JP2015141902A - Impedance element, method of manufacturing the same, noise filter using the same, and method of manufacturing the same - Google Patents

Abstract

An impedance element having a high inductance value and capable of flowing a large current and a noise filter using the impedance element are manufactured. A rectangular parallelepiped magnetic body (3) having at least four even number of through holes (4) is formed. An inverted U-shaped conductor (5) is formed. Insert the tip of the conductor into the through hole. The conductors other than the two diagonals are electrically connected. Then, a spiral coil is formed inside the impedance element (2). By this manufacturing method, an impedance element having a high inductance value and allowing a large current to flow can be obtained. Further, when one or two impedance elements are housed inside the case (6) and the back cover (7), the noise filter (1) having the above-described performance can be manufactured. [Selection] Figure 1

Description

  The present invention relates to an impedance element suitable for removing common mode noise and differential mode noise in an input / output unit such as a switching power supply or a DC power supply of an electronic device, a manufacturing method thereof, a noise filter using the impedance element, and a manufacturing method thereof. .

  Conventionally, Patent Document 1 (Patent No. 2836039) is known as a noise filter or impedance element that is an element for removing a high-frequency voltage change included in an input current to an electronic device and supplying a stable electric signal to the electronic device. As shown in FIG. 14, this type of impedance element has a structure in which a conductor is wound around a magnetic material to form a choke coil.

  That is, the known impedance element 51 is provided with a through hole 53 in the magnetic body 52, and is spiraled by an internal conductive path 54 formed in the through hole 53 and a surface conductive path 55 formed on the surface of the magnetic body 53. A conductive path is formed. Due to this spiral conductive path, the known impedance element 51 exhibits an excellent effect that a high inductance can be obtained.

Japanese Patent No. 2836039

  However, since the known impedance element 51 has the internal conductive path 54, the surface conductive path 55 and the external electrode 56 formed by a method such as baking or plating, the resistance value of the entire impedance element is high as a result. As a result, there is a problem that a large current cannot flow. Accordingly, an object of the present invention is to provide an impedance element capable of flowing a large current, a method for manufacturing the same, a noise filter using the same, and a method for manufacturing the same.

  In order to solve the above problems, a magnetic body forming step for forming a rectangular parallelepiped magnetic body having at least four even number of through holes, a conductor forming step for forming an inverted U-shaped conductor, and the through holes A method of manufacturing an impedance element is adopted, which includes a conductor insertion step of inserting a conductor tip into the conductor and a conductor connection step of electrically connecting the tip of the conductor to form one spiral internal coil. .

  The impedance element can increase the amount of current that can flow through the impedance element and increase the inductance value by the above manufacturing method.

  In the impedance element manufacturing method according to the present invention, the connection is an electrical connection performed by bending the ends of the conductors and bending the ends of the conductors. By this method, the conductor has a structure for sandwiching the magnetic body, and the inductance value of the impedance element can be increased.

  In the impedance element manufacturing method according to the present invention, the connection is an electrical connection performed by inserting the leading end of the conductor into a connecting conductor having holes at both ends and connecting the leading end of the conductor and the connecting conductor. By this method, the conductor and the connection conductor can sandwich the magnetic body, and the inductance value of the impedance element can be increased.

  In the impedance element manufacturing method according to the present invention, the connection is performed by inserting the tip of the conductor into a connection board having a conductor connection circuit and a hole, and performing the connection between the tip of the conductor and the conductor connection circuit. It is a connection. By this method, the inductance value of the impedance element can be increased, the conductor and the insulative substrate can sandwich the magnetic material, and the unevenness of the impedance element can be reduced. To do.

  In the impedance element manufacturing method according to the present invention, the conductor is a conductor having a retaining portion larger than the diameter of the through hole in a part thereof. With this structure, the conductor is fixed to the through hole.

  In order to solve the above problems, a magnetic body forming step for forming a rectangular parallelepiped magnetic body having at least four even number of through holes, a conductor forming step for forming an inverted U-shaped conductor, An impedance element forming step comprising: a conductor inserting step for inserting the tip of the conductor into the through hole; and a conductor connecting step for electrically connecting to the tip of the conductor to form one spiral internal coil; A method of manufacturing a noise filter having a casing step for accommodating one or two impedance elements in a case and a back cover is adopted.

  The noise filter can increase the amount of current that can flow through the noise filter and increase the inductance value by the above manufacturing method. Furthermore, the noise filter is mounted on a substrate on which the noise filter is mounted by a general mounting apparatus.

