Converter module

Abstract

The present invention provides a converter module that can prevent the primary side coil from floating up and falling off, and further prevent the coil frame from being damaged due to the insertion of the primary side coil. The converter module of the present invention comprises: a converter (10), a resin coil frame (20) having a U-shaped primary side coil (30) passing through a primary side coil hole (40) opened through and wound with a secondary side coil (27), and an iron core (50) mounted on the coil frame; a housing (80) that accommodates the converter, wherein the primary side coil is a U-shaped pin having a pair of legs (32, 32) and a U-shaped bent portion (31) connecting the legs, and the housing is provided with a concave abutment portion (82) at a position opposite to the U-shaped bent portion of the primary side coil to inhibit the primary side coil from falling off.

Description

Technical Field

[0001] The present invention relates to a current transformer module for detecting current flowing in various AC devices in order to perform output control or overcurrent protection operations, and more particularly to a current transformer module using a U-shaped pin for a primary side coil. Background Art

[0002] In high-power electrical equipment such as air conditioners or IH equipment that operate with household power, a current transformer is used to detect current. The current transformer has a primary coil and a secondary coil, and an iron core that forms a common magnetic circuit in these coils (for example, refer to Patent Document 1). In the current transformer, a current detection resistor is connected to the secondary coil, an alternating current with a commercial frequency of the power supply of the equipment is energized to the primary coil, and the voltage generated by the current flowing through the secondary coil via the magnetic circuit due to the current change on the primary side is detected. The equipment takes this voltage into the microcomputer, controls the inverter circuit, etc., and performs input and output control of the equipment.

[0003] As in Patent Document 1, the primary side coil uses a so-called U-shaped pin in which a conducting wire is bent into a U shape.

[0004] Generally, in a current transformer, a U-shaped pin to be a primary coil is inserted into a primary coil hole formed in a coil frame made of resin, and then a secondary coil is wound to produce a core member. Then, a current transformer is produced by attaching a core to the core member, and a current transformer is produced by accommodating the current transformer in a resin housing.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent document 1: Japanese Utility Model Application Laid-Open No. 63-18824. Summary of the invention

[0008] Problems to be solved by the invention

[0009] When a U-shaped pin is used for the primary side coil, when the converter module is mounted on a printed wiring board or the like, the terminal portion at the tip of the U-shaped pin may be pressed by the printed wiring board, causing the primary side coil to float.

[0010] Furthermore, as described above, when inserting the U-shaped pin as the primary side coil into the coil bobbin, the U-shaped pin may be difficult to insert due to the bending accuracy of the U-shaped pin, and if it is inserted forcibly, the coil bobbin may be damaged.

[0011] Furthermore, for the coil frame module, the U-shaped pin as the primary side coil is first inserted into the coil frame, and then the secondary side coil is wound to manufacture the core component. In addition, in the later process, the core is installed in the core component and inserted into the housing to manufacture the converter module. However, the U-shaped pin may fall off during the period from the insertion of the U-shaped pin into the coil frame to the storage of the converter in the housing.

[0012] An object of the present invention is to provide a converter module capable of preventing a primary-side coil from floating up or falling off, and further capable of preventing a coil bobbin from being damaged due to insertion of the primary-side coil.

[0013] Solutions to Solve Problems

[0014] The converter module of the present invention comprises:

[0015] A converter comprising a resin bobbin on which a U-shaped primary coil passes through a primary coil hole formed through the coil and around which a secondary coil is wound, and an iron core mounted on the bobbin; and

[0016] a housing accommodating the converter,

[0017] in,

[0018] The primary coil is a U-shaped pin having a pair of legs and a U-shaped bent portion connecting the legs.

[0019] The housing may include a contact portion that is recessed at a position facing the U-shaped bent portion of the primary coil and that prevents the primary coil from falling off.

[0020] The housing is formed by an upper shell and a lower shell,

[0021] The abutment portion may be formed inside the upper surface of the upper housing.

[0022] Preferably, the front end of the leg portion of the primary coil passes through the primary coil hole of the coil bobbin, and a retaining portion larger than the primary coil hole is formed on the leg portion exposed through the primary coil hole.

