JP5932245B2 - Bobbin for coil device and coil device - Google Patents

Description

  The present invention relates to a coil device bobbin and a coil device including a coil device bobbin (hereinafter referred to as a “bobbin type coil device”).

  For example, a bobbin described in Patent Document 1 is used in many large-capacity coil devices (for example, reactors) used in a drive system of a hybrid vehicle or an electric vehicle. A bobbin for a coil device is a member that is interposed between a core and a coil to electrically insulate both, and is generally molded from a resin.

  In particular, in a large-capacity coil device, a split core in which a plurality of core pieces are arranged via a non-magnetic gap plate or gap is used in order to prevent magnetic saturation. In a bobbin type coil device using a split core, the bobbin is used as a formwork for assembling the split core, and a large number of members constituting the core (split core and gap member) are stacked in the bobbin and bonded and fixed. Often.

JP 2009-109437 A

  However, it is difficult to assemble a large number of members constituting the core in the bobbin at a time while assembling the coil to the bobbin, and a long working time is required.

  A bobbin for a coil device according to an embodiment of the present invention is a bobbin for a coil device that is disposed at least partially between a coil and a core and electrically insulates the coil and the core, and is inserted into the coil. The core is inserted into the hollow part, has a substantially cylindrical body part, and the body part protrudes into the hollow part, preventing a plurality of core pieces constituting the core from falling out of the body part. It has a locking part.

Furthermore, the coil device bobbin is divided into a first bobbin and a second bobbin in the middle of the body part in the axial direction, and the core locking part is one end in the axial direction of the body part of the first bobbin and the second bobbin. It is formed so as to protrude from the inside of the tube.

Further, the coil device bobbin is divided at one end, and a plurality of core locking portions are formed at one end of each body portion of the first bobbin and the second bobbin, and the plurality of core locking portions have a plate-like gap. The member is sandwiched from the side so as to restrict movement of the gap member in a direction parallel to the plate surface.

According to this configuration, when assembling the split core using the coil device bobbin as an assembly form, it is not necessary to assemble the entire split core at one time. For example, a large number of members (a plurality of core pieces and a plurality of core pieces and The work of stacking and fixing each half of the gap member) is possible, so that the efficiency of the coil device assembly work is improved.

According to this configuration, the core assembly operation can be performed for each of the divided first and second bobbins, so that the coil device can be assembled more efficiently and in a short time.

  According to this configuration, the gap member can be easily and accurately positioned.

  The trunk portion is a rectangular tube having a substantially rectangular frame shape in cross section, and the core locking portion has a substantially L-shaped plate shape, and is formed at each of the four corners at the other axial end of the barrel portion. The thickness of the portion may be a half or less of the thickness of the gap member. In this case, the first bobbin and the second bobbin may have the same shape.

  According to this structure, it becomes possible to make the shape of the trunk | drum of a 1st bobbin and a 2nd bobbin common, and a mold design and manufacture become easy. Furthermore, if the first bobbin and the second bobbin are formed in the same shape, the first bobbin and the second bobbin can be formed with the same mold, so that the manufacturing cost of the mold is reduced by half. In addition, the common use of members reduces design and manufacturing costs, and can reduce the required inventory.

  The core locking portions of the first bobbin and the second bobbin may be configured to be formed at positions that do not interfere with each other when the first bobbin and the second bobbin are assembled.

  According to this configuration, since the thickness of the core locking part can be increased to be slightly thinner than the gap member, the core locking part can be given high strength, and the coil device using a heavy core It becomes applicable to.

  The trunk portion is a rectangular tube having a substantially rectangular frame shape in cross section, and the core locking portion is formed in a band shape that connects two adjacent wall portions of the trunk portion. A space may be formed therebetween, and when the first bobbin and the second bobbin are assembled, the core locking part of the second bobbin may be accommodated in the space formed by the core locking part of the first bobbin. .

  According to this configuration, the strength of the trunk portion is reinforced by the core locking portion.

  The first bobbin and the second bobbin may further include a coil locking portion that protrudes outward from the other axial end of the body portion perpendicularly to the shaft and abuts on both ends of the coil.

