Magnetic material unit

Abstract

The objective is to provide a magnetic unit that can properly implement a configuration in which a biasing member is assembled to a case. [Solution] The magnetic unit 1 comprises a magnetic core 10 including a divided first core 11 and a second core 12, a base member 20 having a bottom portion 21 that houses the magnetic core 10 and supports the first core 11, and a side wall portion 22 provided on the side of the magnetic core 10, and a leaf spring 40 which is a biasing member whose end portion 42a is held by the side wall portion 22 and biases the second core 12 toward the other side Z2 of the third direction Z, the side wall portion 22 has a biasing member holding portion 23 that engages with the end portion 42a of the leaf spring 40, the leaf spring 40 has a biasing member side inclined contact surface 43 formed at an angle on one side Z1 of the third direction Z, and the biasing member holding portion 23 has a side wall portion side inclined contact surface 23d which is formed at an angle to contact the biasing member side inclined contact surface 43 when the leaf spring 40 is biased.

Description

Technical Field

[0005]

[0001] The present invention relates to a magnetic unit.

Background Art

[0002] As a technology related to a conventional magnetic unit, for example, Patent Document 1 discloses a magnetic unit including a synthetic resin case having an openable and closable hinge portion and a latching means, a split magnetic core formed in a spindle shape and housed in the case, and a biasing member held between the case and the magnetic core. In this magnetic unit, the biasing member presses the split magnetic core to bring the split surfaces of the magnetic core into pressure contact when the case is closed and latched by the latching means.

Prior Art Documents

Patent Documents

[0003] [[ID=2"]]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, such a magnetic unit may require a sub-assembly for preliminarily assembling a biasing member to a case before closing the case and bringing the magnetic core into pressure contact. And there is room for further improvement in the configuration for assembling the biasing member to the case.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to provide a magnetic unit capable of appropriately realizing a configuration for assembling a biasing member to a case.

Means for Solving the Problems

[0006] To achieve the above objective, the magnetic unit of the present invention includes a first core and a second core formed in an annular shape around a first direction and divided along a second direction intersecting the first direction, the second core provided on one side of a third direction intersecting the first and second directions and the first core provided on the other side of the third direction abut along the third direction, the bottom portion housing the magnetic core and supporting the first core, and provided on the side of the magnetic core in the second direction The device comprises a base member having a side wall portion, and a biasing member whose end in the second direction is held by the side wall portion and which biases the second core to the other side in the third direction, wherein the side wall portion has a biasing member holding portion that engages with the end of the biasing member, the biasing member has a biasing member side inclined contact surface formed at an angle to one side of the third direction, and the biasing member holding portion has a side wall portion side inclined contact surface formed at an angle to contact the biasing member side inclined contact surface when the biasing member is in a biased state. [Effects of the Invention]

[0007] The magnetic unit according to the present invention has the effect of enabling a proper configuration for assembling the biasing member to the case. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing a magnetic material unit according to the first embodiment. [Figure 2] Figure 2 is an exploded perspective view showing a magnetic material unit according to the first embodiment. [Figure 3] Figure 3 is a perspective view showing the base member according to the first embodiment. [Figure 4] Figure 4 is a perspective view of the section IV-IV in Figure 3. [Figure 5] Figure 5 is a perspective view showing a bobbin according to the first embodiment. [Figure 6] Figure 6 is a perspective view showing a leaf spring according to the first embodiment. [Figure 7] Figure 7 is a cross-sectional view taken along line VII-VII in Figure 1. [Figure 8] Figure 8 is a perspective view showing the base member according to the first embodiment before the leaf spring is attached. [Figure 9] Figure 9 is a perspective view showing a magnetic core housed in a base member according to the first embodiment, with a leaf spring placed on top. [Figure 10] Figure 10 is a perspective view showing the state in which the leaf spring is rotated in order to lock the leaf spring to the base member according to the first embodiment. [Figure 11] Figure 11 is a perspective view showing a magnetic material unit according to the second embodiment. [Figure 12] Figure 12 is a perspective view showing a leaf spring according to the second embodiment. [Figure 13] Figure 13 is a cross-sectional view taken along line XIII-XIII in Figure 11. [Figure 14] Figure 14 is a perspective view showing the base member according to the second embodiment before the leaf spring is attached, with the tab portion of the leaf spring pinched and contracted. [Figure 15] Figure 15 corresponds to the XIII-XIII section in Figure 11 and is a cross-sectional view showing a leaf spring placed on a magnetic core with its knob pinched and contracted. [Figure 16] Figure 16 is a perspective view showing a magnetic material unit according to the third embodiment. [Figure 17] Figure 17 is a perspective view showing the base member according to the third embodiment. [Figure 18] Figure 18 is a cross-sectional view taken from line XVIII-XVIII in Figure 17. [Figure 19] Figure 19 is a perspective view showing a leaf spring according to the third embodiment. [Figure 20] Figure 20 is a cross-sectional view of Figure 16 along the line XX-XX. [Figure 21] Figure 21 is a perspective view showing the base member according to the third embodiment before the leaf spring is attached. [Figure 22] Figure 22 corresponds to the XVIII-XVIII section in Figure 17 and is a cross-sectional view showing the state in which the inclined contact surface of the leaf spring is inserted into the biasing member holding section. [Figure 23] FIG. 23 is a perspective view showing an example of incorrect assembly of a leaf spring according to the third embodiment.

Mode for Carrying Out the Invention

[0009] Hereinafter, embodiments of the present invention will be described in detail based on the drawings. Note that the present invention is not limited by this embodiment. In addition, the constituent elements in the following embodiments include those that can be replaced by those skilled in the art and are easy to replace, or those that are substantially the same.

