members. Assembly work is facilitated.

  In this embodiment, the stretchable support piece 64 shown in the second embodiment may be provided instead of the support pieces 63a and 63b that are provided in the bobbin 200 and can be cut by pressing against the spacer portion 61. Further, by winding the coil winding 2 around the bobbin 200, a winding component can be obtained. In addition, a coil component having a magnetic core member is formed by inserting the legs of a pair of magnetic core members each having a leg portion around the bobbin 200 while winding the coil winding 2. Can also be manufactured.

  As mentioned above, although embodiment of this invention was described, this invention is not limited to said embodiment, A various change can be made. For example, the shape of the spacer portion 61 is not limited to the shape shown in the above embodiment, and may be a shape different from the shape of the cross section perpendicular to the axial direction around which the coils of the openings 52 and 54 of the cylindrical portion 40b are wound. Good.

  Further, the attachment position in the direction along the central axis of the opening of the spacer portion 61 attached from the support pieces 63a and 63b in the cylindrical portion 40a does not have to be the center in the central axis direction as in the above embodiment. Can move up and down. Further, the number of support pieces 63a, 63 that support the spacer portion 61 can be changed as appropriate.

  Further, the shape of the pair of magnetic core members 8 and 9 is not limited to the so-called UI-type shape in which one magnetic core member 8 includes the leg portions 81 and 82 as shown in the above embodiment. For example, both of the magnetic core members 8 and 9 may have a so-called UU shape having leg portions. Also, a magnetic core member such as EE type or EI type can be used. In this case, the winding component according to the present embodiment is suitably used for the leg portion around which the coil winding is wound among the leg portions of the magnetic core member.

  Further, the number of coil members of the coil winding 2 is not particularly limited. When a plurality of coil members are connected as in the present embodiment, the protrusion provided on the coil member is connected at the time of connection (coil, for example, as in the difference in arrangement between the protrusion 34 and the protrusion 36. In the case of configuring the winding), it is preferable that they are provided at different positions in the axial direction of the coil winding. Further, as in the first and second embodiments, the two coil windings 2 included in the winding component 1 of the coil component 70 may not be connected by the connection member 3 or the like.

  The configuration of the switching power supply device is not limited to FIGS. That is, the bobbins 40 and 200 according to the above embodiment are also suitably used for an inverter, for example. In the switching power supply device 100, the winding component 1 is not limited to the choke coil 70, and is preferably used for the main transformer 140.

DESCRIPTION OF SYMBOLS 1,5 ... Winding components, 2 ... Coil winding, 3 ... Connection member, 8, 9 ... Magnetic core member, 10 ... 1st coil member, 12 ... 2nd coil member, 14, 16, 52, 54, 202 ... opening, 18 ... connecting part, 20, 22 ... slit, 30, 32 ... notched part, 34, 36 ... projecting part, 40, 200 ... bobbin, 61 ... spacer part, 63 ... connecting part, 70 ... Choke coil, 100 ... switching power supply device, 140 ... main transformer.

Claims (10)

A coil bobbin for electrically insulating a pair of magnetic core members having at least one leg and a coil winding sandwiched between the pair of magnetic core members in a state where the leg is inserted Because
A cylindrical portion provided along an axial direction around which the coil winding is wound on the inner peripheral side of the coil winding;
A spacer part provided in the cylindrical part for providing a gap between the pair of magnetic core members;
A support part for connecting the inner wall of the cylindrical part and the spacer part, and supporting the spacer part;
With
The coil bobbin, wherein the support portion is stretched or cut by pressing the spacer portion with the leg portion. A coil winding sandwiched between a pair of magnetic core members, at least one of which has legs, with the legs inserted;
A coil component comprising: the coil bobbin according to claim 1, wherein the coil bobbin and the pair of magnetic core members are electrically insulated from each other. A plurality of coil windings sandwiched in a state where the legs are inserted by a pair of magnetic core members, at least one of which has legs,
The coil bobbin according to claim 1, wherein the plurality of coil windings and the pair of magnetic core members are electrically insulated.
With
The winding component, wherein the plurality of coil windings are arranged side by side along an axial direction around which the coil windings are wound.   The winding component according to claim 2 or 3, wherein the coil bobbin and the coil winding are integrally formed by insert molding. A pair of magnetic core members having at least one leg portion;
A coil winding sandwiched between the pair of magnetic core members in a state where the legs are inserted;
The coil bobbin according to claim 1, wherein the coil winding and the pair of magnetic core members are electrically insulated.
A coil component comprising: A pair of magnetic core members having at least one leg portion;
A plurality of coil windings sandwiched between the pair of magnetic core members in a state where the legs are inserted;
The coil bobbin according to claim 1, wherein the plurality of coil windings and the pair of magnetic core members are electrically insulated.
With
The coil parts, wherein the plurality of coil windings are arranged side by side along an axial direction around which the coil windings are wound.   The winding component according to claim 5 or 6, wherein the coil bobbin and the coil winding are integrally formed by insert molding.   A switching power supply comprising the coil component according to any one of claims 5 to 7. It is a manufacturing method of the coil components according to claim 5,
The manufacturing method, wherein the leg portion of the magnetic core member is inserted into the cylindrical portion of the coil bobbin, and the support portion is stretched or cut by pressing the spacer portion. It is a manufacturing method of the coil components according to claim 6,
The leg portion of the magnetic core member is inserted into the cylindrical portion of the plurality of coil bobbins, and the support portion is stretched or cut by pressing the spacer portion. Method.

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