Coil component and method for assembling coil component

Abstract

The present invention is easy to adjust to a desired leakage inductance value, and prevents a coil winding region from being narrowed. The present invention is provided with: first and second magnetic cores (not shown) which are combined by inserting middle leg sections into hollow sections (42C) of a bobbin (4) such that the front end sections of three leg sections face each other; and an annular third magnetic core (3) that is attached to the outer peripheral surface of the reel section (21) of the bobbin (4) in a divided manner in the circumferential direction so as to generate a desired leakage inductance value in accordance with the positional relationship with the two magnetic cores. The third magnetic core (3) is attached to the spool portion (21) by engaging a plurality of first engaging portions (64) arranged in the circumferential direction of the outer circumferential surface of the spool portion (21) with second engaging portions (65) arranged in the circumferential direction so as to correspond to the first engaging portions (64) on the inner circumferential surface of the third magnetic core (3) (only one magnetic core portion (3A)).

Description

Technical Field

[0001] This invention relates to coil components such as magnetically coupled inductors and transformers mounted on electronic circuits in various devices, as well as methods for assembling these coil components. Background Technology

[0002] In coil components, such as magnetically coupled inductors, ripple is reduced by having the two built-in inductors operate in an interleave manner, and DC superposition characteristics are improved by canceling the DC magnetic flux generated in the core. As a result, it is possible to reduce the size and efficiency of coupled inductors and miniaturize capacitors.

[0003] In such magnetically coupled inductors, as a structure that makes it easy to adjust the leakage inductor, the structure described in Patent Document 1 is known.

[0004] The magnetically coupled inductor shown in Patent Document 1 below is, for example, Figure 12 As shown, a pair of magnetic cores 101, 102 having a middle leg portion and a side wall portion, a winding tube 104 for inserting the middle legs of these magnetic cores 101, 102 and being disposed on the outside, and coil windings 106A, 106B (106B not shown) wound around the winding tube 104 and magnetically coupled to each other. Figure 12 The diagram shows the case where the coil winding 106B is removed, exposing the spool portion 121, which is part of the winding tube 104. Between the coil winding 106B and the spool portion 121, there is a ring core (third magnetic core) 103 for adjusting leakage inductance, and a spacer 175 for insulating the coil windings 106A, 106B from the ring core 103 and for positioning the ring core 103.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: International Publication No. WO2023 / 188026A1 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] However, in the prior art described above, as mentioned above, a spacer is sandwiched between the magnetic core and the ring core. As this spacer is made of a material with low magnetic permeability such as plastic, the magnetic resistance becomes high, which is the main reason for the reduction of leakage inductance.

[0010] Therefore, in order to maintain a higher leakage inductance, the width of the core needs to be increased. Correspondingly, the winding area of ​​the coil becomes narrower, thus reducing the number of coil windings or the diameter of the coil wires, which leads to a decrease in the performance of the magnetically coupled inductor.

[0011] It should be noted that leakage inductance control is also required in coil components such as transformers, presenting the same challenge.

[0012] The present invention was made in view of the above circumstances, and its object is to provide a coil component and a method for assembling the coil component that can be easily adjusted to a leakage inductance value corresponding to the condition and that can ensure the performance of a magnetically coupled inductor by preventing the miniaturization of the winding area of ​​the coil.

[0013] Methods for solving problems

[0014] To achieve this objective, the coil component of the present invention is characterized by comprising:

[0015] The first magnetic core and the second magnetic core each have a middle leg portion, outer legs portions located on both sides of the middle leg portion, and a back portion connecting the middle leg portion and the outer legs portion, and are arranged such that the front ends of the middle leg portions face each other and the front ends of the corresponding outer legs portion face each other.

[0016] A winding tube, through which the middle legs of the first and second magnetic cores pass, and disposed on the outer periphery of the middle legs of the two magnetic cores;

[0017] A third, annular magnetic core, circumferentially segmented along the spool portion of the winding tube through which the middle leg passes; and

[0018] A first coil winding wound on one side of the spool portion divided by the third magnetic core, and a second coil winding wound on the other side.

[0019] The third magnetic core is assembled circumferentially on the outer peripheral surface of the spool portion of the winding tube, with predetermined elements set according to its positional relationship with the first and second magnetic cores in order to generate the desired leakage inductance value.

[0020] The installation of the third magnetic core onto the spool portion is performed by engaging a plurality of first engaging portions arranged circumferentially along the outer peripheral surface of the spool portion and a second engaging portion arranged circumferentially along the inner peripheral surface of the third magnetic core in a manner corresponding to the first engaging portions.

[0021] Based on the above-mentioned coil components, it is preferable that the wires of the first coil winding and the second coil winding are insulated wires.

[0022] Preferably, the wires of the first coil winding and the second coil winding are insulated wires made by covering the outer periphery of the stranded wire with insulating tape.

[0023] Alternatively, preferably, the specified element associated with the third magnetic core, set in a manner that produces the desired leakage inductance value, is the thickness of the third magnetic core.

[0024] Alternatively, preferably, the specified element associated with the third magnetic core, set in a manner that produces the desired leakage inductance value, is the outer diameter of the third magnetic core.

[0025] Furthermore, preferably, the specified element associated with the third magnetic core, set in a manner that produces the desired leakage inductance value, is the magnetic saturation characteristic of the material of the third magnetic core.