[0010] [First Embodiment] The first embodiment will be described based on FIGS. 1 to 10. The magnetic unit 1 of the first embodiment shown in FIGS. 1 and 2 is provided, for example, in a high-voltage junction box to which a high-voltage battery pack mounted on a vehicle such as an electric vehicle or a hybrid vehicle is electrically connected. The magnetic unit 1 includes a bus bar 100 inserted through an annular magnetic core 10 including a first core 11 and a second core 12 which are split cores. The bus bar 100 is a circuit body (conductor) constituting a high-voltage circuit system including a high-voltage battery pack and the like. The magnetic unit 1 provided with the magnetic core 10 can preferably remove high-frequency noise in the bus bar 100 and preferably suppress a surge voltage.

[0011] The magnetic unit 1 includes a magnetic core 10, a base member 20, a leaf spring 40 which is a biasing member, and two bobbins 50. Two bus bars 100 are inserted through the annularly formed magnetic core 10. The bus bar 100 is formed in a long shape, but only a part of it is shown in the figure. The magnetic core 10 and the two bobbins 50 through which the bus bar 100 is inserted are housed in a base member 20 which is a case.

[0012] In the following explanation, the axial direction of the annular magnetic core 10, in which the two busbars 100 extend, will be referred to as the first direction X, and the two directions perpendicular to the first direction X will be referred to as the second direction Y and the third direction Z. The second direction Y is the direction in which the two busbars 100 are arranged. Furthermore, in the following explanation, one side of the first direction X will be referred to as side X1 and the other side as side X2. Similarly, the second direction Y will be referred to as side Y1 and the other side Y2, and the third direction Z will be referred to as side Z1 and the other side Z2.

[0013] As shown in Figure 2, the magnetic core 10 includes a first core 11 and a second core 12, which are divided along the second direction Y. The first core 11 is located on the other side Z2 of the third direction Z, and the second core 12 is located on one side Z1 of the third direction Z. The magnetic core 10 is formed in an annular shape around the first direction X when the first core 11 and the second core 12 are combined (see also Figure 7). The first core 11 and the second core 12 are formed in the same shape and are members containing a magnetic material such as ferrite. The first core 11 and the second core 12 are each substantially U-shaped when viewed from the first direction X and are formed to be long along the first direction X. The first core 11 and the second core 12 have two flat surfaces located on the open side of the substantially U-shape which are the contact surfaces 10a and 10b. The magnetic core 10 has contact surfaces 10a and 10b of the first core 11 and second core 12 that are in contact with each other along the third direction Z.

[0014] As shown in Figure 3, the base member 20 is formed in the shape of a roughly rectangular box with an opening on one side Z1 in the third direction Z. The base member 20 is provided with a roughly rectangular plate-shaped bottom portion 21 that is roughly parallel to the planes including the first direction X and the second direction Y. A core support portion 21a is formed in a grid pattern on one side Z1 in the third direction Z of the bottom portion 21. The surface of the core support portion 21a on one side Z1 in the third direction Z abuts against and supports the surface of the first core 11 on the other side Z2 in the third direction Z. As shown in Figure 7, a grid-like rib 21b similar to the core support portion 21a is also formed on the other side Z2 in the third direction Z of the bottom portion 21.

[0015] At the bottom portion 21, one end Y1 and the other end Y2 in the second direction Y are provided with two side wall portions 22 that are erected toward one side Z1 in the third direction Z. The side wall portions 22 are substantially plate-shaped with their surface facing the second direction Y. Each side wall portion 22 is provided to the side of the magnetic core 10 in the second direction Y (see Figure 7). At each end of each side wall portion 22, one end X1 and the other end X2 in the first direction X are provided with substantially plate-shaped insertion plate portions 26. Each insertion plate portion 26 is provided with its surface facing the first direction X. Each insertion plate portion 26 has a long insertion opening 26a formed approximately in the center in the second direction Y, along the third direction Z. A bobbin 50 is placed in the insertion opening 26a and the busbar 100 is inserted through it.

[0016] Each side wall portion 22 is provided with a biasing member holding portion 23. The biasing member holding portion 23 is formed in a substantially box shape on the outside of the side wall portion 22. One side Z1 of the biasing member holding portion 23 in the third direction Z protrudes Z1 further than the end of the side wall portion 22 in the third direction Z1. An opening 23s is provided on the inside of the biasing member holding portion 23 on one side Z1 of the side wall portion 22 in the third direction Z. The biasing member holding portion 23 on one side Y1 in the second direction Y and the biasing member holding portion 23 on the other side Y2 are formed point-symmetrically around the axis CL3 of the base member 20 along the third direction Z. In the following, the biasing member holding portion 23 on one side Y1 in the second direction Y will be described, and a detailed explanation of the biasing member holding portion 23 on the other side Y2 will be omitted.

[0017] The biasing member holding section 23 has two side plates 23a with their plate surfaces facing the first direction X, provided at a predetermined distance in the first direction X. The other side Y2 in the second direction Y of the two side plates 23a is connected to the side wall section 22. Of the two side plates 23a, the side plate 23a on the first direction X side X1 has the same length in the third direction Z as the side wall section 22. Therefore, the end face 23a1 of the side plate 23a on the first direction X side X1 is continuous with the end face 22a of the side wall section 22 on the side Z1 of the side wall section 22. Of the two side plates 23a, the side plate 23a on the other side X2 in the first direction X protrudes further Z1 than the end face 22a of the side wall section 22 on the side Z1 of the third direction Z.

[0018] One side Y1 of the two side plates 23a in the second direction Y is connected to the support plate 23b. The support plate 23b is provided with its surface facing the second direction Y. The length of the support plate 23b in the third direction Z is the same as that of the side plate 23a on the other side X2 in the first direction X. The support plate 23b and the side plate 23a on the other side X2 in the first direction X are each connected to the locking plate 23c on one side Z1 in the third direction Z. The locking plate 23c is provided with its surface facing the third direction Z. The locking plate 23c is formed to be long along the first direction X. The other side Z2 of the locking plate 23c in the third direction Z is provided with a side wall inclined contact surface 23d (see Figures 4 and 7). The inclined contact surface 23d on the side wall is formed to be inclined from one side Z1 to the other side Z2 in the third direction Z, along one side Y1 to the other side Y2 in the second direction Y (in other words, along the direction from the outside to the inside of the side wall 22).

