JPH0562837A - Inductor - Google Patents

Abstract

PURPOSE:To provide an inductor wherein its winding part having a good characteristic can be formed, the uniformity of its quality can be enhanced, its production cost can be reduced and its productivity can be enhanced in the same manner as in a case wherein a winding operation has been executed by using an automatic winding machine. CONSTITUTION:A plurality of short insulating conductors 2 which have been arranged parallel to each other are arranged respectively on the outer circumferential face of a toroidal core 1 composed of a ferromagnetic substance along its height direction. Both end parts of each insulating conductor 2 are connected electrically to both end parts of its adjacent insulating conductor 2. Thereby, a coil-shaped continuity passage is formed around the core 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductor formed by winding a toroidal core.

[0002]

2. Description of the Related Art Conventionally, for the purpose of, for example, reducing noise in electronic equipment, an inductance element formed by winding a predetermined number of turns on a toroidal core formed of a toroidal ferromagnetic material such as ferrite. (Inductor)
Is built into the circuit.

The formation of the winding portion (winding of the winding) in such an inductor is performed by the inner diameter of the core (the diameter of the air-core portion).
When the winding diameter is remarkably smaller than that of, the automatic winding machine can efficiently perform the winding. However, in recent years, the winding diameter has become thicker in order to cope with the higher power consumption of equipment, which causes the ring of the winding machine to be an obstacle and automatically winds the toroidal core. It is not possible to do this, and the current situation is that the work is done manually.

[0004]

As described above, when the winding portion is formed on the toroidal core by hand winding,
Winding must be done while applying tension to the winding so that the winding sticks to the outer peripheral surface of the core.If the diameter is particularly large or it is necessary to wind several wires in a bundle, winding failure However, there is a problem in that such problems are likely to occur.

Further, the work by manual winding has extremely low work efficiency and poor productivity, resulting in a high manufacturing cost per piece, which hinders reduction of manufacturing cost. Further, in the manual winding, it is difficult to wind under the completely same condition even if the number of turns is the same, so that the shape and the characteristics are different for each worker, and it is difficult to improve the quality.

As in the case where the winding is performed by the automatic winding machine, the present invention forms a winding portion having good characteristics, equalizes and improves quality, and reduces manufacturing cost and productivity. It is an object of the present invention to provide an inductor that can improve the.

[0007]

The inductor of the present invention comprises:
A plurality of short insulated conductors arranged in parallel to each other are arranged along the height direction on the outer peripheral surface of a toroidal core made of a ferromagnetic material, and both ends of the insulated conductor are adjacent to each other. The conductor is electrically connected to both ends of the conductor, and a coil-shaped conduction path is formed around the core.

[0008]

In the inductor of the present invention, a plurality of short insulated conductors are provided along the height direction on the outer peripheral surface of the toroidal core, and the upper and lower ends of each insulated conductor are adjacent to each other. Are electrically connected to the corresponding ends of the. The insulated conductors thus connected in sequence form a coil-shaped conduction path around the toroidal core, and a desired inductance is obtained. In the present invention, some of the ends of the insulated conductor are left without making electrical connection with the adjacent insulated conductor, and these non-connected ends are electrodes themselves, or Other electrode parts are connected and used as electrodes.

[0009]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a perspective view showing an embodiment of the inductor of the present invention. In FIG. 1, reference numeral 1 denotes a toroidal core formed by molding a magnetic powder such as ferrite powder or punching an amorphous magnetic alloy ribbon and then stacking or winding it. The toroidal core 1 may be subjected to insulation coating or fitting to a case, if necessary.

The air core portion 1a of the toroidal core 1 has a plurality of short conductors 2 (eg
An insulated electric wire, which is commonly called an enamel wire, is inserted in parallel with the height (h) direction, and both ends thereof are bent outward so as to follow the outer peripheral surface of the toroidal core 1.

The insulated conductor 2 molded in this way
The conductors are exposed at both ends of each of the insulated conductors 2.
And the upper end of the insulated conductor 2 adjacent to the right side, and the lower end corresponds to the upper end of the insulated conductor 2 adjacent to the left side. Thus, a coil-shaped conduction path is formed as a whole.

Further, an insulating layer is formed on the outside of the conductor connecting portion 3 by applying an insulating treatment. In addition, the insulated conductor 2 is not connected to the adjacent end.
The end portions of are the first end 4 and the end 5 of the conduction path, and are used as electrodes either as they are or by connecting other electrode parts.

The inductor having such a structure can be manufactured, for example, by the following method.

That is, first, as shown in FIG. 2, a plurality of short insulated conductors 2 whose outer peripheral surfaces are insulated are bundled and inserted into the air-core portion 1a of the toroidal core 1.

Next, as shown in FIG. 3, a conical molding jig 6 is pressed against the upper and lower sides of the bundle of insulated conductors 2 inserted through the air-core portion, respectively. At the same time as bending outward along the conical surface of the molding jig 6, the gap between the insulated conductors 2 is radially expanded. At this time, when the main surface of the molding jig 6 is a conical surface, the intervals between the insulated conductors 2 may not spread evenly. Therefore, the slits 7 serving as guides for maintaining the intervals are provided on the conical surface at equal intervals. It is desirable that the conductors 2 be evenly spaced.

In this way, after the space between the adjacent insulated conductors 2 is widened in the upper and lower portions of the insulated conductors 2, as shown in FIG. Press down and bend outward along the end surface of the toroidal core 2.

Next, as shown in FIG. 5, a circular lid-shaped molding jig 9 is vertically fitted on the outside of the side peripheral surface of the toroidal core 1 from above and below, and the end surface of the toroidal core 1 is exposed to the outside. The upper and lower portions of the protruding insulated conductor 2 are molded along the side circumferential surface of the toroidal core 1, and both ends thereof are abutted with the ends of the adjacent insulated conductors 2, respectively. At this time, if both ends of the insulated conductor 2 are insulated, the insulation at the ends is peeled off so that the conductors are exposed at least at the contact portions.