[0026] Furthermore, preferably, at least one second engaging portion is provided for each core member of the third magnetic core that is divided along the circumferential direction, in a manner corresponding to a plurality of first engaging portions arranged circumferentially along the outer peripheral surface of the spool portion.

[0027] Alternatively, the first engaging portion may be a protrusion formed on the outer peripheral surface of the spool portion, and the second engaging portion may be a recess formed on the inner peripheral surface of the third magnetic core that engages with the first engaging portion.

[0028] Furthermore, the assembly method of the coil component of the present invention is characterized in that,

[0029] The second process is carried out after the first process.

[0030] In the first process,

[0031] The front ends of the middle legs and the corresponding front ends of the outer legs are arranged to face each other, with the middle legs having a middle leg portion, outer legs located on both sides of the middle leg portion, and a first magnetic core and a second magnetic core connecting the middle leg portion and the outer legs to the back portion.

[0032] The middle legs of the first magnetic core and the second magnetic core are inserted through the hollow part of the winding tube.

[0033] A third magnetic core, circumferentially segmented, is mounted on the spool portion surrounding the hollow portion through which the middle leg of the winding tube passes.

[0034] In the second process,

[0035] The first coil winding is wound in one region of the spool portion, which is axially divided by the third magnetic core, and the second coil winding is wound in the other region.

[0036] In the first step, the installation of the third magnetic core relative to the spool portion of the winding tube is performed by engaging a second engaging portion provided on the inner circumferential surface of the third magnetic core with a first engaging portion provided on the outer circumferential surface of the spool portion of the winding tube, in a state where predetermined elements are set according to the positional relationship with the first magnetic core and the second magnetic core in order to generate the desired leakage inductance value.

[0037] Invention Effects

[0038] In the coil component and coil component assembly method of the present invention, the spacer used in the past is not used. Instead, the second engaging part provided on the inner peripheral surface of the third magnetic core engages with the first engaging part provided on the outer peripheral surface of the winding tube to position the annular (ring-shaped) third magnetic core. By eliminating the spacer, the magnetic coupling between the first and second magnetic cores and the ring core which is the third magnetic core is improved. A ring core with a smaller width can be used. Therefore, the miniaturization of the coil winding area can be avoided, and the performance of the coil component can be improved.

[0039] In addition, since there is no need to assemble spacers, the number of parts can be reduced, as well as the labor and time required for assembly.

[0040] It should be noted that the coil component and the assembly method of the coil component of the present invention can realize the adjustment of the leakage inductance value in the transformer. Therefore, it is useful not only for magnetically coupled inductors, but also for coil components such as transformers. Attached Figure Description

[0041] Figure 1A This is a perspective view showing the main parts of the coil component according to an embodiment of the present invention.

[0042] Figure 1B This is a perspective view showing the magnetic core portion (first magnetic core, second magnetic core, and third magnetic core) of the coil component according to an embodiment of the present invention.

[0043] Figure 2 It shows from Figure 1A The diagram shown is a three-dimensional view of the coil component with one side of the coil winding removed.

[0044] Figure 3 It shows from Figure 1A The diagram shown is a perspective view of the coil assembly with the coil windings of both sides, the first magnetic core, the second magnetic core, and the third magnetic core of one side removed.

[0045] Figure 4 It is shown Figure 1A A schematic diagram of the third magnetic core (A) of the coil component and one of the third magnetic core components (B).

[0046] Figure 5This is a schematic diagram showing a spacer (A) of a prior art coil component and a third magnetic core component (B).

[0047] Figure 6 yes Figure 1A The cross-sectional view (A) of the coil component shown and its enlarged partial view (B).

[0048] Figure 7 This is a cross-sectional view (A) of a prior art coil component and a partial enlarged view (B).

[0049] Figure 8 It is shown Figure 1A A perspective view of the first insulation method (A) and the second insulation method (B) of the coil winding in the coil component shown.

[0050] Figure 9 This is a schematic cross-sectional view illustrating the flow of magnetic flux in a magnetically coupled inductor (coil component) according to an embodiment of the present invention.

[0051] Figure 10 This is a schematic diagram showing the method of adjusting the leakage inductance value in the magnetically coupled inductor (coil component) according to an embodiment of the present invention ((A) is the method of changing the thickness of the third magnetic core (ring core), (B) is the method of changing the outer diameter of the third magnetic core (ring core), and (C) is the method of changing the magnetic saturation characteristics of the third magnetic core (ring core).

[0052] Figure 11A This is a schematic diagram (one of) illustrating the assembly method of the coil component according to an embodiment of the present invention (A1, A3) and the assembly method of the coil component in the prior art (B1 to B3).

[0053] Figure 11B This is a schematic diagram (second one) showing the assembly method of the coil component according to the embodiment of the present invention (A4 to A7) and the assembly method of the coil component in the prior art (B4 to B7).

[0054] Figure 12 This is a perspective view showing the state of a coil winding with one side removed from a prior art coil component. Detailed Implementation

[0055] Hereinafter, a coil component and its assembly method according to an embodiment of the present invention will be described with reference to the accompanying drawings. It should be noted that the coil component of this embodiment is configured to function as a magnetically coupled inductor 100.