  According to this configuration, a dedicated member for attaching the coil is not necessary, and the bobbin can be assembled and the coil can be attached by a single operation, thereby further improving the work efficiency.

  A coil device according to an embodiment of the present invention includes a coil, a core obtained by alternately bonding a plurality of core pieces and a plurality of gap members, and any one of the above-described bobbins for a coil device.

  According to the configuration of the embodiment of the present invention, it is not necessary to assemble the entire split core at once, and the efficiency of the coil device assembling work is improved.

FIG. 1 is an overall perspective view of a coil according to a first embodiment of the present invention. FIG. 2 is an exploded perspective view of the core and bobbin according to the first embodiment of the present invention. FIG. 3 is an exploded perspective view of the coil according to the first embodiment of the present invention. 4A is a cross-sectional view of the coil according to the first embodiment of the present invention, and FIG. 4B is an enlarged view of FIG. 4A. FIG. 5 is an exploded perspective view of a core and a bobbin according to the second embodiment of the present invention. It is a front view of a 1st bobbin. It is a front view of a 2nd bobbin. FIG. 8A is a view showing a state in which the first bobbin and the second bobbin are overlapped with each other via the center gap plate, and FIG. 8B is a cross-sectional view taken along line BB in FIG.

(First embodiment)
Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an overall perspective view of a reactor 100 according to a first embodiment of the present invention.

  As shown in FIG. 1, the reactor 100 includes a core 110, a bobbin 120, and a coil 130. The core 110 is a ring core having a substantially oval shape as a whole. In addition, the coil 130 has a first linear coil portion 131 and a second linear coil portion 132 that are both formed of a flat enameled wire, arranged in parallel, and one end connected by a coil connecting portion 133. In order not to contact the coil 130 and the core 110, the first linear coil portion 131 and the second linear coil portion 132 of the coil 130 are opposed to the core 110 via the first bobbin 121 and the second bobbin 122, respectively. Attached to two sides.

  Next, detailed configurations of the core 110 and the bobbin 120 will be described. FIG. 2 is an exploded perspective view of the core 110 and the bobbin 120.

  As shown in FIG. 2, the core 110 includes a first core part 111 and a second core part 112 that are U-shaped cores as a whole, and a center gap plate 113. The core 110 is a ring core formed in a substantially oval shape as a whole by adhering end faces to each other via a center gap plate 113 in a state where the first core portion 111 and the second core portion 112 face each other. is there.

  The first core portion 111 is bonded to both ends of a substantially C-shaped C-shaped core portion 111a by attaching substantially I-shaped (substantially rectangular parallelepiped) I-shaped core portions 111b via side gap plates 111c, respectively. It is formed in a substantially U shape as a whole. Similarly, the 2nd core part 112 is formed in the substantially U shape as a whole by adhere | attaching the I-type core part 112b to the both ends of the C-type core part 112a via the side gap board 112c, respectively.

  In the present embodiment, various magnetic cores such as a dust core, a ferrite core, and a laminated core (laminated silicon steel plate) are applied to the C-type core portions 111a and 112a and the I-type core portions 111b and 112b, respectively. The center gap plate 113 and the side gap plates 111c and 112c are formed of an insulating material such as ceramic (for example, alumina) or resin.

  The bobbin 120 is divided into a first bobbin 121 and a second bobbin 122. The first bobbin 121 has a pair of cylindrical portions 121a arranged with their axes in parallel. The pair of cylindrical portions 121a are connected by a flange portion 121b at one end thereof, and the first bobbin 121 is formed in a substantially U shape as a whole when viewed from the upper surface side (the upper side in FIG. 1). The flange portion 121b is a plate-like portion that extends from each tubular portion 121a to the outside of the tube.

  The first bobbin 121 functions as an assembly form when the first core part 111 is assembled. The assembly of the first core part 111 is performed as follows. First, the I-type core portion 111b of the first core portion 111 and the side gap plate 111c are sequentially inserted into the cylindrical portion 121a from the flange portion 121b side of the first bobbin 121. Note that an adhesive is applied in advance to the surface of the I-type core portion 111b facing the side gap plate 111c. Next, an adhesive is applied to the end surface of the C-shaped core portion 111 a, and the distal end portion of the C-shaped core portion 111 a is inserted into each cylindrical portion 121 a of the first bobbin 121. In this state, the first core portion 111 is integrally bonded and fixed. In this way, the first core part 111 is assembled in the first bobbin 121.