[0023] Preferably, the primary coil hole is formed with a hole body having a diameter equal to or larger than that of the anti-detachment portion and a narrowed portion having a smaller diameter than that of the anti-detachment portion at a front end of the hole body.

[0024] The said anti-separation part can be formed by rolling the said leg part.

[0025] Effects of the Invention

[0026] In the converter module of the present invention, the U-shaped bent portion of the primary coil is suppressed by the abutment portion of the case. Therefore, when the leg portion of the primary coil is inserted into the printed wiring board, the primary coil abuts against the abutment portion and does not fall off the coil bobbin.

[0027] Furthermore, in the converter module of the present invention, the retaining portion is formed at the front end of the leg portion of the primary side coil, thereby preventing the primary side coil from falling out of the primary side coil hole of the coil bobbin.

[0028] Furthermore, with regard to the primary side coil hole of the coil frame, the diameter of the hole body is enlarged, and the diameter of the narrowed portion at the front end is made smaller than the anti-slip portion. Thus, when the leg of the primary side coil is inserted into the primary side coil hole, it is easy to insert into the primary side coil hole and difficult to pull out, and the coil frame can be prevented from being damaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a perspective view of a current transformer according to one embodiment of the present invention.

[0030] Figure 2 This is a perspective view showing the coil bobbin and the primary side coil in an exploded manner.

[0031] Figure 3 This is a diagram showing a cross section of the converter along the primary side coil.

[0032] Figure 4 It is along Figure 3 A cross-sectional view of the converter along line A-A.

[0033] Figure 5 1 and 2 are enlarged cross-sectional views of a primary coil hole of a coil bobbin and a leg portion of a primary coil, wherein (a) shows a state in which the primary coil is being inserted, and (b) shows a state in which the primary coil has been inserted into the primary coil hole.

[0034] Figure 6 This is an exploded perspective view of the converter module.

[0035] Figure 7 is a three-dimensional diagram of the converter module.

[0036] Figure 8 is a cross-sectional view of the converter module.

[0037] Fig. 9 It is a bottom view of the upper shell.

[0038] Fig.10 It is a top view of the lower shell. DETAILED DESCRIPTION

[0039] Hereinafter, a converter 10 and a converter module 12 according to an embodiment of the present invention will be described with reference to the drawings.

[0040] Figure 1 is a perspective view of a converter 10 according to an embodiment of the present invention. Figure 2 is an exploded perspective view of the converter 10, Figure 3 is a cross-sectional view along the primary side coil 30 of the converter 10, Figure 4 It is along Figure 3 As shown in the figure, the converter 10 is constructed by providing a U-shaped primary coil 30 and a secondary coil 27 formed by winding a thin wire on a coil frame 20 made of resin, and installing an iron core 50 that forms a common magnetic path for the primary coil 30 and the secondary coil 27.

[0041] <Coil bobbin 20>

[0042] The coil bobbin 20 has primary coil holes 40 and 40 (see in particular the primary coil holes 40 and 40) through which the primary coil 30 is inserted. Figure 3 ), and in the center of the coil frame 20, a secondary coil winding portion 26 around which the secondary coil 27 is wound is recessed (see in particular Figure 4 ).

[0043] In the illustrated embodiment, an upper insulating wall 22 and a lower insulating wall 24 are formed on the coil bobbin 20 between the primary coil hole 40 and the secondary coil winding portion 26 to insulate the primary coil 30 and the secondary coil 27. These insulating walls 22 and 24 ensure the creepage distance (the shortest distance measured along the surface of the insulator) of the insulation between the primary coil 30 and the secondary coil 27.

[0044] In addition, if Figure 1 to Figure 4 As shown in FIG. 1 , the coil frame 20 forms an upper concave portion 23 between the upper insulating wall 22 disposed between the primary coil 30 and the secondary coil 27 and the primary coil 30, so that the upper concave portion 23 and the upper convex portion 83 (see FIG. 1 ) formed on the upper shell 81 described later are connected. Figure 8 , Fig. 9 ) are engaged with the upper insulating wall 22 to ensure the insulation creepage distance.