[0056] <Magnetic Coupled Inductor (Coil Component)>

[0057] Figure 1AThis is a perspective view showing the main parts of the coil component 100 (hereinafter referred to as the magnetically coupled inductor 100) of this embodiment. Figure 1B The diagram shows only the magnetic core portion (composed of a first magnetic core 1, a second magnetic core 2, and a third magnetic core 3) constituting the magnetically coupled inductor 100. Additionally, Figure 2 It shows from Figure 1A The diagram shown is a three-dimensional representation of the magnetically coupled inductor 100 with one coil winding 6B removed. Figure 3 It shows that it has been removed. Figure 1A A perspective view of the state of the third core component 6B of one of the two coil windings 6A and 6B, the first magnetic core 1, the second magnetic core 2 and the third magnetic core 3 in the magnetically coupled inductor 100.

[0058] That is, the magnetically coupled inductor 100 includes: a first magnetic core 1 and a second magnetic core 2, which respectively have middle legs 14, 24, outer legs 12, 22 located on both sides of the middle legs 14, 24, and back faces 13, 23 connecting the middle legs 14, 24 and the outer legs 12, 22, and are arranged such that the front ends of the middle legs 14, 24 and the front ends of the corresponding outer legs 12, 22 face each other; an annular third magnetic core 3 (composed of a magnetic core formed by combining two third magnetic core parts 3A, 3B), which is installed circumferentially along the winding tube 4 through which the middle legs 14, 24 pass; a coil winding 6A, which is wound in the axial region of the winding tube 21 on one of the winding regions 42A, 42B divided by the third magnetic core 3 (42A); and a coil winding 6B, which is wound on the other (42B).

[0059] In addition, the third magnetic core 3 is assembled circumferentially on the outer peripheral surface of the winding portion 21 of the winding tube 4 in a manner that generates the desired leakage inductance value according to its positional relationship with the first magnetic core 1 and the second magnetic core 2.

[0060] Furthermore, the mounting configuration of the third magnetic core 3 to the spool portion 21 is formed by engaging with each other a plurality of first engaging portions 64 (e.g., four at 90-degree intervals) arranged circumferentially along the outer peripheral surface of the spool portion 21 and second engaging portions 65 arranged circumferentially along the inner peripheral surface of the third magnetic core 3 in a manner corresponding to the first engaging portions 64.

[0061] In the prior art coil component 200 (hereinafter referred to as magnetically coupled inductor 200), such as Figure 12As shown, in order to position the third magnetic core 103 relative to the middle legs of the first magnetic core 101 and the second magnetic core 102, the spacer 175 on which the annular third magnetic core 103 is mounted engages with the spool portion 121 of the winding tube 104 disposed around the middle legs. However, the spacer 175, which is sandwiched between the middle legs of the first magnetic core 101 and the second magnetic core 102 and the third magnetic core 103, and between the windings 106A, 106B and the third magnetic core 103, is made of a material with low magnetic permeability such as plastic, which increases magnetic resistance and thus becomes the main reason for the reduction of leakage inductance. Therefore, in order to maintain a high leakage inductance, it is necessary to set the width of the third magnetic core 103 to be wider in the past, but since the space for arranging the windings is narrowed, it is necessary to reduce the number of coil windings and the diameter of the wire, which has an adverse effect on the electrical characteristics.

[0062] Therefore, in this embodiment, instead of using spacers, the third magnetic core 3 is configured to directly engage with the spool portion 21 of the winding tube 4 disposed around the middle legs 14, 24 of the first magnetic core 1 and the second magnetic core 2. This makes the third magnetic core 3 closer to the first magnetic core 1 and the second magnetic core 2, thereby making it easier to ensure leakage inductance. Thus, by utilizing the two effects of narrowing the width of the third magnetic core 3 and eliminating spacers, the spatial area (42A, 42B) for arranging windings 6A, 6B can be expanded, ensuring the desired number of coil windings and the diameter of the coil wires, thereby improving the electrical characteristics.

[0063] The following describes the structure in which the third magnetic core 3 described above engages with the winding tube 4 disposed around the middle legs 14 and 24 of the first magnetic core 1 and the second magnetic core 2.

[0064] like Figure 4 As shown in (A) shows the assembled state of the third magnetic core 3, and (B) shows the third magnetic core portion 3A that constitutes one side of the third magnetic core 3), in this embodiment, a second engaging portion 65 composed of a plurality of recesses arranged in the circumferential direction is provided on the inner peripheral surface of the third magnetic core 3 of the magnetic coupling inductor 100.

[0065] On the other hand, near the center of the outer peripheral surface of the winding tube 4 in the width direction, there are a plurality of first engaging portions 64 (e.g., 4 at 90-degree intervals) arranged circumferentially along the winding tube 21. The first engaging portions 64, which are protrusions, are respectively inserted into the corresponding second engaging portions 65, which are concave. As a result, the third magnetic core 3 is engaged with the outer peripheral surfaces of the winding tube 4 in the winding portions 42A and 42B of the winding tube 4, which are arranged on the outer periphery of the middle legs 14 and 24 of the first magnetic core 1 and the second magnetic core 2, and is thus positioned.

[0066] It should be noted that it is preferable to provide at least one second engaging portion 65 in each of the third magnetic core portions 3A and 3B. In addition, by forming the third magnetic core 3 from the two third magnetic core portions 3A and 3B that can be divided in the circumferential direction, the third magnetic core 3 can be assembled around the spool portion 21 of the winding tube 4.

[0067] It should be noted that in this embodiment, the third magnetic core 3 is composed of two third magnetic core parts 3A and 3B, but the third magnetic core 3 can be composed of three or more third magnetic core parts.