  The second bobbin 122 is a member having the same shape as the first bobbin 121. That is, the second bobbin 122 has a pair of cylindrical portions 122a, and the pair of cylindrical portions 122a are connected to each other by the flange portion 122b, and are formed in a U shape as a whole when viewed from the upper surface side. Yes. Similarly to the first bobbin 121, the second bobbin 122 also functions as an assembly form when the second core part 112 is assembled.

  As shown in FIG. 2, on the other axial end side of the cylindrical portions 121a and 122a (that is, the side opposite to the end where the flange portions 121b and 122b are located), a stopper portion that extends toward the inside of the tube 121c and 122c are formed. When the I-type core portions 111b and 112b are inserted into the cylindrical portions 121a and 122a, the stopper portions 121c and 122c are protruded from the other ends of the cylindrical portions 121a and 122a, respectively. It has a function as a stopper to hold it.

  In addition, spacer portions 121d and 122d, which are a plurality of protrusions extending in the axial direction, are formed on the inner periphery of each of the cylindrical portions 121a and 122a. The spacer parts 121d and 122d have a function as positioning means for positioning the I-type core parts 111b and 112b in a direction orthogonal to the axis thereof.

  Next, the procedure for assembling the reactor 100 will be described. FIG. 3 is an exploded perspective view of the reactor 100. First, each member constituting the first core portion 111 is sequentially inserted into each cylindrical portion 121a of the first bobbin 121 and fixed with an adhesive. Specifically, the I-type core portion 111b is first inserted into the cylindrical portion 121a, and then the side gap plate 111c is inserted into the cylindrical portion 121a. Note that an adhesive is applied in advance to the surface of the I-type core portion 111b in contact with the side gap plate 111c. Next, an adhesive is applied to the end surface of the C-shaped core portion 111 a, and the tip of the C-shaped core portion 111 a is inserted into each cylindrical portion 121 a of the first bobbin 121. In this state, the first core portion 111 is integrally bonded and fixed. Similarly, both ends of the I-type core part 112b, the side gap plate 112c, and the C-type core part 112a, in which an adhesive is applied to the gap surface, are sequentially inserted into the cylindrical part 122a of the second bobbin 122, The core part 112 is integrated. Next, the center gap plate 113 is bonded to the gap surface of the I-type core portion 112 b exposed from the tip of the second bobbin 122. Next, each cylindrical portion 122 a of the second bobbin 122 is inserted into the first linear coil portion 131 and the second linear coil portion 132 from the opposite side of the coil coupling portion 133 of the coil 130. Finally, each cylindrical part 121a of the first bobbin 121 incorporating the first core part 111 is inserted into the first linear coil part 131 and the second coil part 132 from the coil connecting part 133 side, and the center gap plate 113 is inserted. The first core part 111 and the second core part 112 are bonded together.

  As shown in FIG. 2, openings 121e and 122e are formed in the stopper portions 121c and 122c, respectively. Since the dimensions of the openings 121e and 122e are formed slightly larger than the center gap plate 113, the center gap plate 113 does not interfere with the stopper portions 121c and 122c, and the I-type core portion 111b of the first core portion 111. And the I-type core portion 112b of the second core portion 112. Further, since the center gap plate 113 is accommodated in the openings 121e and 122e with almost no gap, the center gap plate 113 is positioned in a plane (in a plane perpendicular to the axis of the cylindrical portion 121a) by the openings 121e and 122e. .

4A is a cross-sectional view of the coil 130 according to the present embodiment, and FIG. 4B is an enlarged view of a region A in FIG. As shown in FIG. 4B, the center gap plate 113 is securely bonded to both the I-type core part 111b of the first core part 111 and the I-type core part 112b of the second core part 112. The sum of the thickness d ₁ of the stopper portion 121 c of the 1 bobbin 121 and the thickness d ₂ of the stopper portion 122 c of the second bobbin 122 is set to be smaller than the thickness d ₃ of the center gap plate 113.