  In the noise filter manufacturing method according to the present invention, the noise filter manufacturing method further includes a step of providing a nonmagnetic layer between the two impedance elements. By this method, in the differential mode, the magnetic flux between the two impedance elements is prevented from being canceled.

  In the noise filter manufacturing method according to the present invention, the connection is an electrical connection performed by bending the ends of the conductors and bending the ends of the conductors. By this method, the conductor has a structure for sandwiching the magnetic body, and the inductance value of the impedance element can be increased.

  In the noise filter manufacturing method according to the present invention, the connection is an electrical connection performed by inserting the leading end of the conductor into a connecting conductor having holes at both ends, and the leading end of the conductor and the connecting conductor. By this method, the conductor and the connection conductor can sandwich the magnetic body, and the inductance value of the impedance element can be increased.

  In the noise filter manufacturing method according to the present invention, in the impedance element manufacturing method according to the present invention, the connection is performed by inserting a tip of the conductor into a connection board having a circuit for conductor connection and a hole, This is an electrical connection performed with a circuit for conductor connection. By this method, the inductance value of the impedance element can be increased, the conductor and the insulative substrate can sandwich the magnetic material, and the unevenness of the impedance element can be reduced. To do.

  In the noise filter manufacturing method according to the present invention, the conductor is a conductor having a retaining portion larger than the diameter of the through hole in a part thereof. With this structure, the conductor is fixed to the through hole. By this method, the conductor is fixed to the through hole.

  An impedance element according to the present invention includes a rectangular parallelepiped magnetic body having at least four even number of through holes, and an inverted U-shaped conductor inserted through the through hole, and a tip portion of the conductor This is an impedance element having one spiral internal coil that is electrically connected. As a result, the impedance element can obtain a high inductance value and can increase the amount of current that can be passed through the impedance element.

  An impedance element according to the present invention includes a rectangular parallelepiped magnetic body having at least four even number of through holes, and an inverted U-shaped conductor inserted through the through hole. It is an impedance element formed by making one spiral internal coil connected to each other and exposing the tip of the spiral internal coil to the outside. As a result, the impedance element can obtain a high inductance value, can increase the amount of current that can be passed through the impedance element, and is connected to the substrate by the tip of the spiral internal coil.

  A noise filter according to the present invention includes a rectangular parallelepiped magnetic body having at least four even number of through holes, and an inverted U-shaped conductor inserted through the through hole, and the tip of the conductor is The noise filter includes an impedance element having one spiral internal coil that is electrically connected, and a pair of cases and back covers that contain one or two impedance elements. As a result, the noise filter can increase the amount of current that can flow through the noise filter, and can obtain a high inductance value. Moreover, it mounts on the board | substrate which mounts a noise filter with a general mounting apparatus.

  A noise filter according to the present invention includes a rectangular parallelepiped magnetic body having at least four even number of through holes, and an inverted U-shaped conductor inserted through the through hole, and the tip of the conductor is An impedance element having one spiral internal coil formed by electrical connection, and a pair of cases and back covers enclosing one or two impedance elements, and the tip of the spiral internal coil It is a noise filter exposed to the outside of the back cover. Accordingly, the noise filter has effects such as obtaining a high inductance value, increasing the amount of current that can be passed through the noise filter, and being connected to the substrate by the tip of the spiral internal coil. Moreover, it mounts on the board | substrate which mounts a noise filter with a general mounting apparatus.

  The present invention exhibits an excellent effect that the amount of current flowing through the noise filter can be increased by employing the above-described means. In addition, the present invention exhibits an excellent effect that a noise filter having high noise removal performance can be manufactured in both the common mode and the differential mode by employing the above-described means.