[0019] The biasing member holding portion 23 is provided with a V-shaped projection 23e on one side X1 of the inclined contact surface 23d on the side wall portion, which is provided along the first direction X, and a regulating wall portion 23f is provided on the other side X2 of the inclined contact surface 23d on the side wall portion. The regulating wall portion 23f is the portion of the side plate 23a on the other side X2 in the first direction X that protrudes from the end face 22a of one side Z1 in the third direction Z of the side wall portion 22 to one side Z1, and is considered to be part of the side plate 23a on the other side X2 in the first direction X. The V-shaped projection 23e protrudes in a V-shape from the locking plate 23c toward the other side Z2 in the third direction Z at the end of one side X1 in the first direction X of the locking plate 23c. The surface of the V-shaped projection 23e on one side X1 in the first direction X is an inclined surface 23e1 that slopes from one side Z1 to the other side Z2 in the third direction Z, along from one side X1 to the other side X2 in the first direction X. The other side Z2 in the third direction Z at the tip 23e2 of the V-shaped projection 23e is an insertion opening 23t that is separated from the end face 22a of the side wall portion 22 on one side Z1. The insertion opening 23t communicates with the internal space of the biasing member holding portion 23.

[0020] As shown in Figure 4, an arc-shaped bulge 23g is provided on the other side Z2 of the locking plate 23c in the third direction Z. The arc-shaped bulge 23g bulges out from the locking plate 23c toward the other side Z2 of the third direction Z, surrounding the inclined contact surface 23d on the side wall in an arc shape. The arc-shaped bulge 23g is connected to the V-shaped projection 23e, the regulating wall portion 23f, and the support plate 23b, respectively. The inclined contact surface 23d on the side wall is formed in an arc shape when viewed from the other side Z2 of the third direction Z, due to being surrounded by the arc-shaped bulge 23g. The surface 23g1 of the arc-shaped bulge 23g toward the other side Z2 of the third direction Z is continuous with the tip 23e2 of the V-shaped projection 23e.

[0021] As shown in Figure 2, the two bobbins 50 are arranged facing each other along the third direction Z. The two bobbins 50 are identical in shape. As shown in Figure 5, the bobbin 50 has two spaced-apart side plates 51a and 51b, and a partition plate 52 provided between the two side plates 51a and 51b. Each side plate 51a, 51b and the partition plate 52 are formed in a roughly elongated rectangular shape, with the longer side plate in the first direction X and the plate surface facing the second direction Y. Each side plate 51a, 51b and the partition plate 52 are connected by a bottom plate 53 at the end in the third direction Z (the end of the other side Z2 in Figure 5). The height of the side plate 51a on one side Y1 in the second direction Y, as shown in Figure 5, is higher than the height of the side plate 51b and partition plate 52 on the other side Y2. Furthermore, the other side Y2 of the partition plate 52 in the second direction Y is provided with three ribs 52a that connect to the bottom plate 53. Each side plate 51a, 51b is provided with a retaining plate 54 at each end of one side X1 and the other side X2 in the first direction X. The retaining plate 54 is provided with its surface facing the first direction X. The retaining plate 54 has an opening corresponding to the space between the side plates 51a, 51b, and a portion is formed that protrudes outward from the side plates 51a, 51b.

[0022] Two bobbins 50 facing each other in the third direction Z are positioned inside the annular shape of the magnetic core 10, and busbar insertion passages 58 are formed on one side Y1 and the other side Y2 in the second direction Y of the partition plate 52 (see Figure 7). The partition plates 52 are arranged so as to overlap near the ends in the third direction Z. In addition, the inner surfaces of the stopper plates 54 of each bobbin 50 are in close proximity to or in contact with the outer surfaces of the insertion plate portions 26 of the base member 20 (see Figure 1).

[0023] As shown in Figure 6, the leaf spring 40 is formed in the shape of a substantially rectangular plate with the second direction Y as its longitudinal direction. The leaf spring 40 is formed from sheet metal material and has a substantially concave shape when viewed from the side in the first direction X. The central portion of the leaf spring 40 in the second direction Y is a biasing contact portion 41 that abuts against the second core 12. The biasing contact portion 41 is formed in the shape of a substantially flat plate with a substantially rectangular shape that is long in the first direction X. Inclined contact portions 42 are provided on one side Y1 and the other side Y2 in the second direction Y of the biasing contact portion 41. Each inclined contact portion 42 is formed by bending on one side Z1 in the third direction Z so as to be inclined with respect to the biasing contact portion 41. In other words, the inclined contact portion 42 is formed to incline from one side Z1 to the other side Z2 in the third direction Z, along the second direction Y, toward the biasing contact portion 41, from each end 42a of the leaf spring 40 on one side Y1 and the other side Y2. The surface on one side Z1 in the third direction Z near the end 42a of each inclined contact portion 42 is the biasing member side inclined contact surface 43. The biasing member side inclined contact surface 43 is formed to incline from one side Z1 to the other side Z2 in the third direction Z, along the second direction Y, toward the biasing contact portion 41, from the end 42a of the inclined contact portion 42, similar to the inclined contact portion 42. In addition, the edge of the end 42a of each inclined contact portion 42 is formed in an arc shape when viewed from the third direction Z, and a bent portion 42a1 is formed where the edge of the end 42a is bent in the direction of the other side Z2 in the third direction Z. The bent portion 42a1 is formed in an arc shape when viewed from the third direction Z, following the edge of the end portion 42a. In addition, each inclined contact portion 42 is provided with a through hole 44 that penetrates and opens in a roughly triangular shape.

