JP2005108976A - Toroidal type coil and current sensor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To reduce material costs and the number of assembling processes in order to lower manufacturing costs while the magnetic characteristic is stabilized by eliminating, as much as possible, an influence of external stress to a core. <P>SOLUTION: A core 14 is formed by laminating seven sheets of a high permeability plate 12, and a plurality of holes 18 are respectively arranged at portions provided oppositely to each other of each high permeability plate 12. An upper case 22 and a lower case 24 made of resin in the U-shaped cross-section are arranged to the upper and lower portions of the core 14. At the part opposing to the hole 18 of a pair of cases 22, 24, projected portions 22A, 24A formed in the shape of polygonal prism are provided, resulting in the shape where the hole 18 of the core 14 is engaged with the projected portions 22A, 24A. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention provides a toroidal coil wound in a toroidal shape that is less affected by external stress on the core and stabilizes magnetic properties, while reducing material costs and assembly man-hours to reduce manufacturing costs. The present invention relates to a current sensor using the toroidal coil.

  Conventionally, a toroidal coil in which a winding wire is wound in a toroidal shape is used for a current sensor or the like. In addition, by placing a gel-like resin in the case, the toroidal coil with a structure that stabilizes the magnetic properties by relaxing external stress applied to the core formed by laminating permalloy sheet materials JP-A-7-239347.

On the other hand, for example, JP-A-8-224938 discloses a structure in which a cylindrical boss is formed and used for positioning. However, positioning using a cylindrical boss is performed in various fields. It is a very general technical content.
JP 7-239347 A JP-A-8-224938

However, in the toroidal type coil having the structure disclosed in Japanese Patent Laid-Open No. 7-239347, it is necessary to put a gel-like resin in the case in order to stabilize the magnetic characteristics, so that the material cost only increases. As a result, the assembly man-hours increased, and the assembly workability decreased.
On the other hand, at the time of winding, it is necessary to hold a pair of cases with the core sandwiched between them. The man-hour increased.

  In consideration of the above facts, the present invention makes it difficult to be affected by external stress on the core and stabilizes the magnetic characteristics, while reducing the material cost and assembly man-hour to reduce the manufacturing cost and the current sensor. The purpose is to provide.

The toroidal coil according to claim 1 is a toroidal coil in which a core formed by laminating plates made of a high magnetic permeability material is placed between a pair of resin cases, and a winding is wound around the pair of cases. Because
A plurality of holes are provided in the core, and protrusions formed in a polygonal pyramid shape are provided in portions facing the plurality of holes of the pair of cases,
The protrusions are inserted while being engaged with the holes of the core, respectively, and the core is housed between a pair of cases.

  According to the toroidal type coil according to claim 1, the core formed by laminating the plates made of a high magnetic permeability material is placed between a pair of resin cases, and a winding is wound around the pair of cases. It has a structure. In addition, a plurality of polygonal pyramid-shaped protrusions each formed on a pair of cases are inserted while being engaged with a plurality of holes provided in the core, and the core is housed between the pair of cases. .

  That is, in this claim, while inserting a plurality of protrusions each having a polygonal pyramid shape into engagement with a plurality of holes, a gap is provided between the core and the inner surfaces of the pair of cases. The core is supported by these protrusions between the pair of cases.

  Accordingly, not only is the clearance dimension between the inner surface of the pair of cases and the core stabilized, but external stress is not applied to the core, so that the magnetic characteristics of the core are stabilized and the yield of the toroidal coil is reduced. Improvement and improvement in magnetic properties can be expected. Further, in the present invention, a plurality of hole portions are provided in the core, and a plurality of protrusions formed in a polygonal pyramid shape are provided in a pair of cases corresponding to the plurality of hole portions. The core is securely supported by the plurality of protrusions between the cases. For this reason, not only is the clearance dimension between the inner surface of the pair of cases and the core more stable, but also external stress is not reliably applied to the core.

  Accordingly, in this claim, it is not necessary to inject a gel-like resin into the case in order to relieve the stress applied to the core as in the conventional example. As a result, the material cost and the assembly man-hour are reduced, the workability is improved, and the total manufacturing cost of the toroidal coil can be expected to be reduced.

  On the other hand, at the time of winding, a pair of cases are held via the core by engaging the plurality of protrusions with the plurality of holes, respectively, so it is necessary to hold the pair of cases across the core. This eliminates the need to fix the pair of cases with a tape or the like, which also reduces the number of assembly steps.