It is a perspective view of the noise filter of the present invention. It is a perspective view of the magnetic body used for the impedance element of the present invention. It is a front view of the conductor used for the impedance element of the present invention. It is the elements on larger scale of the A section of the conductor used for the impedance element of this invention. It is the elements on larger scale of the 1st Example of the A section of the conductor used for the impedance element of this invention. It is the elements on larger scale of the 2nd Example of the A section of the conductor used for the impedance element of this invention. It is the elements on larger scale of the 3rd Example of the A section of the conductor used for the impedance element of this invention. It is a perspective view which shows the conductor insertion step in the manufacturing method of the impedance element of this invention. It is a perspective view which reverses and shows up and down of the conductor insertion step in the manufacturing method of the impedance element of the present invention. It is a perspective view which shows the conductor connection step in the manufacturing method of the impedance element of this invention. It is a perspective view which shows the casing step in the manufacturing method of the impedance element of this invention. It is sectional drawing which shows the connection state of the noise filter of this invention, and a board | substrate. It is a disassembled perspective view of the noise filter which uses two impedance elements of this invention. It is a perspective view which shows the Example using the metal piece for a connection of the conductor connection step of the impedance element of this invention. It is a perspective view which shows the Example using the connection board | substrate of the conductor connection step of the impedance element of this invention. It is a perspective view which shows the Example in the case of providing six through-holes in the magnetic body of the impedance element of this invention. It is a perspective view which shows the conventional impedance element.

  Next, a preferred embodiment of the present invention will be described. First, a method for manufacturing the noise filter 1 according to the present invention shown in FIG. 1 will be described. The manufacturing method includes a magnetic body forming step, a conductor deformation step for deforming a separately prepared conductor from a straight shape to an inverted U shape, and a retaining step for providing a retaining portion on the conductor (the conductor deformation step and the retaining step). Together with the processing step, it is referred to as a “conductor forming step”), and an inverted U-shaped conductor (hereinafter referred to as a “processed conductor”) that has been prevented from being detached is inserted into a through-hole provided in the obtained magnetic body. It comprises a conductor insertion step, a conductor connection step for electrically connecting the tip portions of the conductors, and a package step for attaching the case and the back cover. Hereinafter, each step will be described sequentially.

  (Magnetic body forming step) As the magnetic body 3, as shown in FIG. 2, the magnetic body 3 is formed of a single block-like magnetic body, and four through holes 4 are vertically formed from the upper surface 3a toward the bottom surface 3b. In addition, a magnetic body is prepared in which the through holes are arranged in two rows and two rows when viewed from the top surface 3a or the bottom surface 3b. The material of the magnetic body 3 is preferably Ni—Zn ferrite.

  (Conductor formation step: Conductor deformation step) As shown in FIG. 3, the separately prepared linear conductor 5 is arranged such that the top portion 5e is perpendicular to the conductor tip portions 5a (5c) and 5b (5d) side. The reverse U-shaped conductor 5f is obtained by bending and deforming into an inverted U-shape by pressing.

  (Conductor forming step: retaining process step) Between the tip portions 5a, 5b, 5c, 5d and the top portion 5e of the inverted U-shaped conductor 5f obtained in the conductor deformation step, by pressing, A retaining portion 5g having a shape shown in FIG. 4A is provided to obtain a processed conductor 5h. In addition to the shape shown in FIG. 4A, the shape of the retaining portion 5g can be selected from the shapes shown in FIGS. 4B, 4C, and 4D. The width or diameter of the retaining portion 5g is set to be slightly larger than the diameter of the through hole 4. The retaining portion 5g is not displayed in the drawing unless particularly emphasized.

  The conductor 5 uses one metal selected from Cu, Sn, and Zn, or an alloy thereof. The cross-sectional shape of the conductor 5 is preferably circular except for the retaining portion 5g, but may be rectangular. By using the metal, the conductor 5 has such effects as lowering the resistance value to suppress attenuation of electrical signals other than noise, preventing oxidation of the surface, increasing rigidity and making it difficult to break. can get.

  (Conductor Insertion Step) As shown in FIG. 5, among the four through holes 4 of the magnetic body 3, the two adjacent through holes 4a and 4b are inserted into the tip 5a of the processed conductor 5h from the upper surface 3a side. 5b is inserted. Similarly, the tip portions 5c and 5d of the processed conductor 5h are inserted into the remaining two through holes 4c and 4d from the upper surface 3a side. Therefore, a part of the processed conductor 5h is held inside the through hole 4, and the four tip portions 5a, 5b, 5c, and 5d are exposed.

  (Conductor Connection Step) As shown in FIG. 6, the magnetic body 3 into which the processed conductor 5h is inserted is placed on a table (not shown) so that the lower surface 3b is on top, and the tip portions 5a, 5b, 5c, Of the 5d, the two tip portions 5b and 5c are bent inward as shown in FIG. Thereafter, the tip portions 5b and 5c are electrically connected by a method such as soldering or caulking. By this step, the impedance element 2 is completed. That is, it is composed of a rectangular parallelepiped magnetic body 3 having four through-holes 4 and two inverted U-shaped conductors 5 inserted through the through-holes 4, and tip portions 5 b and 5 c of the conductor 5. The impedance element 2 having one spiral internal coil formed by electrically connecting the two is completed.