[0024] As shown in Figure 7, when the leaf spring 40 is assembled to the base member 20, the surface 41a on the other side Z2 in the third direction Z of the biasing contact portion 41 of the leaf spring 40 abuts against the surface 12a on one side Z1 of the second core 12. The biasing member side inclined contact surfaces 43 of the leaf spring 40, provided at both ends along the second direction Y, abut (surface contact) against the side wall side inclined contact surfaces 23d of the biasing member holding portions 23 on one side Y1 and the other side Y2 in the second direction Y. In other words, the side wall side inclined contact surfaces 23d are formed to be inclined so as to be in surface contact with the biasing member side inclined contact surfaces 43.

[0025] The ends 42a on both sides of the leaf spring 40 in the second direction Y are held by the biasing member holding portion 23 of the side wall portion 22, so that these ends 42a are held in a state where they have moved from a steady state to the other side Z2 in the third direction Z against the biasing force of the inclined contact portion 42 of the leaf spring 40. In other words, the leaf spring 40 is held in a biased state. On the other hand, the first core 11 is supported by the core support portion 21a at the bottom portion 21 of the base member 20. Therefore, the leaf spring 40 biases the second core 12 toward the other side Z2 in the third direction Z (i.e., toward the first core 11) due to the biasing force of the inclined contact portion 42.

[0026] The leaf spring 40 is assembled as follows. First, as shown in Figure 8, the leaf spring 40 is placed on the second core 12 from one side Z1 in the third direction Z, relative to the base member 20 which houses the magnetic core 10 and the two bobbins 50 through which the busbar 100 is inserted. At this time, the leaf spring 40 is oriented so that its longitudinal direction (i.e., the end 42a of the leaf spring 40) is aligned with the first direction X. Also, the surface 41a on the other side Z2 in the third direction Z of the biasing contact portion 41 of the leaf spring 40 is oriented toward the other side Z2. The leaf spring 40 is placed on the second core 12 so that the axis CL40 of the leaf spring 40 along the third direction Z approximately coincides with the axis CL3 of the base member 20 along the third direction Z. When the leaf spring 40 is placed on the second core 12, the surface 41a of the biasing contact portion 41 of the leaf spring 40 on the other side Z2 in the third direction Z comes into contact with the surface 12a of the second core 12 on the one side Z1 in the third direction Z. Then, as shown in Figure 10, the end portion 42a of the leaf spring 40 is rotated around the axis CL40 (axis CL3) as indicated by the arrow D1 pointing toward the V-shaped projection 23e (insertion opening 23t) of the biasing member holding portion 23. As a result, the biasing member side inclined contact surface 43 of the leaf spring 40 slides against the inclined surface 23e1 of the V-shaped projection 23e (see Figure 4), and the inclined contact portion 42 is deflected toward the other side Z2 in the third direction Z. Then, the inclined contact portion 42 (biasing member side inclined contact surface 43) of the leaf spring 40 is positioned on the side wall side inclined contact surface 23d, which is recessed from the arc-shaped bulge 23g, via the tip 23e2 of the V-shaped projection 23e (see Figure 4). At this time, the side wall side inclined contact surface 23d is in contact (surface contact) with the biasing member side inclined contact surface 43, as shown in Figure 7. As shown in Figure 4, since the side wall side inclined contact surface 23d is connected to the arc-shaped bulge 23g via the stepped portion 23g2, the rotation of the leaf spring 40 around the axis CL40 is restricted. Also, when the leaf spring 40 is assembled, if it rotates in the opposite direction to arrow D1 in Figure 10, the edge of the leaf spring 40 will come into contact with the restricting wall portion 23f. This restricts the mounting direction of the leaf spring 40.

[0027] [Second Embodiment] Next, the second embodiment will be described with reference to Figures 11 to 15. As shown in Figure 11, the magnetic unit 1A of this embodiment is a leaf spring 40A with a V-shaped knob 45 in the center, instead of the leaf spring 40 of the first embodiment. Also, the magnetic unit 1A of this embodiment is a base member 20A with a biasing member holding part 23A, which has regulating wall parts 23f at both ends along the first direction X, instead of the base member 20 with a biasing member holding part 23 of the first embodiment. Hereafter, the same reference numerals will be used for the same members and parts as in the first embodiment, and their descriptions will be omitted or simplified.

[0028] The biasing member holding portion 23A has a long sidewall-side inclined contact surface 23Ad along the first direction X (see Figure 13). The sidewall-side inclined contact surface 23Ad is formed inclined along the direction from the outside to the inside of the sidewall portion 22, and from one side Z1 to the other side Z2 in the third direction Z. The biasing member holding portion 23A is provided with regulating wall portions 23f on one side X1 and the other side X2 of the sidewall-side inclined contact surface 23Ad in the first direction X (i.e., both ends of the sidewall-side inclined contact surface 23Ad). Therefore, the internal space of the biasing member holding portion 23A is closed on the outside of the biasing member holding portion 23A and in the direction along the first direction X. The biasing member holding portion 23A has an opening on one side Z1 of the sidewall portion 22a in the third direction Z, and this side Z1 is open, forming an insertion opening 23t. Furthermore, the inner end face 23f1 of the restricting wall portion 23f in this embodiment is located on the same plane as the inner surface of the side wall portion 22 and is continuous with it (see also Figure 13). Therefore, the inner end face 23f1 of the restricting wall portion 23f protrudes inward more than the inner end face 23c1 of the locking plate 23c.