[0068] Furthermore, in the above embodiment, a first engaging portion 64, which is a protrusion, is provided on the outer peripheral surface of the winding portion 21 of the winding tube 4, and a second engaging portion 65, which is a concave portion, is provided on the inner peripheral surface of the third magnetic core 3. However, it is also possible to provide a first engaging portion that is a concave portion on the outer peripheral surface of the winding portion 21 of the winding tube 4, and a second engaging portion that is a protrusion on the inner peripheral surface of the third magnetic core 3. However, if it is desired to set the wall thickness of the winding portion 21 of the winding tube 4 to be thinner, it is preferable to provide a first engaging portion on the outer peripheral surface of the winding portion 21 of the winding tube 4 as a protrusion, as described in the above embodiment.

[0069] It should be noted that in the above embodiment, a second engaging portion 65 as a recess is provided on the inner circumferential surface of the third magnetic core 3, but in this case, the forming of the third magnetic core 3 is preferably carried out using a longitudinal pressing press (vertical pressing press).

[0070] In contrast, in the case of existing magnetically coupled inductors, as described above, in order to position the third magnetic core relative to the middle leg of the first and second magnetic cores, a spacer carrying the annular third magnetic core engages with a winding tube disposed around the middle leg. Figure 5 (A) shows the assembled state of the spacer 175, and (B) shows the third core portion 103A of the third core 103 constituting one side.) The spacer 175 is formed with flange portions 175A and 175B on both sides (see reference). Figure 5 The magnetic core is shaped like a reel, with an annular core mounting groove 175C having an inner diameter that fits along the outer circumferential surface of the winding portion 121 of the winding tube 104. On the inner circumferential surface of the core mounting groove 175C, a plurality of recesses 185 are arranged circumferentially, each of which is fitted along the winding portion 121 of the winding tube 104 (see reference 121). Figure 12 Each of the circumferentially positioned engaging protrusions (not shown) engages with each other to position the third magnetic core 103 relative to the middle leg of the first magnetic core 101 and the second magnetic core 102.

[0071] It should be noted that in the aforementioned prior art, basically, when the third magnetic core 3 is mounted on the magnetic core mounting portion 175C of the spacer 175, the third magnetic core 3 is clamped and positioned between the two flange portions 175A and 175B of the spacer 175. Therefore, the third magnetic core portions 103A and 103B constituting the third magnetic core 103 are different from the third magnetic core 3 of this embodiment, such as... Figure 5 As shown in (B), the third magnetic core 103 is formed into a simple shape without any engaging parts involved in positioning. Therefore, the third magnetic core 103 is formed using a horizontal stamping press.

[0072] According to this embodiment, as described above, since the conventionally used spacer 175 is eliminated, it has the effect of expanding the reel areas 42A and 42B where the windings 6A and 6B are arranged. Hereinafter, this embodiment will be explained by using... Figure 6 and indicating prior art Figure 7 We will compare them and provide further specific explanations.

[0073] Figure 6 Figure 1 shows a cross-sectional view (A) of the magnetically coupled inductor 100 of this embodiment and a partial enlarged view (B). Figure 7 This is a cross-sectional view (A) of a prior art magnetically coupled inductor 200 and a partial enlarged view (B).

[0074] In the magnetically coupled inductor 100 of this embodiment, as Figure 6 As shown in (A) and (B), the third magnetic core 3 (3A, 3B) is arranged in contact with the windings 6A, 6B in such a way that no other components are placed between them. In contrast, in the prior art magnetically coupled inductor 200, as shown in (A) and (B), the third magnetic core 3 (3A, 3B) is arranged in contact with the windings 6A, 6B in a manner that does not involve other components. Figure 7 As shown in (A) and (B), flange portions 175A and 175B of spacers 175 are sandwiched between the third magnetic core 103 (103A, 103B) and the windings 106A and 106B. Therefore, the width b of the third magnetic core 3 (3A, 3B) in this embodiment is allowed to be the same as the width obtained by adding the thickness of the flange portions 175A and 175B of spacers 175 to the width d of the third magnetic core 103 (103A, 103B) in the prior art.

[0075] Therefore, in this embodiment, the number of windings and the wire diameter of the wires constituting windings 6A and 6B are not limited, thus improving the electrical characteristics.

[0076] Furthermore, in the magnetically coupled inductor 100 of this embodiment, such as Figure 6 As shown in (A) and (B), the third magnetic core 3 (3A, 3B) is positioned opposite the first magnetic core 1 and the second magnetic core 2 via the spool portion 21 of the winding tube 4, which is separated by a thickness a. In contrast, in the prior art magnetically coupled inductor 200, as... Figure 7 As shown in (A) and (B), the third magnetic core 103 (103A, 103B) is positioned opposite the first magnetic core 101 and the second magnetic core 102, with a thickness c equal to the thickness of the magnetic core mounting portion 175C of the spacer 175 added to the thickness of the winding portion 121 of the winding tube 4. In this way, compared with the prior art, the magnetic coupling inductor 100 of this embodiment can reduce the distance between the third magnetic core 3 (3A, 3B) and the first magnetic core 1 and the second magnetic core 2 by the amount of the thickness of the magnetic core mounting portion 175C of the spacer 175. This reduces magnetic resistance, allows the use of a narrower third magnetic core 3 (3a, 3b), further avoids miniaturization of the coil winding area, and further improves the performance of the magnetic coupling inductor 100.

[0077] Furthermore, in the aforementioned prior art, the spacer 175 has an insulating function. That is, the spacer 175 uses an insulating material such as plastic, and the flange portions 175A and 175B of the spacer 175 are sandwiched between the windings 106A and 106B and the third magnetic core 3 (see reference). Figure 5 This forms a structure that achieves insulation between windings 106A and 106B and the third magnetic core 3.