[0045] Furthermore, if Figure 4 As shown, the coil frame 20 forms a lower concave portion 25 between the lower insulating wall 24 and the primary side coil 30, so that the lower concave portion 25 and the lower convex portion 87 (see Figure 6 , Figure 8 and Fig.10 ) are engaged with the lower insulating wall 24 to ensure the insulation creepage distance.

[0046] If the primary coil hole 40 of the coil frame 20 is further described in detail, the primary coil hole 40 is opened roughly vertically through the coil frame 20. The primary coil hole 40 is formed so that at least a portion thereof has a smaller diameter than the anti-detachment portion 33 of the leg 32 of the primary coil 30 described later. For the primary coil holes 40, 40, the diameter of the hole body 41 can be the same size from the base end side where the leg 32 is inserted to the front end side where the anti-detachment portion 33 passes through, but as Figure 3 or Figure 5 As shown, the primary side coil hole 40 may form a narrowing portion 42 having a smaller diameter than the anti-slip portion 33 at the front end of the hole body 41. By forming the narrowing portion 42, the diameter of the hole body 41 can be formed to be the same as or larger than the anti-slip portion 33, so that the leg 32 can be smoothly inserted into the hole body 41, and the coil skeleton 20 can be prevented from being damaged. In addition, the narrowing portion 42, for example, makes the connection portion with the hole body 41 into a tapered shape, thereby allowing the leg 32 or the anti-slip portion 33 of the primary side coil 30 to pass smoothly. In addition, by forming a taper at the base end of the hole body 41 (the side where the leg 32 is inserted), the primary side coil 30 can also be easily inserted.

[0047] In addition, if Figure 3 As shown, the coil bobbin 20 has a hollow portion 21 formed in a direction perpendicular to the primary coil 30 and the secondary coil 27 , and the core 50 can be mounted in the hollow portion 21 .

[0048] <Primary coil 30>

[0049] like Figure 1 to Figure 4 As shown, the primary coil 30 is a so-called U-shaped pin formed by bending a conductive wire, and has a pair of legs 32, 32 and a U-shaped bent portion 31 connecting the legs 32, 32. On the primary coil 30, a wire diameter thickening anti-dropping portion 33 is formed on one or both of the legs 32, 32.

[0050] like Figure 2 to Figure 5 As shown, the U-shaped primary side coil 30 has anti-detachment parts 33, 33 formed on the legs 32, 32. The anti-detachment part 33 can be made by rolling the conductive wire using, for example, riveting. The anti-detachment part 33 can be formed at a position exposed from the front end of the primary side coil hole 40 when the leg 32 is inserted into the primary side coil hole 40 of the coil skeleton 20 and the primary side coil 30 is installed on the coil skeleton 20. Preferably, the diameter of the anti-detachment part 33 is formed to have an outer diameter larger than the hole body 41 and the narrowed part 42 of the primary side coil hole 40 mentioned above.

[0051] When the inverter module 12 is formed, the distal ends of the leg portions 32 , 32 of the primary side coil 30 become terminal wires 30 a , 30 a extending from an insertion hole 86 a of a lower case 85 to be described later.

[0052] As a specific size of the primary side coil 30, the primary side coil 30 can adopt a coil with a diameter of 1.0 mm to 2.0 mm. The diameter of the anti-slip portion 33 of the leg 32 is preferably formed to be larger than the diameter of the wire by more than 0.05 mm, and more preferably formed to be larger than the diameter of the wire by about 0.08 mm. On the other hand, if the anti-slip portion 33 is much thicker than the diameter of the wire, the anti-slip portion 33 cannot be inserted into the primary side coil hole 40, or, even if it is inserted, because the portion other than the anti-slip portion 33 is relatively thinner than the anti-slip portion 33, it cannot be properly fixed to the primary side coil hole 40, and sometimes the primary side coil 30 shakes. Therefore, the anti-slip portion 33 is preferably formed to be larger than the diameter of the primary side coil 30 by about 0.13 mm at most.

