JP2003017334A - Converter transformer - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To be manufactured at low cost and to improve assemblability and mass productivity. In addition, heat dissipation is enhanced, and the degree of freedom in design is increased. SOLUTION: It has a core combined body (a pair of E-shaped cores 10) of a divided structure forming a closed magnetic circuit, a low voltage side coil unit and a high voltage side coil unit. The low-voltage side coil unit includes an edgewise coil 20 and a fixing insulating base 22 having a tubular portion and a flange fitted to the core leg, and the edgewise coil surrounds the tubular portion. It is a structure to be put on the part. Instead of the edgewise coil, a flat coil obtained by punching a metal plate may be used. The high-voltage side coil unit has a structure in which a twisted conductor composed of many magnet wires is wound around an insulating bobbin 34 having flange portions formed at both ends of an annular portion. The insulating base and the insulating bobbin can be fitted to each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a converter transformer, and more particularly to a converter transformer in which coil components are incorporated into an insulating base for fixing to improve the assembling and handling of the coil portion. Is. The converter transformer is not particularly limited, but is useful for applications with large current and large output, such as electric components of electric vehicles.

[0002]

2. Description of the Related Art In a DC-DC converter for converting a DC voltage, a converter transformer for increasing or decreasing an input voltage is incorporated. This type of converter transformer has a structure in which a low-voltage side coil and a high-voltage side coil are wound so as to surround a leg portion of the core, using a core coupling body having a two-part structure forming a closed magnetic circuit.

Although there are various core materials and shapes, an EE type ferrite core is generally used. The E-shaped core has a shape in which the middle foot portion and the outer foot portions on both sides are continuously integrated at the end plate portion, and the coil portion is arranged so as to surround the middle foot portion. The coil on the low voltage side and the coil on the high voltage side are
It is formed by winding a copper wire on the bobbin. However, such a conventional structure has a problem in that the coil portion is poor in assembling property and is not suitable for mass production.

Therefore, in recent years, a structure using a low voltage side coil unit in which a punched copper plate is resin-molded in place of the winding of a copper wire, and a plurality of coil boards (printed coils) printed with a coil pattern are laminated and connected to each other. A structure using an integrated high-voltage coil unit and a structure using both of them have been developed.

[0005]

However, even with such a unit structure, the assemblability of the coil portion is not necessarily improved. Even when both the low-voltage side coil unit and the high-voltage side coil unit are used, the mutual attachment is not considered at all in the prior art, and since the units are simply stacked, the coil portions are treated as one block. I can't.

Moreover, the low-voltage coil unit in which the punched copper plate is resin-molded has a poor heat dissipation property and may deteriorate the insulation performance of the resin, and requires a large-scale manufacturing facility. Further, the high-voltage coil unit having a laminated structure lacks mass productivity in terms of a laminating process and a wire connecting process. Therefore, there is a drawback that each component constituting the coil portion is expensive and the manufacturing cost including assembly is high.

An object of the present invention is to provide a converter transformer having a structure in which coil component parts can be manufactured at low cost and which is easy to assemble and mass-produce. Another object of the present invention is to provide a converter transformer having good heat dissipation and a high degree of freedom in designing the number of coil turns.

[0008]

SUMMARY OF THE INVENTION The present invention comprises a core coupling body having a two-part structure forming a closed magnetic circuit, a low voltage side coil unit and a high voltage side coil unit arranged so as to surround the legs of the core. In the transformer, the low-voltage side coil unit includes an edgewise coil formed by winding a strip-shaped conductor so that its wide surface is perpendicular to the winding axis, and a tubular portion that fits into the foot of the core. An insulating base for fixing having a flange portion protruding from the tubular portion is provided, and the edgewise coil has a structure in which the edgewise coil is mounted on the flange portion in a state of surrounding the tubular portion, and the high voltage side coil unit and the insulating base are provided. The converter transformer is characterized in that and can be fitted to each other. When the number of turns is small, a flat coil having a one-turn structure in which a metal plate is punched can be used instead of the edgewise coil.

Further, the present invention is a transformer comprising a core coupling body having a two-divided structure forming a closed magnetic circuit, and a low voltage side coil unit and a high voltage side coil unit arranged so as to surround the legs of the core, The high-voltage side coil unit is formed by winding a twisted conductor wire formed by twisting a large number of magnet wires around an insulating bobbin having an annular portion that fits into the foot portion of the core and flange portions formed at both ends of the annular portion. A converter transformer having a structure in which a low voltage side coil unit and the insulating bobbin can be fitted to each other.