In the present embodiment, the gap is formed between the first core portion 111 and the second core portion 112 using the center gap plate 113 as described above. However, in this invention, it is not limited to said structure, It is good also as a structure which does not use the center gap board 113. FIG. In this case, the stopper portion 121c of the first bobbin 121 and a state in which the stopper portion 122c is abutted to the second bobbin 122, air gap thickness equal to the sum of the thicknesses _{d 1} and _{d 2} are formed.

  In the first embodiment of the present invention described above, the center gap plate 113 is bonded to the second core portion 112 after the second bobbins 122 are attached to the second core portion 112, respectively. However, the present invention is not limited to the above-described configuration, and may be configured as in the second embodiment of the present invention described below.

(Second Embodiment)
FIG. 5 is an exploded perspective view of a core and a bobbin according to the second embodiment of the present invention. The configuration of the present embodiment uses a second bobbin 122 ′ having a gap plate formed of resin instead of the second bobbin 122 and the center gap plate 113 in the first embodiment. Since other configurations of the present embodiment are the same as those of the first embodiment, detailed description thereof is omitted.

  As shown in FIG. 5, in the second bobbin 122 ′, a region corresponding to the opening 122d of the second bobbin 122 (FIG. 2) of the first embodiment is blocked by the center gap plate 122f. Is the same shape as the second bobbin 122 of the first embodiment. The center gap plate 122f is formed integrally with the second bobbin 122 by resin injection molding.

  Thus, in this embodiment, since the center gap plate 122f is formed integrally with the second bobbin 122 ′, the number of steps for assembling the coil can be reduced compared to the first embodiment. It has the effect of being able to.

  In the present embodiment, both of the pair of center gap plates 122f are integrally formed with the second bobbin 122 ′, but the present invention is not limited to the above configuration. For example, one center gap plate may be formed on each of the first bobbin and the second bobbin. With such a configuration, since the first bobbin and the second bobbin have the same shape, it is possible to reduce the manufacturing cost of the coil, and an error that the first bobbin and the second bobbin are mistaken at the time of assembly. Is prevented.

(Third embodiment)
In the above-described first embodiment, the first bobbin 121 and the second bobbin 122 have the same shape, and when the first bobbin 121 and the second bobbin 122 are assembled, the stopper portions 121c and 122c are each cylindrical. It is comprised so that it may overlap in the axial direction of the parts 121a and 122a. Therefore, it is necessary to make the sum of the thickness d ₁ of the stopper portion 121 c of the first bobbin 121 and the thickness d ₂ of the stopper portion 122 c of the second bobbin 122 smaller than the thickness d ₃ of the center gap plate 113. . In the third embodiment (FIGS. 6 to 8) described below, when the first bobbin and the second bobbin are assembled, the first bobbin 221 and the second bobbin 221 are arranged so that the stopper portions of the bobbins do not interfere with each other. The bobbin 222 is provided with stopper portions 221c and 222c having different shapes. The third embodiment has the same configuration as that of the first embodiment except for the shapes of the stopper portions 221c and 222c and the center gap plate 213 of the first bobbin 221 and the second bobbin 222. . In the following description of the third embodiment, detailed description of the configuration common to the first embodiment will be omitted.