[0053] Furthermore, when the primary coil 30 is used, when the primary coil hole 40 formed in the coil bobbin 20 is the same hole body 41, the diameter is preferably formed to be the same as the anti-detachment portion 33, or the same as the diameter of the primary coil 30, or about 0.02 mm larger than the diameter of the primary coil 30. On the other hand, when the narrowing portion 42 is formed on the hole body 41, the diameter of the narrowing portion 42 is preferably the same as the anti-detachment portion 33, or about 0.05 mm to 0.1 mm smaller than the anti-detachment portion 33.

[0054] <Secondary coil 27>

[0055] like Figure 4 As shown, the secondary coil 27 is formed by winding a thin wire around the secondary coil winding portion 26 of the coil frame 20. Figure 1 As shown in FIG. 1 , the outer periphery is protected by tape 28. The electrical end edges of the secondary coil 27 are terminal wires 27a, 27a, and extend from insertion holes 86a, 86b of a lower case 85 described later.

[0056] <Iron core 50>

[0057] The iron core 50 is installed so as to straddle the side and hollow portion 21 of the coil frame 20 (see Figure 3 ) of electromagnetic steel sheet. The iron core 50 is integrated by alternately inserting, for example, an iron core component of a stacked E-type iron core obtained by stamping silicon steel sheets, or an iron core component of a stacked E-type iron core and an I-type iron core from both sides of the hollow portion 21, so that it can be installed on the coil frame 20. In addition, the structure or installation method of the iron core 50 is not limited to the illustrated embodiment.

[0058] <Converter 10>

[0059] Moreover, if Figure 2 to Figure 5 In more detail, as shown Figure 5As shown by arrow B in (a), the primary coil 30 is inserted into the primary coil hole 40 of the coil frame 20. Since the primary coil hole 40 can be configured so that the diameter of the hole body 41 is larger than the outer diameter of the leg 32, the coil frame 20 can be prevented from being damaged when the leg 32 is inserted into the hole body 41. Figure 5 As shown in (b), the leg portions 32 and 32 pass through the primary coil hole 40, and the retaining portion 33 passes over the narrowed portion 42 to be exposed. Thus, the retaining portion 33 serves as a retaining member relative to the narrowed portion 42, and the primary coil 30 can be fixed relative to the primary coil hole 40 so as not to move backward.

[0060] In addition, because the anti-detachment portion 33 passes over the narrowing portion 42 and passes through the primary side coil hole 40, the anti-detachment portion 33 will not cause stress to remain in the primary side coil hole 40, that is, the hole body 41 or the narrowing portion 42, or even the coil frame 20, and can also prevent the coil frame 20 from being damaged when or after the primary side coil 30 is inserted.

[0061] After the primary side coil 30 is inserted, the secondary side coil 27 is wound on the secondary side coil winding portion 26 of the coil frame 20, and the iron core 50 is installed on the coil frame 20, thereby manufacturing the converter 10. Of course, the installation order of the primary side coil 30, the secondary side coil 27, and the iron core 50 is not limited to this. In the present invention, because the primary side coil 30 can be installed on the coil frame 20 in a manner that cannot fall off using the anti-falloff portion 33, even if various operations are performed in a state where the primary side coil 30 is pre-installed, the primary side coil 30 will not fall off from the coil frame 20, and the manufacturing operation of the converter 10 can be made as efficient as possible.

[0062] <Converter module 12>

[0063] The inverter 10 obtained as described above can be housed in the casing 80 and used as the inverter module 12 . Figure 6 is an exploded perspective view of the converter 10 and the housing 80 housing the converter. Figure 7 is a three-dimensional diagram of the converter module 12, Figure 8 is a longitudinal section view. Fig. 9 is a bottom view of the upper shell 81 constituting the housing 80, Fig.10 It is a top view of the lower shell 85.

[0064] As shown in the figure, the housing 80 is formed of an upper case 81 and a lower case 85. The upper case 81 is a frame-shaped body with an open lower surface for accommodating the core 50 and the coil bobbin 20, and the lower case 85 can be a plate-shaped body for placing the coil bobbin 20 and closing the lower surface of the upper case 81.