  (Packaging Step) As shown in FIG. 8, a rectangular parallelepiped resin case 6 having an opening 6a is prepared, placed on a table (not shown) with the opening 6a facing upward, and the impedance element 2 is The magnetic body 3 is housed in the case 6 so that the lower surface 3b of the magnetic body 3 faces up. Further, the back cover 7 having two through holes 9 is installed in the opening 6 a so that the tip portions 5 a and 5 d penetrate the through hole 9, and fixed by the locking projections 8. By the above method, the noise filter 1 having the shape and structure shown in FIG. 1 is completed again. That is, it is composed of a rectangular parallelepiped magnetic body 3 having four through-holes 4 and two inverted U-shaped conductors 5 inserted through the through-holes 4, and tip portions 5 b and 5 c of the conductor 5. As a result, a noise filter 1 including an impedance element 2 having one spiral internal coil and a pair of cases 6 and a back cover 7 that encloses one impedance element 2 is completed. Thereby, the upper surface 3a side of the magnetic body 3 is flattened by the case 6, and the noise filter 1 is mounted on a substrate on which the noise filter is mounted by a general mounting apparatus.

  As shown in FIG. 7 again, the conductor 5 forms a spiral internal coil by winding the inside and the surface of the magnetic body 3. With this structure, the impedance element 2 and the noise filter 1 including the impedance element 2 can obtain a high inductance value, and thus can exhibit high noise removal performance.

  As shown in FIG. 9, the tip portions 5a and 5d are exposed to the outside and serve as terminals for external connection. With this structure, there is a gap between the substrate 26 on which the noise filter 1 is installed and the magnetic body 3, so that the conductor 5 relaxes the stress received by the magnetic body 3 when the substrate 26 is deformed, and the magnetic body 3. Is less likely to break.

  Further, with this structure, the substrate 26 and the conductor 5 are electrically connected. When the cross-sectional area of the conductor 5 is larger than the cross-sectional area of the external electrode 56 of the conventional impedance element 51 shown in FIG. 14 again, the electrical resistance from the substrate to the magnetic body 3 decreases, and the impedance element 2 has a large current. It becomes possible to flow.

  As shown in FIGS. 4 (a), 4 (b), 4 (c), and 4 (d) again, since the conductor 5 has a retaining portion 5g, the conductor 5 is fixed to the magnetic body 3. It is possible to suppress vibration in the through hole 4.

  Here, in the second embodiment of the present invention, as shown in FIG. 10, two impedance elements 2 are accommodated inside the case 6 and the back cover 7 and between the impedance elements 2. The magnetic layer 28 is present. With this structure, it is possible to prevent the two impedance elements 2 from canceling out the magnetic fluxes in the differential mode, and to exhibit high noise removal performance.

  Here, another embodiment of the present invention will be described. (1) For example, in the impedance element manufacturing method, since the magnetic body forming step and the conductor forming step are independent, the conductor forming step can be performed first, and then the magnetic body forming step can be performed.

  (2) In the conductor forming step, it is also possible to first perform a retaining step and then perform a conductor deformation step.

  (3) The processed conductor 5h is connected not only by bending the processed conductor 5h, but also by connecting the connecting metal piece 29 made of the same material as the conductor 5 and having holes 30 at both ends as shown in FIG. A method of electrically connecting after bridging between the portions 5b and 5c, a connection board 32 having a conductor connecting circuit 31 and a hole 33 as shown in FIG. For example, a method of placing the conductor connecting circuit and the conductor 5 electrically on the bottom surface 3b of the magnetic body 3 so as to pass through 5c and 5d can be employed.

  (4) Although the winding direction of the spiral internal coil formed by the connected conductor is not shown, right-handed or left-handed can be selected as necessary.

  (5) The number of through-holes and inverted U-shaped conductors provided in the magnetic body is not limited to two sets if the state of passing one conductor through two through-holes is expressed as one set. In order to obtain a simple inductance value, it is possible to increase the number of sets to three or more as shown in FIG.

  The details of the present invention have been described above with reference to the examples. However, the present invention is only an embodiment of the present invention, and is based on the technical idea of the present invention without significantly impairing the effects of the invention. It is possible to carry out by changing a part of the embodiment.

