JPH04129206A - Thin type transformer - Google Patents

Abstract

PURPOSE:To enable constitution of thin type transformer by comprising a primary coil formed by folding at each couple with an insulating sheet interposed between half-turn coils and a secondary coil piled up together with the primary coil and by coating them with a thermoset resin 3 having a magnetic powder. CONSTITUTION:Many U-shaped half-turn coils 5 are cut out of a strip of sheet semiconductor 4, and many reverse half-turn coils 5 are alternately coupled via couplers 6 to constitute a strip of conductor 7, which is in turn folded at each coupler 6 with an insulating sheet 8 between half-turn coils 5 and 5. A turn of coil is formed in the periphery of a rectangular opening 9 by two adjacent half-turn coils 5 and 5, thereby forming a coil of a given number of turns. Semihardened epoxy resin is mixed with a power of iron-based alloy: this mixture is compression-molded to cover the piled-up primary and secondary coils 1, 2, then hardens by heat.

Description

[Detailed Description of the Invention] [Object of the Invention] (Industrial Application Field) The present invention provides a thin transformer using a thermosetting resin containing magnetic powder as an iron core and a sheet-like conductor as a coil. Regarding.

(Prior Art) A non-oriented silicon steel plate or a grain-oriented silicon steel plate is generally used as an iron core of a transformer.

When these silicon steel plates are used, the iron core is formed by cutting them into rectangular or frame-shaped pieces and stacking them in butt joints or lap joints. In the case of small capacity transformers, a wound core made of a band-shaped silicon steel plate is also used.

On the other hand, transformer coils are generally made by winding a rectangular conductor or round wire conductor into a cylindrical or rectangular shape, a disk-shaped coil, or a sheet-like conductor wound into a cylindrical shape. It will be done. In many cases, a concentric arrangement structure in which the low voltage coil is placed on the inside and the high voltage coil is placed on the outside is common.

(Issues to be solved by the invention l!i) In a conventional iron core structure in which silicon steel plates are stacked, extreme changes in shape cannot be made due to the flow of leakage magnetic flux at the joints. Furthermore, in the case of using a wound core, the shape of each turn is the same, and the shape cannot be changed in the middle of one turn. As described above, in the conventional iron core structure, the degree of freedom in the shape of the iron core is extremely small. - On the other hand, the coil has a cylindrical or rectangular tube shape, and it has been difficult to sufficiently reduce the dimension in the height direction. Therefore, with the conventional structure, it has been difficult to make the transformer sufficiently thin.

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a thin transformer whose height can be reduced and the transformer can be made thinner.

[Structure of the Invention] (Means for Solving the Problem) The present invention alternately connects a large number of half-turn coil parts made of a sheet-like conductor and half-turn coil parts in the opposite direction through connecting parts. a primary coil formed by folding a strip-shaped conductor configured by folding the conductor at each connecting portion with an insulating sheet interposed between each of the half-turn coil portions; and a primary coil formed in the same manner as this primary coil and stacked with the primary coil. The stacked primary and secondary coils are covered with a thermosetting resin containing magnetic powder.

(Function) According to the above-described means, by using a thermosetting resin containing magnetic powder as the iron core, the degree of freedom in the shape of the iron core increases and the height of the iron core can be reduced. Further, by using sheet-like conductors for both the primary coil and the secondary coil, the height of the coil can be reduced.

As a result, a thin transformer with a reduced overall height can be constructed.

(Example) An example of the present invention will be described below with reference to the drawings.

FIG. 1 shows a cross-sectional view of a transformer formed according to the present invention, and this transformer includes a primary coil 1 and a secondary coil 2 formed as coils as described later, and a magnetic material as an iron core. The thermosetting resin 3 has a powder of .

First, as for the coil, as shown in FIG. 2, a large number of U-shaped half-turn coil parts 5 are cut from the strip-shaped sheet-like conductor 4, and as shown in FIG. A strip conductor 7 is constructed by alternately connecting a large number of portions 5 and half-turn coil portions 5 in opposite directions via connecting portions 6. Then, as shown in FIG. 4, this strip-shaped conductor 7 is folded at each connecting portion 6 with an insulating sheet 8 interposed between each half-turn coil portion 5.5. When folded in this manner, a one-turn coil is formed around the rectangular opening 9 by the two adjacent half-turn coil parts 5.5, as shown in FIG. By continuously forming one turn of the coil, a coil having a predetermined number of turns is formed. In this way, the primary coil 1 and the secondary coil 2 are formed together and stacked alternately as shown in FIG. Incidentally, in order to obtain a predetermined impedance, the number of turns of the primary coil 1 and the secondary coil 2 is appropriately set.

On the other hand, the thermosetting resin j113 having magnetic powder constituting the iron core is formed as follows. In this case, an iron-based alloy is used as the magnetic material, and an epoxy resin is used as the thermosetting resin. First, iron-based alloy powder is mixed with semi-hardened epoxy resin, and this mixture is pressure-molded to cover the primary and secondary coils 1.2 stacked as shown in FIG. Thereafter, the epoxy resin is formed by heating and curing. The thermosetting resin 3 thus configured covers the primary and secondary coils 1.2 from the outside, and is also filled in the central opening 9 of the primary and secondary coils 1.2. .

[Effects of the Invention] As explained above, according to the present invention, a thermosetting resin containing magnetic powder is used as the iron core, and a sheet-like conductor is used as the coil for both the primary coil and the secondary coil. This makes it possible to reduce the overall height of the transformer, thereby making it possible to construct an extremely thin transformer. By making it possible to make the transformer thinner, it becomes possible to store the transformer on the floor of a building or embed it in the wall, eliminating the need to secure special space for installing the transformer. There is also an advantage that the heat generated by the transformer can be used for heating purposes.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, in which Fig. 1 is a cross-sectional view of the whole, Fig. 2 is a plan view of a half-turn coil section cut from a sheet-like conductor, and Fig. 3 is a diagram showing a large number of half-turn coil sections. FIG. 4 is a plan view of the connected strip conductors, FIG. 4 is a side view of the strip conductors in a folded state, and FIG. 5 is a plan view of the strip conductors in a folded state. In the drawings, 1 is a primary coil, 2 is a secondary coil, 3 is a thermosetting resin containing magnetic powder, 4 is a sheet-shaped conductor, 5 is a half-turn coil part, 6 is a connecting part, 7 is a strip-shaped conductor, 8 indicates an insulating sheet. Agent Patent Attorney Tsuyoshi Sato

Claims (1)

[Claims] 1. A band-shaped conductor is constructed by alternately connecting a number of half-turn coil parts made of a sheet-shaped conductor and half-turn coil parts in the opposite direction through connecting parts, and an insulating sheet is placed between each of the half-turn coil parts. A primary coil formed by folding at each connecting portion while being interposed, and a secondary coil formed in the same manner as this primary coil and stacked with the primary coil, and these stacked primary and secondary coils, A thin transformer characterized by being covered with a thermosetting resin containing magnetic powder.