[0065] like Figure 8 and Fig. 9As shown, the upper shell 81 has an abutment portion 82 formed on the inner side of the upper surface against which the U-shaped bent portion 31 of the primary side coil 30 abuts when the converter 10 is accommodated. The abutment portion 82 can be formed into a concave shape along the outer shape of the primary side coil 30. When the converter module 12 is installed on a printed wiring board, etc., even if the terminal wires 30a, 30a of the primary side coil 30 are pressed by the printed wiring board, the abutment portion 82 can prevent the primary side coil 30 from floating from the coil frame 20. This can complement the effect of the anti-detachment portion 33 formed on the primary side coil 30 to exert a more excellent effect.

[0066] In addition, the upper case 81 is provided with an upper convex portion 83 that fits into the upper concave portion 23 formed between the upper insulating wall 22 and the primary coil 30 .

[0067] Furthermore, if Figure 6 and Figure 7 As shown, an engaged portion 81 a into which the engaging claw 85 a of the lower case 85 fits can be formed near the lower edge of the upper case 81 .

[0068] like Figure 6 and Fig.10 As shown, the lower case 85 has insertion holes 86a and 86b through which the terminal wires 30a and 30a at the ends of the legs 32 and 32 of the primary coil 30 and the terminal wires 27a and 27a of the secondary coil 27 extend, respectively.

[0069] In addition, the lower case 85 is provided with a lower convex portion 87 that fits into the lower concave portion 25 provided between the lower insulating wall 24 of the bobbin 20 and the primary coil 30 .

[0070] Furthermore, the lower case 85 may be provided with an engaging claw 85 a that fits with the engaged portion 81 a of the upper case 81 .

[0071] Then, the inverter 10 is installed on the lower case 85 by inserting the terminal wires 30a and 27a into the insertion holes 86a and 86b. Figure 8 As shown, the lower protrusion 87 of the lower case 85 is fitted into the lower recess 25 of the coil bobbin 20 .

[0072] Next, with the converter 10 disposed on the lower case 85, the upper case 81 is covered. The engaged portion 81a of the upper case 81 is engaged with the engaging claw 85a of the lower case 85 and engaged with the lower case 85 to form the housing 80. At this time, the upper case 81 is covered on the converter module 12, and the upper convex portion 83 of the upper case 81 is engaged with the upper concave portion 23 of the coil frame 20.

[0073] Through the above, the converter module 12 in which the converter 10 is housed in the housing 80 can be obtained. Figure 7 The resulting converter module 12 is shown in FIG.

[0074] When the converter module 12 is mounted on a printed wiring board or the like, the contact portion 82 formed on the upper shell 81 contacts the U-shaped bent portion 31 of the primary side coil 30 , so that the primary side coil 30 can be prevented from floating even if the terminal wires 30a, 30a of the primary side coil 30 are pressed by the printed wiring board.

[0075] As for the converter module 12 of the present invention, Figure 8 As shown, on the upper surface side of the converter 10, an upper insulating wall 22 is provided on the coil frame 20, and then the upper concave portion 23 of the coil frame 20 and the upper convex portion 83 of the upper shell 81 are engaged, thereby ensuring the creepage distance of insulation. In addition, as for the converter 10, a lower insulating wall 24 is also provided on the lower surface side of the coil frame 20, and then the lower concave portion 25 of the coil frame 20 and the lower convex portion 87 of the lower shell 85 are engaged, thereby ensuring the creepage distance of insulation. In this way, the insulation of the primary side coil 30 and the secondary side coil 27 can be ensured.

[0076] In addition, there is a demand for miniaturization of the converter module 12. In order to achieve miniaturization of the converter module 12, miniaturization of the converter 10 is required. On the other hand, in the converter 10, as described above, insulation of the primary coil 30 and the secondary coil 27 is required, but in the present invention, as described above, the upper insulating wall 22, the upper recess 23, and the upper convex portion 83, the lower insulating wall 24, the lower recess 25, and the lower convex portion 87 are used to ensure the creepage distance of insulation. Therefore, it is possible to appropriately achieve insulation without increasing the protruding height of the upper insulating wall 22 and the lower insulating wall 24, and it is also possible to achieve miniaturization of the converter 10 and the converter module 12.