  As described above, according to the present invention, it is possible to obtain a toroidal coil that reduces the manufacturing cost by reducing the material cost and the assembly man-hour while stabilizing the magnetic characteristics by being hardly influenced by the external stress to the core. It becomes like this.

  According to the toroidal type coil according to claim 2, in addition to the same configuration as the toroidal type coil according to claim 1, the concave and convex portions are provided in the mutually facing portions of the respective plates of the high magnetic permeability material. It has a configuration in which these plate members are stacked while being fitted to each other and engaged with each other.

  Therefore, according to this claim, for example, a semi-recessed uneven portion is provided on each plate material made of a high magnetic permeability material, and these uneven portions are fitted to each other, and the necessary number of layers are stacked while engaging each plate material. After that, an integrated core was formed by pressing and heat treatment. As a result, when the cores are formed by laminating the respective plate materials, the respective plate materials are securely adhered to each other, so there is no need to fix several portions of the core with tape or the like, and the assembly man-hour is further reduced. Will come to be.

  According to the toroidal type coil according to claim 3, in addition to the same configuration as the toroidal type coil of claim 1, between the core and each case excluding the engaging portion between the core and the pair of cases. , There is a configuration in which a gap of a predetermined size exists. Therefore, according to this claim, the gap between the inner surface of the pair of cases and the core is further stabilized as a result of the gap being reliably provided between the core and the inner surfaces of the pair of cases. In addition, external stress is not more reliably applied to the core.

The current sensor according to claim 4 is provided with a sensor body capable of detecting current attached to a core formed by laminating plates made of a high magnetic permeability material, and the core is housed between a pair of cases made of resin together with the sensor body, A current sensor using a toroidal coil in which a wire is wound around the pair of cases,
A plurality of holes are provided in the core, and protrusions formed in a polygonal pyramid shape are provided in portions facing the plurality of holes of the pair of cases,
The protrusions are inserted while being engaged with the holes of the core, respectively, and the core is housed between a pair of cases.

  According to the current sensor of claim 4, a sensor body capable of detecting current is attached to a core formed by laminating plates made of a high magnetic permeability material, and the core is attached between the pair of cases made of resin together with the sensor body. And a toroidal coil having a structure in which a wire is wound around the pair of cases. Further, as in claim 1, the polygonal pyramid-shaped protrusions formed on the pair of cases are respectively inserted into the plurality of holes provided in the core, and the core is accommodated between the pair of cases. It has also become a structure.

  As described above, according to the present invention, similarly to the first aspect, it is not necessary to inject a gel-like resin into the case. Thus, it is possible to obtain a current sensor with reduced manufacturing costs by reducing material costs and assembly man-hours.

  According to the present invention, it is possible to obtain a toroidal coil and a current sensor in which the manufacturing cost is reduced by reducing the material cost and the number of assembling steps while stabilizing the magnetic property by being hardly influenced by the external stress on the core. Is possible.

1 to 6 show an embodiment of a toroidal coil and a current sensor according to the present invention, and the embodiment will be described based on these drawings.
As shown in FIG. 1, the ring-shaped core 14 comprises the main-body part of the toroidal type coil 10 which concerns on a present Example. The core 14 is formed by laminating seven high magnetic permeability plates 12 each made of a high magnetic permeability material formed in a ring shape with one end notched. The high permeability plate 12 is made of, for example, a permalloy material that is an alloy of nickel and iron having a thickness of 0.5 mm. Further, a sensor body 32 made of a Hall element capable of detecting a current is disposed in the cutout portion 14A of the core 14 formed integrally with the cutout portion of the high magnetic permeability plate 12.

  As shown in FIGS. 1 and 2, a plurality of (three in this embodiment) uneven portions 16 are respectively arranged on the portions of the high permeability plates 12 facing each other. Each of these concavo-convex portions 16 is formed by cutting each high-permeability plate 12 in a half-cut shape, but the concavo-convex portion 16 of the lowermost high-permeability plate 12 is a through hole. Further, as shown in FIGS. 1 and 3, a plurality of (two in the present embodiment) through-holes 18 are arranged in the mutually opposing portions of each of the high magnetic permeability plates 12. ing.

  Then, the concavo-convex portions 16 of the respective high permeability plates 12 are fitted to each other, and the respective high permeability plates 12 are laminated while being engaged with each other, and are pressed, heat-treated, etc., so that they are integrated. The core 14 is formed. At this time, since the holes 18 are arranged at the same position as shown in FIG. 3, the holes 18 penetrate the core 14.