[0029] As shown in Figure 12, the leaf spring 40A is made of sheet metal and has a V-shape formed in the central part along the second direction Y. That is, the leaf spring 40A has a bent portion 45a formed on one side Z1 in the third direction Z at approximately the center position along the second direction Y, and a V-shaped bent gripping portion 45 is provided. The gripping portion 45 has a V-shaped plate portion 45b that is bent at the bent portion 45a and arranged opposite to it along the second direction Y. The leaf spring 40A is also provided with two inclined contact portions 42A. Each inclined contact portion 42A is provided at an angle from the other side Z2 in the third direction Z to the one side Z1 along the second direction Y of each V-shaped plate portion 45b in the gripping portion 45. The portion where each inclined contact portion 42A is bent and connected to each V-shaped plate portion 45b is designated as a biasing contact portion 41A. Each inclined contact portion 42A is formed in a roughly elongated rectangular shape. Each inclined contact portion 42Aa is formed in a substantially straight line along the first direction X and is a bent portion 42Aa1 that is bent in the direction of the other side Z2 of the substantially third direction Z. The surface of each inclined contact portion 42A near its end 42Aa on one side Z1 of the third direction Z is the biasing member side inclined contact surface 43. The inclined contact portion 42A is formed to be inclined from each end 42Aa on one side Y1 and the other side Y2 of the leaf spring 40A toward the biasing contact portion 41A along the second direction Y, and toward one side Z1 and the other side Z2 of the third direction Z. The biasing member side inclined contact surface 43 is formed similarly to the inclined contact portion 42A, being inclined from the end 42Aa of the inclined contact portion 42A toward the biasing contact portion 41A along the second direction Y, and toward one side Z1 and the other side Z2 of the third direction Z.

[0030] As shown in Figure 13, when the leaf spring 40A is assembled to the base member 20, each biasing contact portion 41A of the leaf spring 40A abuts against the surface 12a on one side Z1 of the second core 12. The biasing member-side inclined contact surfaces 43 on both sides of the leaf spring 40A in the second direction Y abut (surface contact) against the side wall-side inclined contact surface 23Ad of the biasing member holding portion 23. In other words, each inclined contact portion 42A on which the biasing member-side inclined contact surface 43 is provided extends inclined from the biasing contact portion 41A toward the biasing member holding portion 23A located on one side Z1 of the third direction Z relative to the biasing contact portion 41A. The side wall-side inclined contact surface 23Ad is formed inclined to abut (surface contact) with the biasing member-side inclined contact surface 43.

[0031] The ends 42Aa on both sides of the leaf spring 40A in the second direction Y are held by the biasing member holding portion 23A of the side wall portion 22, so that these ends 42Aa are held in a state where they have moved from a steady state to the other side Z2 in the third direction Z against the biasing force of the inclined contact portion 42A of the leaf spring 40. In other words, the leaf spring 40A is held in a biased state. On the other hand, the first core 11 is supported by the core support portion 21a at the bottom portion 21 of the base member 20. Therefore, the leaf spring 40 biases the second core 12 toward the other side Z2 in the third direction Z (i.e., toward the first core 11) by the biasing force of the inclined contact portion 42A.

[0032] The leaf spring 40A is assembled as follows. First, as shown in Figure 14, the leaf spring 40A is placed on the second core 12 from one side Z1 in the third direction Z to the base member 20 which houses the magnetic core 10 and the two bobbins 50 through which the busbar 100 is inserted. At this time, the leaf spring 40A is oriented so that its longitudinal direction (i.e., the end 42Aa of the leaf spring 40A) is aligned with the second direction Y. The biasing contact portion 41A of the leaf spring 40A is positioned on the other side Z2 in the third direction Z, and the gripping portion 45 is grasped to bring the two V-shaped plate portions 45b closer together against the biasing force in the direction that separates them. Then, as shown in Figure 15, the leaf spring 40A is placed on the second core 12 such that the biasing member side inclined contact surface 43 of the leaf spring 40A is in a position corresponding to the insertion opening 23t of the biasing member holding part 23A. After that, when the fingers are released from the gripping part 45 of the leaf spring 40A, the V-shaped plate part 45b separates due to the restoring force, and the biasing member side inclined contact surface 43 comes into contact (surface contact) with the side wall side inclined contact surface 23Ad, resulting in the state shown in Figure 13.

[0033] [Third Embodiment] Next, the third embodiment will be described with reference to Figures 16 to 23. As shown in Figure 16, the magnetic unit 1B of this embodiment is a leaf spring 40B in which the leaf spring 40 of the first embodiment is replaced with a biasing member side inclined contact surface 43 on one inclined contact portion 42B and a bent end portion 46 (see Figure 19) on the other inclined contact portion 42B. Furthermore, the magnetic unit 1B of this embodiment is a base member 20B in which the base member 20 equipped with the biasing member holding portion 23 of the first embodiment is replaced with a biasing member holding portion 23B equipped with regulating wall portions 23f on both ends along the first direction X and a biasing member locking portion 25 (see Figure 20) that locks onto the bent end portion 46 of the leaf spring 40B.Hereafter, the same reference numerals will be used for the same members and parts as in the first embodiment, and their descriptions will be omitted or simplified.

[0034] A biasing member locking portion 25 is provided on the side wall portion 22 of the base member 20B on one side Y1 in the second direction Y. A biasing member holding portion 23B is provided on the side wall portion 22 of the base member 20B on the other side Y2 in the second direction Y. The biasing member holding portion 23B has the same configuration as the biasing member holding portion 23A in the second embodiment. That is, the biasing member holding portion 23B has a long side wall inclined contact surface 23Bd along the first direction X (see Figure 20), and regulating wall portions 23f are provided at both ends of the side wall inclined contact surface 23Bd along the first direction X. The side wall inclined contact surface 23Bd is formed inclined along the direction from the outside to the inside of the side wall portion 22, from one side Z1 to the other side Z2 in the third direction Z.

[0035] The biasing member locking portion 25 is formed in a substantially box shape on the outside of the side wall portion 22. As shown in Figure 17, one side Z1 of the biasing member locking portion 25 in the third direction Z protrudes one side Z1 beyond the end face 22a of the side wall portion 22 in the third direction Z1. The biasing member locking portion 25 on the side Z1 of the side wall portion 22 in the third direction Z is provided with an insertion opening 25t that opens inward.