[0078] However, in this embodiment, since the spacer 175 is eliminated, the wires constituting windings 6A and 6B have an insulating function. That is, as windings 6A and 6B, for example, Figure 8 As shown in (A), a winding insulated by covering the stranded wire 91A with insulating tape 92A (composed of PET, PEN, PI, etc.) is used, or as... Figure 8 As shown in (B), a winding is used insulated by molding stranded wire 91B with a multi-layered insulating covering 92B (composed of ETFE, FEP, PFA nylon, etc.).

[0079] Therefore, even if windings 6A and 6B are in direct contact with the third magnetic core 3, insulation can be ensured. Furthermore, insulation between the wires constituting windings 6A and 6B can also be ensured.

[0080] It should be noted that the insulation function (withstand voltage) of the wires constituting the above windings 6A and 6B is set, for example, to meet 0.6kV / s between the wires constituting the windings 6A and 6B and the third magnetic core 103, and to meet 1.8kV / s between the wires constituting the windings 6A and 6B.

[0081] Furthermore, in the above examples, stranded wires 91A and 91B are shown as windings 6A and 6B with insulating function, but other wires, such as single copper wires, can also be used instead of stranded wires.

[0082] The following is a supplementary structural description of each part of the magnetically coupled inductor 100 of this embodiment.

[0083] In this magnetically coupled inductor 100, the lengths of the middle legs 14 and 24 of the first magnetic core 1 and the second magnetic core 2 are approximately half the distance between the opposing back legs 13 and 23, and the outer legs 12 and 22 are in the shape of a planar plate.

[0084] In addition, the corresponding front ends of the three legs 12, 14 constituting the first magnetic core 1 and the three legs 22, 24 constituting the second magnetic core 2 are arranged opposite each other with a small gap 32, 34 between them.

[0085] Furthermore, the third magnetic core 3 is, for example, made of ferrite core and is a ring-shaped structure with a rectangular cross-section. Additionally, this third magnetic core 3 is formed by combining a pair of third magnetic core portions 3A and 3B.

[0086] In addition, the winding tube 4 is made of insulating resin, such as Figure 3 As shown, the cylindrical spool portion 21 has flange portions 43A and 43B at both ends, and suspension portions 45A and 45B for external mounting are provided on the outer side of each flange portion 43A and 43B. Terminal blocks 41A and 41B are provided below each flange portion 43A and 43B. Multiple terminal pins 9 are provided on each terminal block 41A and 41B.

[0087] On the other hand, a plurality of first engaging portions 64 (e.g., four at 90-degree intervals) arranged circumferentially along the outer peripheral surface of the winding tube 4 are provided at approximately the center of the axial direction of the outer peripheral surface. A plurality of second engaging portions 65 of the third magnetic core 3, which engage with the first engaging portions 64, are arranged circumferentially along the inner peripheral surface of the third magnetic core 3 (e.g., four at 90-degree intervals). When the first engaging portions 64 and the second engaging portions 65 engage with each other, the third magnetic core 3 is fitted into the winding tube 4's winding portion 21. It should be noted that the third magnetic core 3 is formed by combining two semi-annular third magnetic core portions 3A and 3B, and is fixed by winding the outer peripheral surface with a third magnetic core fixing strap 77.

[0088] The magnetically coupled inductor 100 of this embodiment, having the basic structure described above, is configured such that a ring-shaped third magnetic core 3 is sandwiched between the first magnetic core 1 and the second magnetic core 2, and the core portion is formed in a 2-in-1 (2-in-1) structure in plan view. Thus, the magnetic flux 8 in the magnetically coupled inductor 100, where the core portion is formed in a 2-in-1 shape in plan view, becomes... Figure 9 The flow indicated by the arrows is that the magnetic flux 8 through the third magnetic core 3 generated by the currents through coil windings 6A and 6B is in the same direction.

[0089] More specifically, as described above, the first core 1 and the second core 2 are separated by forming gaps 32 and 34 between the middle legs 14 and 24 and the outer legs 12 and 22, respectively. Therefore, in the first core 1, the magnetic fluxes 8 passing through the outer legs 12 on both sides and the back face 13 converge at the middle leg 14 and flow toward the front face of the middle leg 14.

[0090] On the other hand, in the second core 2, the magnetic fluxes passing through the back face 23 from the outer legs 22 on both sides converge at the middle leg 24 and flow toward the front face of the middle leg 24.

[0091] The magnetic fluxes 8 flowing in these two middle legs 14 and 24 collide with each other on the front faces of the middle legs 14 and 24 and cancel each other out. On the other hand, the magnetic fluxes 8 that branch toward the third core 3 before the collision pass through the third core 3 and reach the outer legs 12 and 22 of the first core 1 and the second core 2.

[0092] As a result, a magnetic loop is formed in the first core 1, the second core 2, and the third core 3, which is composed of the magnetic fluxes 8 circulating in the direction of the arrow as shown. Figure 9 shown.

[0093] It should be noted that, as shown, a gap 33 with a specified interval is also formed between the third core 3 and the outer legs 12 and 22 of the first core 1 and the second core 2. Figure 9 shown.