Further, the present invention is a transformer including a core coupling body having a two-divided structure forming a closed magnetic circuit, and a low voltage side coil unit and a high voltage side coil unit arranged so as to surround a foot portion of the core. The low-voltage side coil unit is fitted with an edgewise coil in which a wide conductor is wound such that its wide surface is perpendicular to the winding axis or a flat coil with a one-turn structure in which a metal plate is punched, and a foot of a core. A fixing insulating base having a mating tubular portion and a brim portion protruding from the tubular portion is provided, and the edgewise coil or the flat plate coil is mounted on the brim portion in a state of enclosing the tubular portion. The high-voltage side coil unit is an insulating bobbin that has a twisted conductor formed by twisting a large number of magnet wires and has an annular portion that fits into the middle leg and flange portions formed at both ends of the annular portion. None the winding structure, their insulating bobbin of the insulating base and the high voltage side coil unit of the low-voltage coil units are converter transformers that are enabled fit together.

The insulating base of the low-voltage side coil unit preferably has a structure in which a wall portion is provided so as to protrude on most of the outer peripheral edge of the flange portion, and the coil end portion is pulled out from the lacking portion of the wall portion. . Further, the insulating bobbin of the high-voltage side coil unit has a structure in which a wall portion is projectingly provided on the outer peripheral edge of one of the flange portions, and the wall portion of the insulating bobbin and the wall portion of the insulating base are fitted to each other, It is preferable that the annular portion of the insulating bobbin and the tubular portion of the insulating base are also fitted together.

For example, the coil unit on the low voltage side is almost U
The collar portion of the mold has an insulating base located in the center of the tubular portion,
The high voltage side coil unit has a structure in which coils are placed on both sides of the flange, and the flange portion of the insulating bobbin is substantially U-shaped, and the high voltage side coil unit is provided on both sides so as to sandwich the low voltage side coil unit. Deploy.

The core combination having a two-part structure is preferably
Two E-shaped cores in which the middle foot part and the outer foot parts on both sides are continuously integrated at the end plate part are combined so that the tip end surfaces of the foot parts abut against each other, and the coil is Placed around the foot

[0014]

1 is an exploded perspective view showing an embodiment of a converter transformer according to the present invention, and FIG. 2 is an assembled perspective view thereof. This converter transformer is composed of a core combination having a two-part structure, a low voltage side coil unit and a high voltage side coil unit. It should be noted that in FIGS. 1 and 2, in order to clearly show the bobbin structure of the high-voltage coil unit, the twisted conductor wire to be wound is omitted from the drawing.

The divided core combination is a structure in which two E-shaped cores 10 are combined. Both E-shaped cores 10 are ferrite cores of the same shape, and the central leg portion 12 of the central column and the outer leg portions 14 of the rectangular parallelepiped block shape on both sides are continuously integrated with a rectangular flat plate end plate portion 16. It has a shape.
The two E-shaped cores 10 are combined so that the front end surfaces of the middle foot portion 12 and the front end surfaces of the outer foot portions 14 collide with each other to form a closed magnetic circuit.

The low voltage side coil unit has two edgewise coils 20 and an insulating base 22 for fixing. The edgewise coil 20 is formed by winding a strip-shaped conductor such that its wide surface is perpendicular to the winding axis. It may be a band-shaped conductor wound with insulation coating, or may be a band-shaped conductor wound with insulation coating after being wound. The fixing insulating base 22 includes a cylindrical portion 24 that fits in the middle leg portion 12 of the E-shaped core 10, a U-shaped flange portion 26 that extends from the center of the outer peripheral surface of the cylindrical portion 24, The wall portion 2 protruding from most of the outer peripheral edges (U-shaped portions) of the upper and lower surfaces of the collar portion 26.
8 is a synthetic resin integrally molded product. The edgewise coil 20 is placed on the upper and lower surfaces of the collar portion 26 so as to surround the cylindrical portion 24 and is housed inside the wall portion 28.
The coil end portion is drawn out from the portion where the wall portion is absent (U-shaped opening portion).

As shown in FIG. 3, the high voltage side coil unit has a structure in which a twisted conductor 32 formed by twisting a large number of magnet wires 30 is wound around an insulating bobbin 34, and the two coils arranged vertically have the same shape. You can The magnet wire 30 is a thin (for example, 0.1 mmφ or less) metal wire whose surface is provided with an insulation coating, and is used by, for example, tens to hundreds of tens being twisted together. The insulation bobbin 34 is
U-shaped flange portions 38 formed at both ends of the annular portion 36 and the outer peripheral edge of one of the flange portions (U-shaped portion)
It is an integrally molded product made of a synthetic resin having a wall portion 40 protruding from.

The insulating bobbin 34 and the insulating base 22 have a wall portion 28 of the insulating base 22 fitted inside a wall portion 40 of the insulating bobbin 34, and an annular portion 36 of the insulating bobbin 34.
The cylindrical portion 24 of the insulating base 22 is designed to fit inside the.

