JPH07211549A - Electromagnetic equipment - Google Patents

Abstract

PURPOSE:To ensure the insulation easily between a core and a conductor without using a bobbin and reduce the manufacturing cost by locating the conductor on an insulating film with one edge of the conductor being away from one edge of the insulating film at least such a distance that is the same as the winding inner face length of the insulating film. CONSTITUTION:A copper foil 3 is located on an insulating film 2. At that time, a distance A between a winding starting-side edge Ba of the copper foil 3 and a winding starting-side edge 2a of the insulating film 2 is longer than the winding inner face length of the insulating film so that when the insulating film 2 is wound around a core 1, the core can be wound at least one turn by the insulating film 2 only. And, a distance B between a winding finishing-side edge 3b of the copper foil 3 and a winding finishing-side edge 2b of the insulating film 2 should be longer than the winding outer face length of the copper foil 3 so that the external face of a coil which is made by winding the copper foil 3 can be wound at least one turn by the insulating film 2 only.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic device formed by winding an insulating film and a foil-shaped conductor.

[0002]

2. Description of the Related Art A so-called foil winding transformer, in which a metal foil is wound as a conductor to form a winding of an electromagnetic device, has been widely used. As a method therefor, an insulating film and a metal foil having substantially the same shape are alternately stacked. There are known ones in which a conductor is wound, a conductor is formed by vapor-depositing a metal on an insulating film, and the conductor is wound. Also, as a composite element of an inductor and a capacitor, by winding a metal foil on a magnetic body through an insulating film to obtain an inductive reactance and at the same time, to obtain a capacitive reactance between the metal foils by the insulating film. An electromagnetic device having the function of is also proposed.

6 to 12 are shown in US Pat.
This shows an example of the conventional electromagnetic device disclosed in 521513, and the electromagnetic device is mainly composed of a core 1, an insulating film 2, and a copper foil 3 which is a conductor.

The core 1 is formed by laminating thin silicon steel plates in a substantially rectangular shape in plan view.
As shown in FIGS. 6 and 8, two long copper foils 3 and two insulating films 2 having substantially the same shape as the copper foils 3 are alternately laminated and wound to form an electromagnetic device. is doing.

In the electromagnetic device thus constructed, the winding start terminal portion S1 which is one end of one of the two copper foils 3, that is, the winding start terminal portion S1 and the other end of the two copper foils 3 which are wound are wound. The induction element (inductor) L is provided between the end terminal portions F1 and between the winding start terminal portion S2 and the winding end terminal portion F2 of the other copper foil 3.
On the other hand, it functions as a capacitive element (capacitor) C between the two copper foils 3 existing with the insulating film 2 interposed therebetween. FIG. 7 shows an equivalent circuit (however, the circuit is formed in a distributed constant). 9 shows a developed view of the copper foil 3 of FIG.

FIGS. 10 and 11 show the winding end terminal portion F1 of one copper foil 3 and the winding start terminal portion S1 of the other copper foil 3 as the input terminals 4 in the above electromagnetic device. In the example, a current flowing from the winding end terminal portion F1 of the one rolled copper foil 3 which is an inductor to the winding start terminal portion S1,
Through the capacitor, from the winding end terminal portion F2 of the other rolled copper foil 3 that is an inductor to the winding start terminal portion S2.
Current flowing through the circuit and its circuit becomes a series LC circuit as shown in FIG. Further, here, the winding start terminal portion S1 of the one copper foil 3 and the winding end terminal portion F of the other copper foil 3 are provided.
If 2 is shorted, the circuit becomes a parallel LC circuit.

FIG. 13 shows the terminal structure of the electromagnetic device disclosed in Japanese Patent Laid-Open No. 2-123707, which is one of such electromagnetic devices. The winding start terminal S1 and the winding end terminal are shown in FIG. The terminal pin 5 is attached to the portion of the copper foil 3 of F1 by fixing another conductor, for example, by spot welding.

[0008]

Generally, such an electromagnetic device tends to have insufficient capacity in a circuit which is excited at a commercial frequency, but in recent years, a switching power supply,
The number of high-frequency circuits such as inverter ballasts that are excited at 20 KHz or more has increased, and the capacity of capacitors has become smaller. Therefore, it can be used in such high-frequency circuits. We are at a practical stage.

However, Mn-Zn ferrite is often used in the core 1 used in a circuit excited at a high frequency in terms of core loss, and its specific resistance is about several Ω · m. It is necessary to secure insulation between the foil 3 and the core 1. For this reason, in the conventional electromagnetic device configured as described above, for example, a bobbin made of phenol resin or the like is used between the core 1 and the conductor 3. However, there is a problem that the cost of the electromagnetic device is increased.