[0036] The biasing member locking portion 25 has two side plates 25a with their surfaces facing the first direction X, spaced apart in the first direction X. The other side Y2 of the two side plates 25a in the second direction Y is connected to the side wall portion 22. One side Y1 of the two side plates 25a in the second direction Y is connected to the support plate 25b. The support plate 25b is provided with its surface facing the second direction Y. The length of the support plate 25b in the third direction Z is the same as the length of the side plate 25a in the third direction Z. The support plate 25b and the two side plates 25a are each connected to a locking plate 25c on one side Z1 in the third direction Z. The locking plate 25c is provided with its surface facing the third direction Z. The locking plate 25c is formed to be long along the first direction X. The portion of the side plate 25a that protrudes from the end face 22a of the side wall portion 22 in the third direction Z on one side Z1 is also referred to as the regulating wall portion 25f.

[0037] As shown in Figures 17 and 18, the other side Z2 of the locking plate 25c in the third direction Z is provided with a locking projection 25d that protrudes toward the other side Z2. The bent end 46 of the leaf spring 40B engages with the locking projection 25d. The locking projection 25d is provided on the other side Y2 of the locking plate 25c in the second direction Y. The locking projection 25d is provided in an elongated shape along the first direction X so as to connect to the two side plates 25a (regulating wall portions 25f). That is, the regulating wall portions 25f are provided at both ends of the locking projection 25d along the first direction. As shown in Figure 18, the locking projection 25d has a guide inclined surface 25d1 that is inclined on the magnetic core 10 side. The guide inclined surface 25d1 is inclined from one side Z1 to the other side Z2 of the third direction Z, along Y1 from the other side Y2 of the second direction Y (in other words, along the inside to the outside of the biasing member locking portion 25). The other side Y2 of the second direction Y on the guide inclined surface 25d1 is connected to the end face 25c1 of the other side Y2 of the second direction Y on the locking plate 25c. The one side Y1 of the second direction Y on the guide inclined surface 25d1 is connected to the jaw surface 25d3 via the tip 25d2 of the locking projection 25d. The jaw surface 25d3 is formed as a surface parallel to the plane including the first direction X and the third direction Z. The end face 25f1 of the regulating wall portion 25f is located on the same plane as the inner surface of the side wall portion 22 and is provided continuously. Therefore, the end face 25f1 of the restricting wall portion 25f protrudes inward, which is the other side Y2 in the second direction Y, compared to the end face 25c1 of the locking plate 25c.

[0038] As shown in Figure 19, the leaf spring 40B is formed in the shape of a substantially rectangular plate with the second direction Y as its longitudinal direction. The leaf spring 40B is formed in a substantially concave shape from sheet metal material. The central portion of the leaf spring 40B in the second direction Y is formed in a substantially flat shape and is a biasing contact portion 41B that abuts against the second core 12. The biasing contact portion 41B is formed in a substantially rectangular shape that is long in the first direction X. At the ends of the biasing contact portion 41B in the first direction X, one side X1 and the other side X2, there are bent portions 41Bb that bend toward one side Z1 in the third direction Z. At the ends of the biasing contact portion 41B in the second direction Y, one side Y1 and the other side Y2, there are inclined contact portions 42B, respectively. Each inclined contact portion 42B is formed by bending so that it is inclined toward one side Z1 in the third direction Z from the biasing contact portion 41B. In other words, the inclined contact portion 42B is formed to be inclined from one end 42a on one side Y1 and the other end 42a on the leaf spring 40B toward the biasing contact portion 41B along the second direction Y, and toward the other end 42a on the third direction Z toward the other end 42a on the third direction Z.

[0039] The end 42Ba of each inclined contact portion 42B is formed in a straight line along the first direction X. A bent end portion 46 is formed at the end 42Ba of the inclined contact portion 42B on one side Y1 of the second direction Y. The bent end portion 46 has a bent base portion 46a that bends slightly toward the other side Z2 of the third direction Z with respect to the inclination direction of the inclined contact portion 42B, and a bent locking portion 46b that bends from the bent base portion 46a toward one side Z1 of the third direction Z. The bent locking portion 46b has a bent portion 46b1 that connects to the bent base portion 46a, and a rising portion 46b2 that rises from the bent portion 46b1 toward one side Z1 of the third direction Z.

[0040] Furthermore, the inclined contact portion 42B on one side Y1 in the second direction Y is provided with a mounting regulating plate portion 47 that protrudes in a flat shape from the edge of one side X1 in the first direction X near the bending base portion 46a of the bent end portion 46.

[0041] The end edge 42Ba of the inclined contact portion 42B on the other side Y2 in the second direction Y is provided with a bent portion 42Ba1 that bends in the direction of the other side Z2 in the third direction Z. The surface on the biasing contact portion 41B side of the inclined contact portion 42B on the other side Y2 in the second direction Y, on one side Z1 in the third direction Z, is the biasing member side inclined contact surface 43.

[0042] As shown in Figure 20, when the leaf spring 40B is assembled to the base member 20B, the surface 41Ba on the other side Z2 in the third direction Z of the biasing contact portion 41B of the leaf spring 40B abuts against the surface 12a on one side Z1 of the second core 12. The bent end portion 46 of the leaf spring 40B is locked with the locking projection 25d of the biasing member locking portion 25. More specifically, the tip 25d2 of the locking projection 25d abuts against the bent portion 46b1 of the bending locking portion 46b of the bent end portion 46, and the rising portion 46b2 of the bending locking portion 46b faces the jaw surface 25d3 of the locking projection 25d in the second direction Y. The biasing member side inclined contact surface 43 of the leaf spring 40B abuts (surface contact) against the side wall side inclined contact surface 23Bd of the biasing member holding portion 23B. In this way, by holding both ends of the leaf spring 40B in the second direction Y, the ends 42Ba of the two opposing inclined contact portions 42B along the second direction Y are held in a state where they have moved from the steady state to the other side Z2 in the third direction Z against the biasing force of the inclined contact portions 42B of the leaf spring 40B. That is, the leaf spring 40B is held in a biased state. On the other hand, the first core 11 is supported by the core support portion 21a at the bottom 21 of the base member 20B. Therefore, the leaf spring 40B biases the second core 12 toward the other side Z2 in the third direction Z (i.e., toward the first core 11).