The stranded conductor 32 is wound around the insulating bobbin 34 in advance a predetermined number of times. The edgewise coil 20 is placed on the collar portion 26 of the insulating base 22, and the insulating bobbin 34 is fitted therein. By performing this operation on both sides of the collar portion 26, the edgewise coils 20 are located on both sides of the single insulating base 22, and the insulating bobbins 34 around which the twisted conductors 32 are wound are fitted. In this way, the coil portions in which the high-voltage coil units are arranged on both sides of the low-voltage coil unit are sandwiched so that they can be assembled as a single unit. E above and below this coil
Fitting the mold core 10 and fastening member (not shown)
A converter transformer is obtained by coupling with.

In the present embodiment, the insulating base 22 is used as the center, and the edgewise coil 20 and the insulating bobbin 34 are attached to the insulating base 22.
Since the structure is assembled, the coil portion can be handled as a single unit, and the characteristic inspection can be easily performed. Further, since the stranded conductor 32 is used on the high-voltage side, the surface area can be increased, the heat dissipation can be improved, and the winding can be examined easily, which increases the degree of freedom in design. Further, by using the edgewise coil 20 on the low voltage side, the heat dissipation is improved, and by devising the shapes of the insulating base 22 and the insulating coil 34, the problem of complexity of assembly is solved.

In the above embodiment, the edgewise coil is used on the low voltage side. However, when the number of turns is small (one turn is sufficient), the edgewise coil is replaced by
As shown in FIG. 4, it is also possible to use a flat coil 42 having a one-turn structure in which a metal plate is punched out. Flat coil 42
Since it is sandwiched between the flange portion of the insulating base and the flange portion of the insulating bobbin and is surrounded by the wall portion, the insulating coating may be omitted, but of course, an insulating insulation treatment may be performed.

FIG. 5 is an explanatory view showing another embodiment of the converter transformer according to the present invention. 5A is a plane, B is
Indicates the vertical section. Further, FIG. 6 is an explanatory view seen from the left side in FIG. 5, and a part is drawn in a cross section.
Since the basic structure of this converter transformer is the same as that of the above-mentioned embodiment, mainly different parts will be described.

The two E-shaped cores 50 are different in shape from the E-shaped cores of the above-described embodiments, but similarly, the central columnar middle foot portion 52 and the outer foot portions 54 on both sides are end plate portions 56. It is a continuous, integrated shape. In order to avoid the coil portion to be housed, the outer foot portion 54 has a curved surface with an arcuate inside so as to be miniaturized, and the end plate portion 56 has a shape in which the width between both outer foot portions is narrowed (both outer foot portions). The portion between the legs and outside the middle leg does not work effectively as a magnetic path), thereby saving the core material and reducing the weight. However, such a shape is conventionally known.

The low voltage side coil unit has an edgewise coil 60 and an insulating base 62. Insulation base 62
In addition to the cylindrical portion 64, the collar portion 66 and the wall portion 68,
0 is an integrated structure. The flange portion 66 is substantially U-shaped and has a shape in which an arcuate portion and a rectangular portion are continuous and the rectangular portion extends outwardly for a long time. A terminal portion 70 is connected to the tip of the arc-shaped portion of the collar portion 66 via a connecting portion 72. Terminal part 7
0 is a structure in which three inverted L-shaped pin terminals 74 are arranged in parallel. The pin terminal 74 may be fixed by insert molding or may be press-fitted later.

The high voltage side coil unit has a structure in which a twisted conductor wire 82 formed by twisting a large number of magnet wires is wound around an insulating bobbin 84, and the basic structure is the same as that of the above embodiment. However, the flange portion 88 of the insulating bobbin 84 is substantially U-shaped and has a shape in which an arcuate portion and a rectangular portion are continuous and the rectangular portion is shortly projected outward. In order to avoid the connecting portion 72 of the insulating base 62, a part of the wall portion 90 is cut out. Twisted conductor 8 wrapped around the annular portion 86
Insulating tape 92 is wound around the outer circumference of the twisted conductor wire 82 to fix the wire 2. The end of the stranded conductor wire 82 is the terminal portion 7
0 pin terminal 74. This makes handling of the winding ends even easier.

The preferred embodiment of the present invention has been described above, but the present invention is not limited to such a structure and shape. The structure and shape of the insulating base, the insulating bobbin, or the core can be changed as appropriate. The core is EE type, EI type, UU type, U-type
It can also be configured with an I type or the like. The low-voltage side coil and the high-voltage side coil can be configured by one.

[0027]

As described above, according to the present invention, the insulating base for fixing is used, and the respective parts are incorporated to form the coil portion, so that the assembly is extremely easy. Further, the coil portion can be handled as a single body, and characteristic inspection and the like can be easily performed.