The present invention has been made to solve the above problems, and an object thereof is to provide an inexpensive electromagnetic device in which insulation between a core and a conductor is easily secured without using a bobbin. To provide.

[0011]

SUMMARY OF THE INVENTION In order to solve the above problems, the present invention provides a core 1 according to the first aspect of the invention.
And an insulating film 2 wound around the core 1 from one end thereof, and a conductor 3 which is disposed in close contact with the insulating film 2 and is wound around the core 1 together with the insulating film 2 to form a coil. In the electromagnetic device provided, the one end 3a of the conductor 3 is arranged at a distance from the one end 2a of the insulating film 2 at least more than the winding inner circumference of the insulating film 2. .

Further, in the second aspect of the invention, the other end 3b of the conductor 3 is replaced with the other end 2b of the insulating film 2.
From at least the outer circumference length of the winding of the conductor 3.

Further, in the invention according to claim 3, a plurality of the conductors 3 are arranged substantially parallel to each other on the insulating film 2 so as to form a coil of about one turn in a wound state. At the same time, when the plurality of conductors 3 are wound, a predetermined angle is formed with respect to the winding direction so that the other end 3b of one conductor 3 and the one end 3a of the other conductor 3 which are adjacent to each other face each other. The other end 3b of one conductor 3 facing each other and the one end 3 of the other conductor 3 of the conductors 3 which are arranged and wound adjacent to each other.
It is characterized in that it is electrically connected to a.

[0014]

With the above construction, in the invention according to claim 1, the core 1, the insulating film 2 wound around the core 1 from one end side thereof, and the insulating film 2 are closely adhered to each other. In the electromagnetic device having the conductor 3 wound around the core 1 together with the insulating film 2 to form a coil, the one end 3a of the conductor 3 is at least separated from the one end 2a of the insulating film 2. Since the insulating film 2 is disposed farther from the inner circumference of the winding, only the insulating film 2 in the portion where the conductor 3 is not provided is wound to form an insulating layer on the core 1 side of the coil. Insulation between the core 1 and the conductor 3 is ensured, and the conductor 3 provided on the insulating film 2 is wound thereon to form a coil. For this reason, it is not necessary to provide a bobbin as a separate component in the electromagnetic device, the insulation between the core 1 and the conductor 3 of the electromagnetic device can be easily secured without using the bobbin (bobbin-less), and the electromagnetic device is inexpensive. Become.

According to the second aspect of the invention, the other end 3b of the conductor 3 is replaced with the other end 2b of the insulating film 2.
Since the conductor 3 is disposed at a distance more than at least the winding outer peripheral length of the conductor 3, the same effect as the invention according to claim 1 is obtained, and the conductor 3 is provided on the outer shell of the coil formed by winding the conductor 3. Only the portion of the insulating film 2 not provided is wound to form an electromagnetic device, and the outer insulating film 2 forms an outer insulating layer of the electromagnetic device to ensure insulation of the outer shell of the coil. Therefore, the electromagnetic device does not need to be provided with the insulating layer of the outer shell of the coil as a separate component, and the cost of the electromagnetic device is further reduced.

Further, in the third aspect of the present invention, a plurality of the conductors 3 are arranged on the insulating film 2 substantially in parallel with each other so as to form a coil of about one turn in a wound state. At the same time, when the plurality of conductors 3 are wound, a predetermined angle is formed with respect to the winding direction so that the other end 3b of one conductor 3 and the one end 3a of the other conductor 3 which are adjacent to each other face each other. The other end 3b of one conductor 3 facing each other and the one end 3 of the other conductor 3 of the conductors 3 which are arranged and wound adjacent to each other.
Since it is electrically connected to a, it is possible to provide the same effect as the invention according to claim 1 and to provide a thin electromagnetic device.

[0017]

1 to 3 show a first embodiment of an electromagnetic device according to the present invention, which mainly comprises a core 1, an insulating film 2 and a copper foil 3 which is a conductor. Is configured.

The core 1 is made of Mn-Zn ferrite and is formed in a substantially square shape in a plan view and has a substantially circular cross section, for example, SB7H made by Hitachi Ferrite, and the diameter of the cross section is about 10 mm.
It is said that.