[0094] However, as described above, the core part (the first core 1, the second core 2, and the third core 3) is formed in a figure-eight shape as a whole in a top view. The proportion of the magnetic fluxes 8 flowing in the middle legs 14 and 24 of the first core 1 and the second core 2, which branch toward the third core 3 and flow toward the outer legs 12 and 22 of the first core 1 and the second core 2, can be adjusted by changing the degree of ease of flow of the magnetic fluxes 8 from the middle legs 14 and 24 of the first core 1 and the second core 2 to the third core 3.

[0095] In the magnetic coupled inductor 100 of the present embodiment, focusing on the above aspects, it is configured that by changing (selecting) at least one of the thickness (width) of the third core 3, the outer diameter of the third core 3, and the magnetic saturation characteristic of the third core 3, the degree of ease of flow of the magnetic fluxes 8 from the middle legs 14 and 24 to the third core 3 direction can be adjusted to a desired leakage inductance (leakage magnetic flux) value.

[0096] Hereinafter, these elements will be specifically described.

[0097] For example, as Figure 10As shown in (A), multiple third magnetic cores 3 with different thicknesses (widths) can also be prepared, and the third magnetic core 3 that can obtain the desired leakage inductance value can be assembled on the outer peripheral surface of the winding portion 21 of the winding tube 4. This is because the thicker the third magnetic core 3, the better. Figure 9 The larger the magnetic flux 8 branching towards the third magnetic core 3, the greater the leakage inductance.

[0098] In addition, such as Figure 10 As shown in (B), multiple third magnetic cores 3 with the same inner diameter but different outer diameters can also be prepared, and the third magnetic core 3 that can obtain the desired leakage inductance value can be assembled on the outer peripheral surface of the winding portion 21 of the winding tube 4. This is because the greater the wall thickness (difference between the outer diameter and the inner diameter) of the third magnetic core 3, the better. Figure 9 The greater the leakage inductance in the direction of the third magnetic core 3, the better.

[0099] Furthermore, such as Figure 10 As shown in (C), multiple third magnetic cores 3 with different magnetic saturation characteristics can also be prepared, and the third magnetic core 3 that can obtain the desired leakage inductance value can be assembled on the outer peripheral surface of the winding portion 21 of the winding tube 4. This is because the higher the magnetic saturation characteristic of the third magnetic core 3, the better. Figure 9 The greater the leakage inductance in the direction of the third magnetic core 3, the better.

[0100] According to the magnetic coupling inductor 100 of this embodiment, a plurality of third magnetic cores 3 with different leakage inductance values ​​are prepared as described above. The third magnetic cores 3 that can obtain the desired leakage inductance value are assembled on the outer peripheral surface of the winding portion 21 of the winding tube 4, so that the leakage inductance value can be easily adjusted.

[0101] <Assembly Method of Magnetic Coupled Inductor (Coil Component)>

[0102] Next, use Figure 11A (A1) ~ Figure 11B Section (A7) describes the assembly method of the magnetically coupled inductor 100 according to this embodiment. Furthermore, for comparison, the assembly method of the magnetically coupled inductor described in the prior art (Patent Document 1 above) is shown below. Figure 11B (B1) ~ Figure 11B (B7). It should be noted that for each component of the magnetically coupled inductor 200 shown in the drawings of the prior art, the reference numerals are obtained by adding 100 to the reference numerals of the corresponding components of the magnetically coupled inductor 100 shown in the drawings of this embodiment.

[0103] First, make such Figure 11A The winding tube 4 shown in (A1) is set in the assembly position (winding tube setting process).

[0104] As mentioned above, the winding tube 4 is made of insulating resin and is manufactured using a mold. (For reuse) Figure 3 To explain, the spool portion 21 of the winding coils 6A and 6B is cylindrical with a hollow portion 42C. Furthermore, roughly circular flange portions 43A and 43B are provided at both ends of the spool portion 21. Terminal blocks 41A and 41B are provided below each flange portion 43A and 43B, and a suspension outer mounting strap 79 is provided above each flange portion 43A and 43B (see reference). Figure 11B The suspension sections 45A and 45B of (A7) have six metal terminal pins 9 and 9 arranged side by side on each terminal block 41A and 41B, facing to the side and downward respectively.

[0105] In addition, as described above, on the outer peripheral surface of the winding tube 4, at approximately the center of its axial direction, a first engaging portion 64 consisting of four protrusions is provided at 90-degree intervals along the outer peripheral surface.

[0106] It should be noted that in the assembly method of the existing magnetically coupled inductor 200, a similar process is also fabricated. Figure 11A The winding tube 104 shown in (B1) has a first engaging portion 164 with a shape that is substantially the same as the first engaging portion 64 described above.

[0107] Next, as Figure 11A As shown in (A3), a second engaging portion 65 consisting of a recess is provided (see reference). Figure 3 and Figure 4 The third magnetic core 3 of (A) and (B) is engaged with the outer peripheral surface of the winding portion 21 of the winding tube 4 by each of the third magnetic core portions 3A and 3B (third magnetic core assembly process (hereinafter also referred to as toroidal core assembly process)). This engagement process is performed by fitting the second engagement portion 65 of the third magnetic core 3, which is composed of a concave portion, with the first engagement portion 64, which is composed of a convex portion, formed on the outer peripheral surface of the winding portion 21 of the winding tube 4. With both the third magnetic core portions 3A and 3B fitted into the outer peripheral surface of the winding portion 21 of the winding tube 4, as Figure 4 As shown in (A), the third magnetic core parts 3A and 3B are combined with each other to form a ring.