[0043] The leaf spring 40B is assembled as follows. First, as shown in Figure 21, the leaf spring 40B is placed on the second core 12 from one side Z1 in the third direction Z, relative to the base member 20B which houses the magnetic core 10 and the two bobbins 50 through which the busbar 100 is inserted. At this time, the leaf spring 40B is oriented so that its longitudinal direction (i.e., the end 42Ba of the leaf spring 40B) is aligned with the second direction Y. Then, as shown in Figure 22, the other end Y2 of the leaf spring 40B (bent portion 42Ba1) is inserted into the insertion opening 23t of the biasing member holding portion 23B. Insertion of the end portion 42Ba on the other side Y2 in the second direction Y of the leaf spring 40B is performed by positioning the inclined contact portion 42B on the other side Y2 in the second direction Y such that the biasing member side inclined contact surface 43 and the side wall side inclined contact surface 23Bd of the leaf spring 40B are substantially opposite each other in the third direction Z. At this time, it is preferable and easier to work with the leaf spring 40B if the inclined contact portion 42Bb on the other side Z2 in the third direction Z of the inclined contact portion 42B having the biasing member side inclined contact surface 43 is brought into contact with the surface 12a on one side Z1 in the third direction Z of the second core 12, and the inclined contact portion 42B having the biasing member side inclined contact surface 43 is slid into the insertion opening 23t. Then, the inclined contact portion 42B on one side Y1 in the second direction Y of the leaf spring 40B is pushed toward the other side Z2 in the third direction Z, that is, the bent end portion 46 of the leaf spring 40B is pushed toward the biasing member locking portion 25. At this time, the biasing member side inclined contact surface 43 of the leaf spring 40B moves toward one side Z1 in the third direction Z, and the biasing member side inclined contact surface 43 and the side wall side inclined contact surface 23Bd come into contact (surface contact). Meanwhile, the bent end portion 46 of the pushed-in leaf spring 40B has its outer surface 46b3 of the bent locking portion 46b sliding against the end surface 25c1 of the locking plate 25c, and the bent base portion 46a is elastically curved. Then, the bending locking portion 46b is guided by the guide inclined surface 25d1 of the locking projection 25d, which causes the tip of the bending locking portion 46b to slide against it, and the tip 25d2 of the locking projection 25d fits inside the bent portion 46b1 of the bending locking portion 46b, resulting in the state shown in Figure 20.

[0044] On the other hand, incorrect assembly of the leaf spring 40B is reduced by the interference of the mounting restricting plate portion 47 of the leaf spring 40B with the biasing member holding portion 23B. For example, as shown in Figure 23, when attempting to attach the leaf spring 40B to the base member 20B with the bent end portion 46 of the leaf spring 40B facing the other side Y2 of the second direction Y, and the inclined contact portion 42B on which the biasing member side inclined contact surface 43 is provided facing the one side Y1 of the second direction Y, the mounting restricting plate portion 47 of the leaf spring 40B interferes with the restricting wall portion 23f of the biasing member holding portion 23B. Therefore, the leaf spring 40B cannot be attached to the base member 20B with its longitudinal orientation incorrect, and problems such as the leaf spring 40B coming off due to such incorrect assembly are reduced.

[0045] The magnetic material units 1, 1A, and 1B described above include a magnetic material core 10 formed in an annular shape around a first direction X, and divided along a second direction Y intersecting the first direction X, wherein the second core 12 provided on one side Z1 of the third direction Z intersecting the first direction X and the second direction Y and the first core 11 provided on the other side Z2 of the third direction Z abut along the third direction Z, and a base member 20, 20A, 20B having a bottom portion 21 that houses the magnetic material core 10 and supports the first core 11, and a side wall portion 22 provided on the side of the magnetic material core 10 in the second direction Y, and ends 42a, 42Aa, 42 in the second direction Y The system includes leaf springs 40, 40A, and 40B, which are biasing members that are held by the side wall portion 22 and bias the second core 12 toward the other side Z2 in the third direction Z. The side wall portion 22 has biasing member holding portions 23, 23A, and 23B that engage with the ends 42a, 42Aa, and 42Ba of the leaf springs 40, 40A, and 40B. The leaf springs 40, 40A, and 40B have biasing member side inclined contact surfaces 43 that are formed at an angle to the surface of one side Z1 in the third direction Z. The biasing member holding portion 23 has side wall portion side inclined contact surfaces 23d, 23Ad, and 23Bd that are formed at an angle to contact the biasing member side inclined contact surface 43 when the leaf springs 40, 40A, and 40B are biased.

[0046] This allows the leaf springs 40, 40A, and 40B to be directly attached to the base members 20, 20A, and 20B without the need for pre-assembly such as attaching the leaf springs 40, 40A, and 40B to the cover members. The biasing force of the leaf springs 40, 40A, and 40B is used to bring the biasing member-side inclined contact surface 43 and the side wall-side inclined contact surfaces 23d, 23Ad, and 23Bd into surface contact, thereby locking the leaf springs 40, 40A, and 40B in place. Surface contact, which allows for increased frictional force, makes it less likely for the leaf springs 40, 40A, and 40B to shift position relative to the biasing member holding parts 23, 23A, and 23B. In this way, the locking structure for the leaf springs 40, 40A, and 40B can be made simple and easy to assemble, while the leaf springs 40, 40A, and 40B can be fixed securely, and a configuration in which the leaf springs 40, 40A, and 40B, which serve as biasing members, are assembled into a case including the base members 20, 20A, and 20B can be properly realized.