  As shown in FIG. 1, an upper case 22 and a lower case 24 each made of a resin and having a U-shaped cross section are disposed on the upper and lower portions of the core 14, and the holes of the pair of cases 22 and 24 are arranged. Protrusions 22A and 24A each formed in a polygonal pyramid shape are provided in a portion facing 18 and the hole 18 of the core 14 and the protrusions 22A and 24A are fitted.

  That is, the protrusions 22A and 24A shown in FIG. 5 have a substantially triangular cross section, and the diameter D1 of the circumscribed circle at the tips of the protrusions 22A and 24A is the diameter of the hole 18 of the core 14 shown in FIG. Although it is almost the same as D0, the diameter D2 of the circumscribed circle at the bases of the protrusions 22A and 24A has a larger shape, and the protrusions 22A and 24A have a triangular pyramid shape with a flat tip. . As shown in FIG. 3, core receiving portions 22B and 24B each having a larger diameter than the base portions of the protrusions 22A and 24A are provided below the base portions of the protrusions 22A and 24A, respectively.

  Then, these protrusions 22A and 24A are inserted while being engaged with the holes 18 of the core 14, and the protrusions 22A and 24A are press-fitted into the holes 18 of the core 14, respectively. A portion around the hole portion 18 bites in. Accordingly, in this embodiment, the core 14 is housed between the pair of cases 22 and 24 while the core 14 is fixed in a state where a gap is provided between the core 14 and the inner surfaces of the pair of cases 22 and 24. Yes.

  That is, as shown in FIG. 4, in a state where the pair of cases 22, 24 are set on the core 14 in a form in which the core 14 is accommodated between the pair of cases 22, 24, the protrusions 22 A, 24 A and the hole 18 are formed. A gap G1 having a predetermined size exists between the inner surface of the pair of cases 22 and 24 excluding the engaging portion and the core 14, and the inner surface of the side walls of the pair of cases 22 and 24 and the side surface of the core 14 A gap G2 also exists between the two. Further, a gap G3 also exists between the upper and lower protrusions 22A and 24A facing each other after fitting with the hole 18 of the core 14.

  Further, a winding wire 26 is wound around a pair of cases 22 and 24 in a shape containing the core 14 as shown in FIG. 6 to complete the toroidal coil 10. The completed toroidal coil 10 is stored in the storage box 34, the circuit board 36 connected to the sensor body 32 is screwed to the storage box 34, and the connector 38 is connected to the circuit board 36. The current sensor 30 according to this embodiment is completed.

Next, the operation of the toroidal coil 10 and the current sensor 30 according to this embodiment will be described.
According to the toroidal coil 10 according to the present embodiment, the concavo-convex portions 16 are provided in the mutually opposing portions of the respective high magnetic permeability plates 12, and the concavo-convex portions 16 are fitted to each other, so that each of these high magnetic permeability plates 12. The cores 14 are formed by stacking layers while engaging each other. Further, the core 14 is housed between a pair of cases 22 and 24 made of resin, and a winding wire 26 is wound around the pair of cases 22 and 24.

  Further, a plurality of polygonal pyramidal protrusions 22A and 24A formed on the pair of cases 22 and 24 are respectively engaged with a plurality of holes 18 provided in the core 14, and the holes 18 are formed on the protrusions 22A and 24A. The protrusions 22 </ b> A and 24 </ b> A are inserted into the holes 18 of the core 14 and the core 14 is accommodated between the pair of cases 22 and 24.

  The toroidal coil 10 is housed in the housing box 34 of the current sensor 30 according to the present embodiment, and the sensor body 32 disposed in the notched portion of the core 14 detects the current, whereby the circuit board. Current value detection data can be output to the outside of the current sensor 30 via the connector 36 and the connector 38.

  That is, in this embodiment, the plurality of polygonal pyramid-shaped protrusions 22A and 24A are inserted while being engaged with the plurality of hole portions 18 respectively, so that the core 14 and the inner surfaces of the pair of cases 22 and 24 are inserted. While the gaps G1 and G2 are provided, the core 14 is reliably supported by the protrusions 22A and 24A between the pair of cases 22 and 24.