[0077] The above description is for explaining the present invention and should not be understood as limiting or narrowing the scope of the invention described in the claims. In addition, the various structures of the present invention are not limited to the above embodiments, and it is self-evident that various changes can be made within the scope of the claims.

[0078] For example, it is ideal to provide a step portion 88 on the lower shell 85 to support the lower surface of the coil frame 20, so that when the coil frame 20 abuts against the lower shell 85, the lower surface of the coil frame 20 abuts against the step portion 88, thereby maintaining the coil frame 20 in the shell 80 without tilting.

[0079] In addition, after the converter module 12 is manufactured, the output voltage characteristics can be measured respectively, such as Figure 7The obtained characteristic data is printed or attached to the upper housing 81 as a data matrix 89 as shown. Therefore, when the converter module 12 is applied to an AC device, the data matrix 89 can be read and the characteristic adjustment can be performed in the control based on the corresponding characteristic data. Thus, a more accurate output voltage characteristic can be achieved. Example

[0080] The U-shaped pin of the primary coil 30 is made by bending the conductive wire, and the outer diameter of the anti-detachment portion 33 is changed in various ways and inserted into the primary coil hole 40 of the coil frame 20. The degree of fixation of the primary coil 30 is measured and compared based on the pull-out strength.

[0081] The primary side coil 30 is formed by bending a solder-plated copper wire having a diameter of 1.6 mm into a U shape. Figure 5 As shown in (b), the two legs 32, 32 are subjected to rolling processing so that the outer diameter of the anti-slip portion 33 is 1.63mm to 1.75mm and the length is 2.0mm as shown in Table 1 (Examples 1 to 7). The primary side coil hole 40 is penetrated and opened in the coil skeleton 20 made of phenolic resin in such a way that the diameter of the hole body 41 is 1.8mm, the diameter of the narrowed portion 42 is 1.63mm, and the hole depth is 5mm. The primary side coil hole 40 is tapered from the hole body 41 toward the narrowed portion 42 to narrow the hole diameter. In addition, Figure 5 Only one leg portion 32 and one primary-side coil hole 40 are shown in the figure, but the two leg portions 32 and 32 of the primary-side coil 30 are provided with the anti-detachment portion 33 , and the primary-side coil hole 40 is also a pair.

[0082] Furthermore, the push-through strength of the primary side coil 30 when the legs 32, 32 of the primary side coil 30 are inserted into the primary side coil holes 40, 40 and the pull-out strength when the primary side coil 30 is pulled out from the primary side coil hole 40 are measured to determine the degree of fixation. The results are shown in Table 1. In addition, with regard to the determination of the degree of fixation, the state in which the primary side coil 30 does not detach from the coil bobbin 20 even if the coil bobbin 20 on which the primary side coil 30 is mounted is rotated by hand and the coil bobbin 20 is rotated at 12000 rpm for 20 seconds in order to wind the secondary side coil 27 is set as "OK", and the state in which the primary side coil 30 detaches from the coil bobbin 20 is set as "NG".

[0083] Table 1

[0084] Anti-drop diameter (mm) Push-through strength (each) Pull-out strength (each) Determination of the degree of fixation Example 1 1.63 0N 0N NG Example 2 1.65 0N 0N NG Example 3 1.68 13N 11N OK Example 4 1.70 19N 15N OK Example 5 1.72 38N 38N OK Example 6 1.73 50N 42N OK Example 7 1.75 60N === Cannot determine

[0085] Referring to Table 1, the push-through strength of Examples 1 and 2 is 0 N, and the pull-out strength is also 0 N. That is, the leg portion 32 fits into the primary coil hole 40, but the anti-detachment portion 33 passes through the narrowed portion 42 without hindrance. Moreover, the fixing degree is also judged as NG.

[0086] The push-through strength of Examples 3 to 6 is 13N to 50N (per strand), and the pull-out strength is also 11N to 42N (per strand). As for the push-through strength, as shown in Example 7, the coil frame 20 is damaged at about 60N, but if it is 50N or less, the legs 32, 32 do not bend, and the coil frame 20 does not break. Therefore, in Examples 3 to 6, there is no particular problem when the primary side coil 30 is mounted on the coil frame 20.