[0108] In contrast, in existing technologies, before performing the ring core assembly process, such as Figure 11A As shown in (B2), the annular spacer 175 needs to be assembled onto the outer peripheral surface of the winding portion 21 of the winding tube 4 (spacer assembly process). In this embodiment, the advantage is that such spacer assembly process can also be omitted.

[0109] That is, in the prior art, it is necessary to engage the engaging portion provided on the inner peripheral surface of the spacer 175 with the engaging portion provided on the outer peripheral surface of the winding portion 21 of the winding tube 4, and to position the third magnetic core 103 on the magnetic core mounting portion 175C provided between the two flange portions of the spacer 175 (see reference). Figure 5 (A)). Furthermore, when the third magnetic core 103 is mounted on the core mounting section 175C, the semi-annular third magnetic core portions 103A and 103B constituting the third magnetic core 103 need to be assembled on the core mounting section 175C to form... Figure 11A The circular shape shown in (B3) is an advantage of this embodiment, which omits the processing involved in such prior art steps and reduces the labor and time required for these steps.

[0110] Next, as Figure 11B As shown in (A4), relative to the third magnetic core 3 mounted on the outer peripheral surface of the winding section 21 of the winding tube 4, the third magnetic core parts 3A and 3B are combined and kept in a ring shape, and the outer peripheral surface of each third magnetic core part 3A and 3B is wound by the third magnetic core fixing strip 77 (third magnetic core strip fixing treatment (hereinafter also referred to as ring core strip fixing treatment)).

[0111] On the other hand, in existing technologies, such as Figure 11B As shown in (B4), relative to the third magnetic core 103 mounted on the magnetic core mounting portion 175C of the spacer 175, the third magnetic core portions 103A and 103B are combined and held in a circular shape, and the outer peripheral surface of each third magnetic core portion 103A and 103B is wound around by the third magnetic core fixing band 177.

[0112] Next, as Figure 11B As shown in (A5), in the winding regions 42A and 42B of the spool portion 21 divided by the third magnetic core 3, coil windings 6A and 6B are wound in approximately the same number (winding assembly process).

[0113] Next, as Figure 11B As shown in (A6), in the hollow portion 42C of the cylindrical spool portion 21 of the winding tube 4 (refer to...) Figure 3 Insert the middle leg 14 of the first magnetic core 1 from one end and insert the middle leg 24 of the second magnetic core 2 from the other end (main core assembly process).

[0114] At this point, the core fixing strip 78 is used to wind the winding tube 4 and each core 1 to 3 together by wrapping around the circumferential surface of the sides of the first magnetic core 1 and the second magnetic core 2. It should be noted that, as a means of physically integrating the winding tube 4 and each core 1 to 3, adhesives, fasteners, etc., can also be used instead of the core fixing strip 78.

[0115] Next, as Figure 11B As shown in (A7), the outer mounting tape 79 is wound in a direction orthogonal to the core fixing tape 78 so that the coil windings 6A and B are not exposed to the outside, thereby more firmly fixing the winding tube 4 and each core 1 to 3 (outer mounting tape fixing treatment). It should be noted that, as a means of physically integrating the winding tube 4 and each core 1 to 3, adhesives, fasteners, etc. can also be used with the outer mounting tape 79.

[0116] It should be noted that in existing technologies, such as Figure 11B As shown in (B5 to B7), the winding assembly process, the main core assembly process, and the outer casing fixing process described above are performed in roughly the same way as in this embodiment.

[0117] The magnetically coupled inductor and its assembly method of the present invention are not limited to the above embodiments and can be modified into various other solutions.

[0118] For example, the coil component of the above embodiment has been described as being used as a magnetically coupled inductor. However, as the coil component of the present invention, it can be applied to a transformer with the same structure as the magnetically coupled inductor of the above embodiment. That is, when the present invention is applied to a transformer, it can have the same useful effects as when it is applied to a magnetically coupled inductor.

[0119] In addition, in the above embodiment, PQ cores are used as the first magnetic core 1 and the second magnetic core 2, but various types of cores such as EE cores and EER cores can also be used instead.

[0120] In addition, cores of various forms, such as EE cores and EER cores, can also be constructed by combining multiple I core components and cylindrical core components.

[0121] Furthermore, in the above embodiments, as a method for setting the leakage inductance value to a desired value, a method is shown that sets any one or a combination of the thickness of the third magnetic core 3, the outer diameter of the third magnetic core 3, and the magnetic saturation characteristics of the third magnetic core 3 to a desired value. However, other methods can also be used, such as setting elements of the shape of the third magnetic core 3 or elements of the material properties of the third magnetic core 3 to a desired value. For example, a method can also be used to set the desired value by combining the inner diameter of the third magnetic core 3 or other elements with the inner diameter of the third magnetic core 3.

[0122] Furthermore, in the above embodiments, in Figure 9 The same effect can be achieved by adjusting the winding direction of coil windings 6A and 6B or the direction of the current flowing in coil windings 6A and 6B in a way that completely reverses the direction of the flow (the direction of the arrow).

[0123] Furthermore, the shape of the winding tube 4 is not limited to the shape described in the above embodiment, and can be other shapes. For example, the first engaging portion 64 provided on the outer peripheral surface of the spool portion 21 can be a concave portion instead of a convex portion, and the second engaging portion 65 provided on the inner peripheral surface of the third magnetic core 3 that engages with the spool portion 21 can be a convex portion instead of a concave portion.