Then, as shown in FIG. 6, the conductor abutting portion 10 is sandwiched by electrodes 11 for spot welding, a current is applied to perform welding, and then, for example, an insulating varnish is applied and baked on the outside of the welded portion. Then, an insulating layer is formed.

In this way, a state in which the insulated conductor 2 is wound N times around the toroidal core 1 is formed, and an inductor having excellent characteristics can be obtained.

In the above embodiment, the insulated conductors 2 are arranged in a single layer (a single layer) around the toroidal core 1, but they may be arranged in a multiple layer (multilayer). In such a case, after inserting the insulated conductors 2 bundled so as to form a multilayer into the air-core portion of the toroidal core 1,
It is desirable to perform molding and connection one by one in order from the insulated conductors 2 arranged on the outside. Also, by inserting the insulated conductors 2 one by one in order and molding them, it is possible to obtain an inductor wound in multiple layers.

Further, for the connection between the insulated conductors 2, in addition to electric welding such as spot welding, a welding method using a laser beam, a gas burner or the like can be adopted, and any electrical connection can be obtained. It is also possible to use various methods such as pressure bonding, adhesion, and insertion.

Furthermore, in the above embodiments, an example in which an enameled wire is used as the insulated conductor 2 is shown, but the present invention is not limited to this, and any insulated conductor having an insulating layer coated on the conductor may be used. Anything can be used.

That is, as shown in FIG. 7, even if a flat conductor 12 is cut into a strip shape and an insulating layer 13 is formed on the outer peripheral surface except the upper and lower end portions as an insulated conductor, Similar effects can be achieved. These insulated conductors are provided in the central portion 14 that contacts the inner peripheral surface of the toroidal core.
It is desirable that they be integrally joined with an insulating resin or the like and then be inserted into the air-core portion of the toroidal core in a state of being further wound into a tubular shape.

Next, another embodiment of the present invention will be described.

In this embodiment, as shown in FIGS. 8 and 9, the toroidal core 1 is fitted in a case made of a conductive material such as copper and having a housing portion 15 and a lid portion 16. It is enclosed. Here, grinding or a burner,
Radial slits are provided at equal intervals by laser light or the like. An insulating resin 17 is embedded in the slit portion, and a plurality of conductor portions 18 are arranged at a predetermined interval and fixed integrally with each other through the insulating resin 17.

When the toroidal core 1 is made of a conductive material, the portions of the housing portion 15 and the lid portion 16 that contact the core are insulated so that a rare short circuit does not occur in the conductor portion 18 of the case. Has been applied. Further, the contact portion 19 of the conductor portion 18 of the housing portion 15 and the lid portion 16 is connected by electric welding, welding of laser light, gas burner, or the like, or by a method such as crimping, bonding, or inserting. Further, a part of the conductor portion 18 of the housing portion 15 is cut and the cut ends serve as electrodes.

In the embodiment constructed as described above,
The conductor portion 18 is wound around the toroidal core 1 N times, and an inductor having excellent characteristics is obtained.

In the above description, an example in which the toroidal core 1 is enclosed in a single case has been described, but the number of turns of the conductor portion 18 can be further increased by using a multiple case.

[0030]

As is apparent from the above description, according to the inductor of the present invention, the formation of the winding portion on the toroidal core is performed as efficiently as when using the automatic winding machine, and the manufacturing cost is reduced. Is reduced and productivity is improved. Also,
The winding conditions and characteristics of each product are made uniform, and the quality can be improved.

[Brief description of drawings]

FIG. 1 is a perspective view showing a configuration of an embodiment of an inductor of the present invention.

FIG. 2 is a perspective view illustrating one manufacturing process of the inductor shown in FIG. 1, and is a diagram for explaining a process of inserting the bundled insulated conductors in the air-core portion of the toroidal core.

FIG. 3 is a perspective view illustrating one manufacturing process of the inductor shown in FIG. 1, and is a diagram for explaining a process of expanding the bundled insulated conductors.

FIG. 4 is a perspective view illustrating one manufacturing process of the inductor shown in FIG. 1, and a diagram for explaining a process of bending the insulated conductor along the end surface of the core.

5 is a perspective view for explaining one manufacturing process of the inductor shown in FIG. 1, and is a drawing for explaining a process of molding the insulated conductor along the outer peripheral surface of the core.

FIG. 6 is a perspective view illustrating one manufacturing process of the inductor shown in FIG. 1, and is a drawing for explaining a conductor connecting process.

FIG. 7 is a perspective view illustrating an inductor manufacturing method according to another embodiment of the present invention.

FIG. 8 is a perspective view showing the configuration of an inductor according to still another embodiment of the present invention.

9 is a perspective view showing a state after assembling the inductor shown in FIG. 8. FIG.

[Explanation of symbols] 1 ... Toroidal core 2 ... Insulated conductor 3 ... Conductor connection part 6 ... Cone-shaped molding jig 7 ... Slit 8 ... Disk-shaped molding jig 9 ... Circular lid-shaped molding jig DESCRIPTION OF SYMBOLS 11 ... Electrode for spot welding 12 ... Flat conductor 15 ... Housing 16 ... Lid 17 ... Insulating resin 18 ... Conductor

Claims (1)

[Claims] 1. A plurality of short insulated conductors arranged in parallel to each other are arranged along the height direction on the outer peripheral surface of a toroidal core made of a ferromagnetic material, and
An inductor, characterized in that both ends of the insulated conductor are electrically connected to both ends of an adjacent insulated conductor, and a coiled conduction path is formed around the core.