  By using the present invention, it is possible to provide an impedance element and a noise filter that can be widely used in the field of electronic devices that require noise removal simply and efficiently.

1: Noise filter 2: Impedance element 3: Magnetic body 3a: Upper surface 3b: Bottom surface 4, 4a, 4b, 4c, 4d: Through hole 5: Conductor 5a, 5b, 5c, 5d: Tip portion 5e: Top portion 5f: Reverse U Character-shaped conductor 5g: retaining part 5h: processed conductor 6: case 6a: opening 7: back cover 8: latching part 9: through hole 26: substrate 27: solder 28: non-magnetic layer 29: for connection Metal piece 30: Hole 31: Conductor connection circuit 32: Connection board 33: Hole 51: Impedance element 52: Magnetic body 53: Through hole 54: Internal conductive path 55: Surface conductive path 56: External electrode

Claims (15)

  A magnetic body forming step for forming a rectangular parallelepiped magnetic body having at least four even number of through holes, a conductor forming step for forming an inverted U-shaped conductor, and inserting the tip of the conductor into the through hole A method for manufacturing an impedance element, comprising: a conductor insertion step; and a conductor connection step in which one end of the conductor is electrically connected to form one spiral internal coil.   The method of manufacturing an impedance element according to claim 1, wherein the connection is an electrical connection performed by bending the ends of the conductors and connecting the bent ends of the conductors.   2. The method of manufacturing an impedance element according to claim 1, wherein the connection is an electrical connection in which a leading end of the conductor is inserted into a connecting conductor having holes at both ends, and the leading end of the conductor and the connecting conductor are used.   2. The impedance according to claim 1, wherein the connection is an electrical connection performed by inserting a tip of the conductor into a connection board having a conductor connection circuit and a hole, and the tip of the conductor and the conductor connection circuit. Device manufacturing method.   5. The method of manufacturing an impedance element according to claim 1, wherein the conductor is a conductor having a retaining portion larger than a diameter of the through hole in a part of the conductor.   A magnetic body forming step for forming a rectangular parallelepiped magnetic body having at least four even number of through holes, a conductor forming step for forming an inverted U-shaped conductor, and inserting the tip of the conductor into the through hole An impedance element forming step comprising a conductor inserting step and a conductor connecting step of forming one spiral internal coil by electrically connecting to the tip of the conductor, and one or two impedance elements are A method for manufacturing a noise filter, comprising: a pair of cases and a casing step that is housed inside the case back.   The method for manufacturing a noise filter according to claim 6, further comprising a step of providing a non-magnetic layer between the two impedance elements.   The method for manufacturing a noise filter according to claim 6, wherein the connection is an electrical connection in which the ends of the conductors are bent and the ends of the bent conductors are connected to each other.   The method for manufacturing a noise filter according to claim 6, wherein the connection is performed by inserting the leading end of the conductor into a connecting conductor having holes at both ends and connecting the leading end of the conductor and the connecting conductor.   2. The noise according to claim 1, wherein the connection is an electrical connection performed by inserting a tip of the conductor into a connection board having a conductor connection circuit and a hole, and the tip of the conductor and the conductor connection circuit. A method for manufacturing a filter.   The method of manufacturing a noise filter according to any one of claims 6 to 10, wherein the conductor is a conductor having a retaining portion larger than a diameter of the through hole in a part of the conductor.   A rectangular parallelepiped magnetic body having at least four even number of through-holes and an inverted U-shaped conductor inserted through the through-hole, and electrically connected at the tip of the conductor 1 An impedance element having a spiral internal coil.   One consisting of a rectangular parallelepiped magnetic body having at least four even number of through-holes and an inverted U-shaped conductor inserted through the through-hole, and electrically connecting the leading ends of the conductors An impedance element formed by exposing the tip of the spiral internal coil to the outside.   A rectangular parallelepiped magnetic body having at least four even number of through-holes and an inverted U-shaped conductor inserted through the through-hole, and electrically connected at the tip of the conductor 1 A noise filter comprising an impedance element having a spiral internal coil, a pair of cases enclosing one or two impedance elements, and a back cover. A rectangular parallelepiped magnetic body having at least four even number of through-holes and an inverted U-shaped conductor inserted through the through-hole, and electrically connected at the tip of the conductor 1 It comprises an impedance element having a spiral internal coil, a pair of cases enclosing one or two impedance elements and a back cover, and the tip of the spiral internal coil is exposed to the outside of the back cover. Noise filter.

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