[0124] Furthermore, in the above embodiment, the coil windings 6A and B use round wire, but they are not limited to this; other windings can also be used, for example, windings based on edge coils wound with flat wire are not excluded. Also, the coil windings 6A and B can be formed by inserting a pre-wound hollow coil into the spool portion 21.

[0125] In the above embodiment, the third magnetic core 3 is divided into two parts, but it can also be divided into three or more parts.

[0126] Explanation of reference numerals in the attached figures:

[0127] 1.101 First magnetic core

[0128] 2.102 Second magnetic core

[0129] 3.103 Third magnetic core (toroidal core)

[0130] 3A, 3B, 103A, 103B Third magnetic core section

[0131] 4. 104 winding tube

[0132] 6A, 6B, 106A, 106B coil windings

[0133] 8. Magnetic Flux

[0134] 9-terminal pin

[0135] 12, 22 Outer leg

[0136] 13, 23 Back side

[0137] 14, 24 Middle Legs

[0138] 21, 121 Scroll section

[0139] Gap 32, 33, 34

[0140] 41A, 41B Terminal Blocks

[0141] 42A and 42B Reel Areas

[0142] 42C Hollow Section

[0143] 43A, 43B (Flanges)

[0144] 45A and 45B with suspension unit

[0145] 64, 164 First Card Section

[0146] 65 Second Card Section

[0147] 77, 177 Third magnetic core fixing strap

[0148] 78 and 188 core fixing straps

[0149] 79, 179 outer packaging belt

[0150] 91A and 91B stranded wires

[0151] 92A Insulating Tape

[0152] 92B Insulation Cover

[0153] 100, 200 magnetically coupled inductors

[0154] 175 spacer

[0155] 175A, 175B (spacer) flange portion

[0156] 175C core mounting slot

[0157] 185 concavity.

Claims

1. A coil component characterized by comprising: first and second magnetic cores each having a middle leg portion, outer leg portions on both sides of the middle leg portion, and a back portion connecting the middle leg portion and the outer leg portions, and being arranged so that the front ends of the middle leg portions face each other and the front ends of the corresponding outer leg portions face each other; a bobbin through which the middle leg portions of the first and second magnetic cores pass and which is arranged on the outer periphery of the middle leg portions of the two magnetic cores; a third magnetic core in the shape of a circular ring which is fitted in a divided manner in the circumferential direction of a winding shaft portion of the bobbin through which the middle leg portions pass; and a first coil winding wound around a region of one of the winding shaft portions divided by the third magnetic core and a second coil winding wound around a region of the other winding shaft portion, the third magnetic core being fitted in a divided manner in the circumferential direction of the outer periphery of the winding shaft portion of the bobbin in a state in which a prescribed element is set in a manner so as to produce a desired leakage inductance value in accordance with the positional relationship with the first and second magnetic cores, the fitting of the third magnetic core to the winding shaft portion being performed by engaging a plurality of first engaging portions arranged in the circumferential direction of the outer periphery of the winding shaft portion with a plurality of second engaging portions arranged in the circumferential direction of the inner periphery of the third magnetic core in a manner corresponding to the first engaging portions.

2. The coil component according to claim 1, characterized in that: the wire of the first and second coil windings is an insulated wire.

3. The coil component according to claim 2, characterized in that: the wire of the first and second coil windings is an insulated wire in which an insulated tape covers the outer periphery of a twisted wire.

4. The coil component according to any one of claims 1 to 3, characterized in that: the prescribed element related to the third magnetic core which is set in a manner so as to produce the desired leakage inductance value is the thickness of the third magnetic core.

5. The coil component according to any one of claims 1 to 3, characterized in that: the prescribed element related to the third magnetic core which is set in a manner so as to produce the desired leakage inductance value is the outer diameter of the third magnetic core.

6. The coil component according to any one of claims 1 to 3, characterized in that: the prescribed element related to the third magnetic core which is set in a manner so as to produce the desired leakage inductance value is the magnetic saturation characteristic of the material of the third magnetic core.

7. The coil component according to any one of claims 1 to 3, characterized in that: at least one second engaging portion is provided for each of the core members of the third magnetic core fitted in a divided manner in the circumferential direction in a manner corresponding to the plurality of first engaging portions arranged in the circumferential direction of the outer periphery of the winding shaft portion.

8. The coil component according to any one of claims 1 to 3, characterized in that: the first engaging portion is a protrusion formed on the outer periphery of the winding shaft portion and the second engaging portion is a recess formed on the inner periphery of the third magnetic core which engages with the first engaging portion.

9. A method of assembling a coil component characterized by comprising: performing a second process after performing a first process, ​ ​ In the first process, the front ends of the middle legs of the first magnetic core and the second magnetic core and the front ends of the outer legs of the first magnetic core and the second magnetic core are made to face each other, the middle legs of the first magnetic core and the second magnetic core are inserted into the hollow portion of the bobbin, a third magnetic core that is divided in the circumferential direction and has a circular ring shape is attached to the bobbin portion around which the middle legs are inserted, In the second process, a first coil winding is wound around one region of the bobbin portion that is divided in the axial direction by the third magnetic core, and a second coil winding is wound around the other region, the attachment of the third magnetic core to the bobbin portion in the first process is performed by engaging a second engagement portion provided on the inner circumferential surface of the third magnetic core with a first engagement portion provided on the outer circumferential surface of the bobbin portion in a state in which the positions of the first magnetic core and the second magnetic core are set in such a manner as to produce a desired leakage inductance value.

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