  6 and 7 are front views of the first bobbin 221 and the second bobbin 222 as viewed from the other end side (side on which the center gap plate 213 is disposed) of the cylindrical portions 221a and 222a, respectively. FIG. 8A is a view of a state where the first bobbin 221 and the second bobbin 222 are overlapped via the center gap plate 213 as viewed from one end side (flange portion 221b side) of the first bobbin 221. FIG. 8B is a cross-sectional view taken along the line BB in FIG. At the four corners of the other ends of the respective cylindrical portions 221a and 222a, long plate-like stopper portions 221c and 222c that obliquely connect the adjacent cylindrical walls of the respective cylindrical portions 221a and 222a are formed in place of the stopper portions, respectively. Has been. The stopper portion 221c of the first bobbin 221 is longer than the stopper portion 222c of the second bobbin 222, and is disposed near the central axis of the cylindrical portion 221a. Therefore, a relatively wide space 221s surrounded by the stopper portion 221c and the corner of the cylindrical portion 221a is formed. As shown in FIG. 8, when the first bobbin 221 and the second bobbin 222 are overlapped, the stopper portion 222c of the second bobbin 222 is accommodated in the space 221s. With this configuration, if the thickness of the stopper portion 221c and the stopper portion 222c is formed to be equal to or less than the thickness of the center gap plate 213, the stopper portion 221c and the stopper portion are overlapped when the first bobbin 221 and the second bobbin 222 are overlapped. 222c do not interfere with each other. Accordingly, since the stopper portion 221c and the stopper portion 222c can be formed to be sufficiently thick, the stopper portions 221c and 222c are prevented from being damaged during the assembly operation. Further, the rigidity of the cylindrical portions 221a and 222a can be improved.

  In addition, stoppers 221c and 222c are provided at the four corners at the other ends of the cylindrical portions 221a and 222a where the center gap plate 213 is disposed, so that the rectangular center gap plate as in the first embodiment is provided. 113 cannot be arranged. Therefore, in the third embodiment, a center gap plate 213 having a shape in which four corners of a rectangle are cut off at an oblique angle of 45 ° is used so as not to interfere with the stopper portions 221c and 222c.

100 Coil device 110 Core 111 First core portion 111a, 112a C-type core portion 111b, 112b I-type core portion 111c, 112c Side gap plate 113, 122f Center gap plate 121 First bobbin 121a, 122a, 221a, 222a Cylindrical portion 121b, 122b Flange part 121c, 122c, 221c, 222c Stopper part 121d, 122d Spacer part 121e, 122e Opening 122, 122 'Second bobbin 130 Coil 131 First linear coil part 132 Second linear coil part 133 Coil connecting part

Claims (7)

A bobbin for a coil device that is at least partially disposed between a coil and a core and electrically insulates the coil and the core;
Having a generally cylindrical body inserted into the coil and into which the core is inserted into the hollow part;
The trunk portion has a core locking portion protruding into the hollow portion, which prevents a plurality of core pieces constituting the core from falling out of the trunk portion,
The coil bobbin is divided into a first bobbin and a second bobbin in the axial direction of the body part,
A plurality of the core locking portions are formed so as to protrude to the inside of the cylinder at one end in the axial direction of the body portion of each of the first bobbin and the second bobbin,
The plurality of core locking portions of the first bobbin and the second bobbin sandwich a plate-like gap member from the side and restrict movement of the gap member in a direction parallel to the plate surface. A formed bobbin for a coil device. The trunk is a rectangular tube having a substantially rectangular frame shape in cross section,
The core locking portion has a substantially L-shaped plate shape, and is formed at each of the four corners of the one end ,
2. The bobbin for a coil device according to claim 1, wherein a thickness of the core locking portion is not more than half of a thickness of the gap member. The bobbin for a coil device according to claim 2, wherein the first bobbin and the second bobbin have the same shape. 2. The core locking portions of the first bobbin and the second bobbin are formed at positions that do not interfere with each other when the first bobbin and the second bobbin are assembled. A bobbin for a coil device according to any one of claims 1 to 3. The trunk is a rectangular tube having a substantially rectangular frame shape in cross section,
The core locking portion is formed in a band shape that connects two adjacent wall portions of the body portion, and forms a space between the two wall portions to be connected,
The core locking part of the second bobbin is accommodated in a space formed by the core locking part of the first bobbin when the first bobbin and the second bobbin are assembled. Item 5. A coil device bobbin according to Item 4. The first bobbin and the second bobbin further include a coil locking portion that protrudes outward from the other axial end of the body portion perpendicularly to the shaft and abuts on both ends of the coil, respectively. The bobbin for coil devices according to any one of claims 1 to 5. Coils,
A core obtained by alternately bonding a plurality of core pieces and a plurality of gap members;
The coil apparatus provided with the bobbin for coil apparatuses as described in any one of Claims 1-6.

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