The insulating film 2 is made of polypropylene,
It is a long film having a thickness of about 30 μm, and the conductor 3 is shorter than the insulating film 2 and has a thickness of about 35 μm.
m of copper foil 3, which is provided on the insulating film 2. Moreover, the copper foil 3 which is the conductor
As shown in FIGS. 2 and 3, the distance A between the one end 3a, which is the winding start side end of the copper foil 3, and the one end 2a, which is the winding start side end of the insulating film 2, is 2 is core 1
When the core 1 is wound around, the core 1 is wound one or more times only in the portion of the insulating film 2 only, and the winding inner circumference length is made longer than πD (π is the circular constant), and the distance A Is about 350 mm. Further, the distance B between the other end 3b, which is the winding end side end of the copper foil 3, and the other end 2b, which is the winding end side end of the insulating film 2, is also configured by the copper foil 3 being wound. The distance B is set to about 350 mm so that the outer circumference of the coil is wound at least once in the outer shell of the coil at least once so as to be longer than the winding outer circumference length πE of the copper foil 3. .

That is, when the insulating film 2 is wound around the core 1 from one end thereof, about 10 parts of the copper foil 3 are not provided.
The inner insulating layer 6 is formed by being wound, and is wound on the inner insulating layer 6.
Copper foil 3, insulating film 2, copper foil 3 and insulating film 2
The coil portion 7 is formed by being wound in this order,
Further, the other end 3b, which is the end of the winding of the copper foil 3, has the copper foil 3
When the winding is completed, the portion of the insulating film 2 on the other end 2b side where the copper foil 3 is not provided is further wound around the outer periphery for about 5 turns to terminate and form the outer insulating layer 8.

Therefore, in the electromagnetic device thus constructed, the inner insulating layer 6 having a thickness of about 0.3 mm exists between the core 1 and the innermost copper foil 3. The inner insulating layer 6 functions as a bobbin, while the outer insulating layer 8 having a thickness of about 0.15 mm is provided between the outermost layer of the coil portion 7 and the outer shell of the electromagnetic device. It will be present and its outer insulating layer 8 will serve as a peripheral tape, which is usually wrapped around the outer contour of the coil.

Because of this structure, in the electromagnetic device of this embodiment, only the insulating film 2 in the portion where the copper foil 3 as the conductor is not provided is wound around the portion of the coil on the core 1 side. The inner insulating layer 6 is formed to secure the insulation between the core 1 and the copper foil 3, and the copper foil 3 provided on the insulating film 2 is wound thereon to form the coil portion 7. The outer portion of the coil portion 7 formed by winding the foil 3 is wound only on the portion on the other end 2b side of the insulating film 2 where the copper foil 3 is not provided to form the outer insulating layer 8, and the coil portion is formed. 7
And ensure the insulation of the outer shell of the electromagnetic device,
The electromagnetic device is configured by protecting the electromagnetic device from a mechanical shock from the outside. For this reason, it is not necessary to provide a bobbin or an insulator of the outer shell of the coil as a separate component in the electromagnetic device, and the insulation between the core 1 and the conductor 3 of the electromagnetic device and the insulation of the outer shell of the coil can be easily ensured without a bobbin and the electromagnetic The device becomes inexpensive.

Actually, the inventor of the present application prototyped the electromagnetic device as described above, and made AC2000 between the core 1 and the copper foil 3 and between the copper foil 3 and the insulating film 2 of the outer periphery of the electromagnetic device, respectively.
I tried to apply a voltage of V, but the electromagnetic device did not have problems such as dielectric breakdown, and switching power supplies often use series LC circuits and parallel LC circuits, but they also withstand surge voltage at that time. It was a reward.

FIGS. 4 and 5 show a second embodiment of the present invention. The difference from the first embodiment is the insulating film 2 and the copper foil 3 which is a conductor, and the others. The configuration is similar to that of the first embodiment.

The insulating film 2 is made of a polyester film and has a thickness of about 50 μm. A plurality of copper foils 3 are arranged on the insulating film 2 in parallel with each other. The length F is set to a length that forms a coil of approximately one turn when the copper foil 3 is wound around the core 1. Further, the adjacent copper foils 3 have one length when the copper foil 3 is wound. The other end 3b, which is the end of winding of the copper foil 3, and the copper foil 3 next to it
Is arranged at a predetermined angle with respect to the winding direction so that one end 3a which is the winding start end of
In addition, at one end 3a and the other end 3b of the copper foil 3, small copper foils connected to the copper foil 3 on the front side of the insulating film 2 are also provided on the back surface side of the insulating film 2 by winding. , One end 3a of one copper foil 3 on the front side of the insulating films 2 of the adjacent copper foils 3 and a small copper foil provided on the back side of the insulating film 2 on the other end 3b side of the other copper foil 3 The electrical connection is obtained by abutting or welding.