[0087] Regarding the pull-out strength, usually, even if the coil frame 20 on which the primary side coil 30 is mounted is rotated by hand, and even if the coil frame 20 is rotated at 12000 rpm for 20 seconds in order to wind the secondary side coil 27, the primary side coil 30 does not fall off from the coil frame 20, and the force applied to the converter module 12 when the converter module 12 is installed on the printed wiring board is only about 10N (per strand) at most. That is, the pull-out strength is required to be ensured to be above 10N. Because the pull-out strength in Examples 3 to 6 exceeds 10N, the primary side coil 30 does not fall off from the coil frame 20 even if the secondary side coil 27 is wound, and even if the converter module 12 is installed on the printed wiring board, the primary side coil 30 does not fall off. Therefore, the fixation degree is also judged as OK. This is the effect of forming the anti-detachment portion 33 on the legs 32, 32.

[0088] On the other hand, in Example 7 in which the outer diameter of the anti-detachment portion 33 is 1.75 mm, a force of 60 N (per leg) is required to insert the legs 32, 32 into the primary side coil holes 40, 40, and the coil bobbin 20 is damaged when pushed in. Therefore, the pull-out strength was not measured, and since the degree of fixation could not be determined, it could not be determined.

[0089] As described above, when the diameter of the narrowed portion 42 is 1.63 mm, by adjusting the outer diameter of the retaining portion 33 to 1.68 mm to 1.73 mm, the primary coil 30 can be properly fixed to the coil bobbin 20 and damage to the coil bobbin 20 can be prevented.

[0090] Explanation of symbols

[0091] 10 Converter

[0092] 12 Converter module

[0093] 20 Coil skeleton

[0094] 30 Primary coil

[0095] 32 Legs

[0096] 33 Anti-slip part

[0097] 40 Primary coil hole

[0098] 41 hole body

[0099] 42 Constriction

[0100] 50 Iron Core

[0101] 80 Shell

[0102] 82 Butt.

Claims

1. A method for manufacturing a converter module, the converter module comprising: A converter including a coil bobbin made of resin and an iron core attached to the coil bobbin, wherein the coil bobbin has a primary coil hole through which a U-shaped primary coil passes and around which a secondary coil is wound; and a housing accommodating the converter, The primary side coil is a U-shaped pin having a pair of legs and a U-shaped bent portion connecting the legs. The housing is formed by an upper shell and a lower shell, wherein an abutment portion for preventing the primary side coil from falling off is concavely provided on the inner side of the upper surface of the upper shell, and the lower shell has an insertion hole through which the front end of the leg portion of the primary side coil is inserted. in, The manufacturing method comprises the following steps: Inserting the leg of the primary side coil from the front end into the primary side coil hole of the coil frame so that the front end of the leg is exposed from the coil frame and the primary side coil is mounted on the coil frame, and the secondary side coil is wound on the coil frame, thereby obtaining the converter; a step of mounting the converter on the lower housing, that is, a step of inserting the front end of the primary coil through the insertion hole of the lower housing so that the front end protrudes from the lower housing; The step of engaging the upper case with the lower case is a step of covering the converter with the upper case so that the U-shaped bent portion of the primary coil faces the contact portion of the upper case.

2. The method for manufacturing a converter module according to claim 1, wherein: The method comprises the step of forming a disengagement prevention portion on the leg portion which is larger than the primary side coil hole before mounting the primary side coil on the coil frame. In the step of obtaining the inverter, the retaining portion is exposed from the lower case beyond the primary-side coil hole.

3. The method for manufacturing a converter module according to claim 2, wherein: The primary coil hole is formed with a hole body having a diameter equal to or larger than that of the anti-detachment portion and a narrowing portion having a smaller diameter than that of the anti-detachment portion at the front end of the hole body. In the step of obtaining the inverter, the anti-detachment portion is exposed from the lower case beyond the narrowed portion.

4. The method for manufacturing a converter module according to claim 3, wherein: The anti-detachment portion is formed by flattening the leg portion before the primary side coil is mounted on the coil bobbin.

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