[0047] Furthermore, the leaf springs 40, 40A, and 40B each have biasing contact portions 41, 41A, and 41B that contact the second core 12, and inclined contact portions 42, 42A, and 42B that are inclined from the ends 42a, 42Aa, and 42Ba in the second direction Y toward the biasing contact portions 41, 41A, and 41B along the second direction Y, and toward one side Z1 and the other side Z2 in the third direction Z, and are provided with a biasing member side inclined contact surface 43. This allows the use of leaf springs 40, 40A, and 40B made of sheet metal material, which have a simple structure and maintain a strong biasing force, as biasing members, and can be biased to properly hold the magnetic core 10.

[0048] Furthermore, the biasing member holding portion 23 is provided on each of the side wall portions 22 provided on one side Y1 and the other side Y2 of the second direction Y. The biasing member holding portion 23 on one side Y1 of the second direction Y is provided with a V-shaped projection 23e on one side X1 of the inclined contact surface 23d on the side wall portion that is provided along the first direction X, and a regulating wall portion 23f on the other side X2 of the inclined contact surface 23d on the side wall portion. The biasing member holding portion 23 on the other side Y2 of the second direction Y is provided with a V-shaped projection 23e on the other side X2 of the inclined contact surface 23d on the side wall portion that is provided along the first direction X, and a regulating wall portion 23f on one side X1 of the inclined contact surface 23d on the side wall portion. As a result, the leaf spring 40 can be easily assembled to the base member 20 by rotating it around the axis CL3 along the third direction Z in the base member 20, thereby improving the workability of the assembly process.

[0049] Furthermore, the biasing member holding sections 23A and 23B are provided with regulating wall sections 23f at both ends of the inclined contact surfaces 23Ad and 23Bd on the side wall section, which are provided along the first direction X. As a result, the leaf springs 40A and 40B can be locked to the biasing member holding sections 23A and 23B simply by inserting the ends 42Aa and 42Ba of the leaf springs 40A and 40B into the biasing member holding sections 23A and 23B from a direction along the second direction Y, thus simplifying the assembly work of the leaf springs 40A and 40B.

[0050] Furthermore, the biasing member holding portion 23A is provided on each of the side wall portions 22 provided on one side Y1 and the other side Y2 of the second direction Y, and the leaf spring 40A is formed in a V-shape in the central part in the second direction Y. This allows the V-shaped portion to be used as a gripping portion 45, and the leaf spring 40A can be assembled to the base member 20A by simply gripping it, further improving the workability of the assembly work of the leaf spring 40A.

[0051] Furthermore, the magnetic material unit according to the embodiments of the present invention described above is not limited to the embodiments described above, and various modifications are possible within the scope of the claims.

[0052] In the above description, the side walls 22 of the base members 20, 20A, and 20B are provided on one side Y1 and the other side Y2 in the second direction Y. However, it is also possible to provide the side walls 22 (and the biasing member holding parts 23, 23A, and 23B provided on the side walls 22) on only one side, and to use the other side to lock the ends 42a, 42Aa, and 42Ba of the leaf springs 40, 40A, and 40B. Furthermore, although leaf springs 40, 40A, and 40B were used as the biasing members, other forms of biasing members can also be used.

[0053] The magnetic unit according to this embodiment may be constructed by appropriately combining the components of the embodiments and modified examples described above. [Explanation of Symbols]

[0054] 1,1A,1B: Magnetic material unit 10: Magnetic core 11: First Core 12: Second Core 20, 20A, 20B: Base members 21: Bottom 22: Side wall section 23, 23A, 23B: Biasing member holding part 23d, 23Ad, 23Bd: Side wall side inclined contact surface 23e: Mountain-shaped protrusion 23f: Restrictive wall section 40, 40A, 40B: Leaf spring 41,41A,41B: Forced contact part 42,42A,42B: Inclined contact part 42a, 42Aa, 42Ba: End section 43: Slanted contact surface on biasing member side X: 1st direction Y: Second direction Z: 3rd direction

Claims

1. A magnetic core comprising a first core and a second core formed in an annular shape around a first direction and divided along a second direction intersecting the first direction, wherein the second core provided on one side of a third direction intersecting the first and second directions and the first core provided on the other side of the third direction abut along the third direction, A base member having a bottom portion that houses the magnetic core and supports the first core, and a side wall portion provided on the side of the magnetic core in the second direction, A biasing member whose end in the second direction is held by the side wall and which biases the second core to the other side in the third direction, Equipped with, The side wall portion has a biasing member holding portion that engages with the end of the biasing member, The biasing member has a biasing member-side inclined contact surface that is formed at an angle to one side of the third direction, The biasing member holding portion has a side wall portion with an inclined contact surface that is inclined to contact the biasing member side inclined contact surface when the biasing member is in a biased state. Magnetic material unit.

2. The biasing member has a biasing contact portion that contacts the second core, and an inclined contact portion that is inclined from one side to the other in the third direction, extending from the end in the second direction toward the biasing contact portion along the second direction, and having a biasing member side inclined contact surface. The magnetic material unit according to claim 1.

3. The biasing member holding portion is provided on each of the side wall portions provided on one side and the other side in the second direction, On one side of the second direction, the biasing member holding portion is provided with a V-shaped projection on one side of the inclined contact surface on the side wall portion that is provided along the first direction, and a regulating wall portion is provided on the other side of the inclined contact surface on the side wall portion. The biasing member holding portion on the other side of the second direction is provided with the V-shaped projection on the other side of the inclined contact surface on the side wall portion that is provided along the first direction, and the regulating wall portion is provided on one side of the inclined contact surface on the side wall portion. A magnetic material unit according to claim 1 or claim 2.

4. The biasing member holding portion is provided with regulating wall portions at both ends of the inclined contact surface on the side wall portion that is provided along the first direction. A magnetic material unit according to claim 1 or claim 2.

5. The biasing member holding portion is provided on each of the side wall portions provided on one side and the other side in the second direction, The biasing member consists of a leaf spring whose central portion in the second direction is formed in a V-shape. The magnetic material unit according to claim 4.

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