In the present invention, since the edgewise coil or the punched flat plate coil is used for the low voltage side coil unit, it can be manufactured at a lower cost than the conventional resin molded product, and the number of turns can be easily examined, and The heat dissipation is also good.

In the present invention, since the twisted conductor wire of the magnet wire is used for the high voltage side coil unit, the manufacturing cost can be reduced as compared with the conventional laminated substrate type, the number of turns can be easily changed, and the winding number is thin. Since it is an assembly of copper wires, the surface area is very large and the heat dissipation is good.

[Brief description of drawings]

FIG. 1 is an exploded perspective view showing an embodiment of a converter transformer according to the present invention.

FIG. 2 is an assembled perspective view thereof.

FIG. 3 is a cross-sectional view of a high voltage side coil unit.

FIG. 4 is a perspective view showing an example of a flat plate coil.

FIG. 5 is an explanatory view showing another embodiment of the converter transformer according to the present invention.

FIG. 6 is a partial cross-sectional view thereof.

[Explanation of symbols]

10 E type core 20 edgewise coil 22 Insulation base 32 stranded conductor 34 insulated bobbin

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Masami Nonaka             F-de, 5-36-1 Shimbashi, Minato-ku, Tokyo             K.K Co., Ltd. F-term (reference) 5E043 AB04                 5E044 BB02

Claims (8)

[Claims] 1. A transformer comprising a core coupling body having a two-divided structure forming a closed magnetic circuit, a low voltage side coil unit and a high voltage side coil unit arranged so as to surround the legs of the core, wherein a low voltage side coil is provided. The unit includes an edgewise coil formed by winding a strip-shaped conductor so that a wide surface thereof is perpendicular to a winding axis, a tubular portion fitted to a foot portion of a core, and an overhanging portion of the tubular portion. The edgewise coil has a structure in which the edgewise coil is mounted on the flange portion so as to surround the tubular portion, and the high voltage side coil unit and the insulating base can be fitted to each other. A converter transformer characterized in that 2. A transformer comprising a core coupling body having a two-part structure forming a closed magnetic circuit, a low-voltage side coil unit and a high-voltage side coil unit arranged so as to surround the legs of the core, wherein the low-voltage side coil The unit includes a flat coil having a one-turn structure in which a metal plate is punched out, a fixing insulating base having a tubular portion that fits into the foot portion of the core, and a flange portion that extends from the tubular portion, A converter transformer characterized in that the flat plate coil is mounted on a collar portion so as to surround a tubular portion, and the high voltage side coil unit and the insulating base can be fitted to each other. 3. A transformer comprising a core coupling body having a two-part structure forming a closed magnetic circuit, and a low-voltage side coil unit and a high-voltage side coil unit arranged so as to surround the legs of the core. The unit has a structure in which a twisted conductor wire formed by twisting a large number of magnet wires is wound around an insulating bobbin having an annular portion fitted to the foot portion of the core and flange portions formed at both ends of the tubular portion. None, A converter transformer characterized in that the low voltage side coil unit and the insulating bobbin can be fitted to each other. 4. The high voltage side coil unit comprises a twisted conductor wire formed by twisting a large number of magnet wires, an annular portion fitted to a leg portion of a core, and flange portions formed at both ends of the tubular portion. The converter transformer according to claim 1 or 2, wherein the converter transformer has a structure wound around an insulating bobbin, and the insulating base of the low voltage side coil unit and the insulating bobbin of the high voltage side coil unit can be fitted to each other. 5. The insulating base of the low voltage side coil unit is
The converter transformer according to any one of claims 1 to 4, wherein a wall portion is provided so as to project on most of the outer peripheral edge of the flange portion, and the coil end portion is pulled out from the lacking portion of the wall portion. 6. The insulating bobbin of the high voltage side coil unit comprises:
A structure is provided in which a wall portion is projected on the outer peripheral edge of one of the flange portions, the wall portion of the insulating bobbin and the wall portion of the insulating base are fitted to each other, and the annular portion of the insulating bobbin and the cylindrical shape of the insulating base are 6. The converter transformer according to claim 5, wherein the parts are also fitted to each other. 7. The low-voltage coil unit has a structure in which an approximately U-shaped collar portion has an insulating base located in the center of a tubular portion, and coils are placed on both sides of the collar portion. 7. The converter transformer according to claim 6, wherein the flange portion of the insulating bobbin is substantially U-shaped, and the high voltage side coil units are arranged on both sides so as to sandwich the low voltage side coil unit. 8. A core combination having a two-part structure has two E-shaped cores in which a central middle foot portion and outer foot portions on both sides are continuously integrated at an end plate portion, and the front end surfaces of the foot portions collide with each other. The converter transformer according to any one of claims 1 to 7, wherein the converter transformers are combined so as to match with each other, and the coil is arranged so as to surround the middle foot portion.