Even with this structure, the same effects as those of the first embodiment can be obtained, and since the coil of the electromagnetic device having a plurality of turns has one layer, a thin electromagnetic device can be provided. It also has an effect.

In the above first and second embodiments, the conductor 3 is made of copper foil, but the present invention is not limited to this. It may be a vapor-deposited metal.

[0028]

Since the electromagnetic device of the present invention is constructed as described above, in the invention of claim 1,
An electromagnetic device comprising a core, an insulating film wound around the core, and a conductor that is disposed on the insulating film and that is wound around the core together with the insulating film to form a coil. Since the one end is arranged at a distance from the one end of the insulating film at least longer than the winding inner circumferential length of the insulating film, only the insulating film of the portion not provided with the conductor is wound around the core side portion of the coil for insulation. A layer is formed to ensure insulation between the core and the conductor, on which the conductor provided on the insulating film is wound to form a coil. Therefore, it is not necessary to provide a bobbin as a separate component in the electromagnetic device, the insulation between the core and the conductor of the electromagnetic device can be easily secured without using the bobbin (bobbinless), and the electromagnetic device becomes inexpensive.

Further, in the invention according to claim 2, since the other end of the conductor is arranged at a distance from the other end of the insulating film at least more than the winding outer peripheral length of the conductor, While having the same effect as the invention of, the outer shell of the coil formed by winding the conductor, only the insulating film of the portion not provided with the conductor is wound to form the electromagnetic device, the insulating film of the outer shell is An outer insulation layer of the electromagnetic device is formed to ensure insulation of the outer shell of the coil. Therefore, the electromagnetic device does not need to be provided with the insulating layer of the outer shell of the coil as a separate component, and the cost of the electromagnetic device is further reduced.

Further, in the invention according to claim 3, a plurality of the conductors are arranged substantially parallel to each other on the insulating film so as to form a coil of about one turn in a wound state. , The plurality of conductors are arranged at a predetermined angle with respect to the winding direction so that the other end of one adjacent conductor and the one end of the other conductor face each other when wound.
Since the other end of one conductor and the other end of the other conductor of the wound adjacent conductors are electrically connected to each other, the same effect as that of the invention according to claim 1 is obtained, and a thin electromagnetic device is provided. It also has the effect of being able to.

[Brief description of drawings]

FIG. 1 is a perspective view showing a first embodiment of the present invention.

FIG. 2 is a partial cross-sectional side view of the above.

FIG. 3 is a perspective view showing a developed state of the insulating film and the conductor, wherein (a) is a perspective view of one end which is a winding start end;
(b) is a perspective view of the other end, which is the end of winding.

FIG. 4 is a perspective view showing a developed state of an insulating film and a conductor according to a second embodiment of the present invention.

FIG. 5 is a perspective view of an essential part showing a state where the insulating film and the conductor in the same way are being wound.

FIG. 6 is a perspective view showing a conventional electromagnetic device.

FIG. 7 is an equivalent circuit diagram of the above.

FIG. 8 is a perspective view showing a state where the above insulating film and a conductor are being wound.

FIG. 9 is a developed side view of the above conductor.

FIG. 10 is a connection diagram showing a usage example of the above.

FIG. 11 is a connection diagram in which the conductors of the same are expanded.

FIG. 12 is an equivalent circuit diagram of the above.

FIG. 13 is a perspective view showing a connection state of the above terminals.

[Explanation of reference numerals] 1 core 2 insulating film 2a one end of insulating film 2b other end of insulating film 3 conductor 3a one end of conductor 3b other end of conductor

Claims (3)

[Claims] 1. A core, an insulating film wound around the core from one end side thereof, and a conductor which is disposed in close contact with the insulating film and is wound around the core together with the insulating film to form a coil. In the electromagnetic device having, the one end of the conductor is arranged at a distance from at least one end of the insulating film by at least a winding inner circumferential length of the insulating film. 2. The electromagnetic device according to claim 1, wherein the other end of the conductor is arranged so as to be separated from the other end of the insulating film by at least a winding outer peripheral length of the conductor. 3. A plurality of the conductors are arranged substantially parallel to each other on the insulating film so as to form a coil of about one turn in a wound state, and when the plurality of conductors are wound. It is arranged at a predetermined angle with respect to the winding direction so that the other end of one adjacent conductor and one end of the other conductor face each other. The electromagnetic device according to claim 1, wherein the other end is electrically connected to one end of the other conductor.