  Accordingly, not only the dimensions of the gaps G1 and G2 between the inner surfaces of the pair of cases 22 and 24 and the core 14 are stabilized, but external stress is not applied to the core 14, so that the magnetic characteristics of the core 14 are improved. As a result, the yield of the toroidal coil 10 and the improvement of the magnetic characteristics can be expected. Accordingly, it is not necessary to inject a gel-like resin into the case in order to relieve the stress applied to the core as in the conventional example. As a result, material costs and assembly man-hours are reduced, workability is improved, and a reduction in total manufacturing cost of the toroidal coil 10 can be expected.

  On the other hand, at the time of winding, since the pair of cases 22 and 24 are held via the core 14 by engaging the protrusions 22A and 24A with the hole 18, the pair of cases with the core 14 in between. Since it becomes unnecessary to hold | maintain 22 and 24, it becomes unnecessary to fix a pair of cases 22 and 24 with a tape etc., and also the assembly man-hour of the toroidal type coil 10 will be reduced by this.

  As described above, according to the present embodiment, the toroidal coil 10 that reduces the manufacturing cost by reducing the material cost and the assembly man-hour while stabilizing the magnetic property by being hardly influenced by the external stress to the core 14 and Thus, the current sensor 30 using the toroidal coil 10 can be obtained.

  On the other hand, according to the present embodiment, the concavo-convex portions 16 are provided on the portions of the high permeability plates 12 facing each other, the concavo-convex portions 16 are fitted to each other, and the high permeability plates 12 are mutually engaged. After the necessary number of layers are stacked together, the high permeability plates 12 are securely adhered to each other as a result of pressing to form an integral core 14. For this reason, it is not necessary to fix several portions of the core 14 with a tape or the like, and the assembly man-hour is further reduced.

  In the above embodiment, the protrusions 22A and 24A are formed in a triangular pyramid shape, but may be formed in another polygonal pyramid shape such as a quadrangular pyramid shape. Further, in the above embodiment, when the core 14 is housed in the pair of cases 22 and 24 as shown in FIG. 4, the core 14 is not in contact with the core receiving portions 22B and 24B. The core 14 may be supported more reliably by bringing the core 14 into contact with the receiving portions 22B and 24B.

  In the above embodiment, the high permeability material is made of permloy material having a thickness of 0.5 mm and μm ≧ 150,000, but the permeability range of the plate material is about μm ≧ 30,000. And the thickness of the plate material may be changed.

It is a disassembled perspective view which shows the components which comprise the toroidal type coil which concerns on one Example of this invention. It is sectional drawing to which the principal part of the core applied to the toroidal type coil which concerns on one Example of this invention was expanded, Comprising: It is the 2-2 arrow line drawing of FIG. It is sectional drawing which expands and shows the decomposition | disassembly state of the principal part of the toroidal type | mold coil which concerns on one Example of this invention. It is sectional drawing which expands and shows the principal part of the toroidal type coil which concerns on one Example of this invention. It is a figure which expands and shows the protrusion of the case applied to the toroidal type coil which concerns on one Example of this invention, Comprising: (A) is a top view, (B) is a front view. It is a disassembled perspective view which shows the current sensor which concerns on one Example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Toroidal type coil 12 High permeability board 14 Core 16 Uneven part 18 Hole part 22 Upper case 22A Protrusion 24 Lower case 24A Protrusion 26 Lead wire 30 Current sensor 32 Sensor main body

Claims (4)

A toroidal coil in which a core formed by laminating a plate made of a high magnetic permeability material is placed between a pair of resin cases, and a winding is wound around the pair of cases,
A plurality of holes are provided in the core, and protrusions formed in a polygonal pyramid shape are provided in portions facing the plurality of holes of the pair of cases,
A toroidal coil, wherein the protrusion is inserted while being engaged with the hole of the core, and the core is housed between a pair of cases. An uneven part is provided in the part of each plate of the high magnetic permeability material facing each other,
2. The toroidal coil according to claim 1, wherein the concave and convex portions are fitted to each other, and the respective plate materials are laminated while being engaged with each other.   2. The toroidal coil according to claim 1, wherein a gap of a predetermined size exists between the core and each case excluding an engagement portion between the core and the pair of cases. A sensor body capable of detecting an electric current is attached to a core formed by laminating plates made of a high permeability material, and the core is placed between a pair of resin cases together with the sensor body, and a wire is wound around the pair of cases. Is a current sensor using a toroidal coil wound with
A plurality of holes are provided in the core, and protrusions formed in a polygonal pyramid shape are provided in portions facing the plurality of holes of the pair of cases,
A current sensor characterized in that the cores are housed between a pair of cases by inserting the protrusions while engaging the holes in the cores.

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