Coil Device

Abstract

To provide a coil device that can be created with less welding man-hours.SOLUTION: A coil device 1 includes a laminated core 20 in which a plurality of plate-shaped cores are laminated, and that has a first laminated core 22 and a second laminated core 24 butted against each other, and a fixing bracket 30 for fixing the core to the substrate. The fixing bracket includes a base portion 32 on which the core is placed, and a first portion 34 that has a shape that stands up against the base portion by bending a part of a sheet metal that forms the base portion, and has a width in the stacking direction of the plate-shaped cores of each stacked core orthogonal to a standing direction of standing close to a butt portion 28 between the first laminated core and the second laminated core and standing up against the base portion. In this coil device, the first portion, the first laminated core, and the second laminated core are joined by attaching the first portion and the butt portion together.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a coil device. [Background technology]

[0002] Coil devices such as reactors are incorporated into household electrical appliances such as washing machines and refrigerators. For example, Patent Document 1 describes a specific configuration of this type of coil device. In Patent Document 1, a core is made by joining two core parts by welding. A fixing bracket for fixing the core to a substrate is joined to the made core by welding. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2002-93643 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, since it is necessary to weld the fixing metal fitting to the core after welding the core parts, there is a problem in that the number of welding steps is large.

[0005] The present invention has been made in view of the above circumstances, and has an object to provide a coil device that can be produced with fewer welding steps. [Means for solving the problem]

[0006] A coil device according to one embodiment of the present invention includes a laminated core formed by stacking multiple plate-shaped cores, the core having a first laminated core and a second laminated core butted together, and a fixture for fixing the core to a substrate. The fixture has a base on which the core is placed, and a first portion formed by bending a portion of the sheet metal forming the base so as to stand upright relative to the base. The first portion is adjacent to the butt portion of the first laminated core and the second laminated core, and has a width in the stacking direction of the plate-shaped cores of each laminated core, perpendicular to the standing direction relative to the base. This coil device is joined together by co-attaching the first portion and the butt portion, thereby joining three portions: the first portion, the first laminated core, and the second laminated core. Furthermore, the center of curvature of the bent shape formed by bending a portion of the sheet metal is located on the opposite side of the core from the first portion.

[0007] In the coil device configured in this manner, the first section, the first laminated core, and the second laminated core are joined together by a single welding operation, which allows the coil device to be produced with fewer welding steps than conventional coil devices.

[0008] A coil device according to one embodiment of the present invention includes a laminated core formed by stacking multiple plate-shaped cores, the core having a first laminated core and a second laminated core butted against each other, and a fixture for fixing the core to a substrate. The fixture has a base on which the core is placed, and a first portion formed by bending a portion of the sheet metal forming the base so as to stand upright relative to the base. The first portion is adjacent to the butt portion of the first laminated core and the second laminated core, and has a width in the stacking direction of the plate-shaped cores of each laminated core, perpendicular to the standing direction relative to the base. This coil device is joined together by attaching the first portion and the butt portion, thereby joining three portions: the first portion, the first laminated core, and the second laminated core. Furthermore, a cut penetrating the sheet metal, modeling the first portion, is formed in the sheet metal. The first portion is formed upright relative to the base by bending the portion of the portion modeling the first portion that is connected to the base.

[0009] A coil device according to one embodiment of the present invention includes a laminated core formed by stacking multiple plate-shaped cores, the core having a first laminated core and a second laminated core butted together, and a fixture for fixing the core to a substrate. The fixture has a base on which the core is placed, and a first portion formed by bending a portion of the sheet metal forming the base so as to stand upright relative to the base. The first portion is adjacent to the butt joint between the first laminated core and the second laminated core, and has a width in the stacking direction of the plate-shaped cores of each laminated core. This coil device is joined by co-attaching the first portion and the butt joint, thereby joining three portions: the first portion, the first laminated core, and the second laminated core. The first portion stands upright at an angle relative to the base, so that at least a portion of the first portion is adjacent to the butt joint.

[0010] In one embodiment of the present invention, the first laminated core and the second laminated core each have a first end face and a second end face aligned with the end faces of the plate-shaped core, and the width of the first portion in the lamination direction may be smaller than or substantially equal to the thickness in the lamination direction of the end faces of the core consisting of the first end face and the second end face.

[0011] In one embodiment of the present invention, the first laminated core and the second laminated core are stacked in the upright direction, for example, on the base.

[0012] In one embodiment of the present invention, for example, the first laminated core and the second laminated core each have a first end face and a second end face aligned with the end faces of the plate-like core, and the core has an end face consisting of the first end face and the second end face. In this configuration, the coil device may be configured such that three parts, namely the first part, the first laminated core, and the second laminated core, are joined together by attaching the first part, whose height in the standing direction is lower than the height of the boundary between the first end face and the second end face on the end face of the core, to the butted part.

[0013] A coil device according to an embodiment of the present invention may have a configuration in which a first laminated core is disposed on a base, and a second laminated core is disposed on the first laminated core.

[0014] In one embodiment of the present invention, the core is an EI core made up of a first laminated core, for example an I core, and a second laminated core, for example an E core. [Effects of the Invention]

[0015] According to one embodiment of the present invention, it is possible to provide a coil device that can be produced with fewer welding steps. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is an external perspective view of a coil device according to an embodiment of the present invention; [Figure 2] 1 is an exploded perspective view of a coil device according to an embodiment of the present invention; [Figure 3A] 5A to 5C are diagrams schematically showing a manufacturing process of a coil device according to an embodiment of the present invention. [Figure 3B] 5A to 5C are diagrams schematically showing a manufacturing process of a coil device according to an embodiment of the present invention. [Figure 3C] 5A to 5C are diagrams schematically showing a manufacturing process of a coil device according to an embodiment of the present invention. [Figure 3D] 5A to 5C are diagrams schematically showing a manufacturing process of a coil device according to an embodiment of the present invention. [Figure 3E] 5A to 5C are diagrams schematically showing a manufacturing process of a coil device according to an embodiment of the present invention. [Figure 4] 1 is an enlarged side view of the vicinity of a rising portion of a fixing metal fitting of a coil device according to an embodiment of the present invention. [Figure 5] FIG. 10 is an enlarged side view of the vicinity of a rising portion of a fixing metal fitting of a coil device according to a comparative example. [Figure 6] 10 is an enlarged side view of the vicinity of a rising portion of a fixing metal fitting of a coil device according to a modified example of the present invention. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following description, common or corresponding elements will be denoted by the same or similar reference numerals, and redundant description will be omitted.

[0018] Fig. 1 is an external perspective view of a coil device 1 according to one embodiment of the present invention. Fig. 2 is an exploded perspective view of the coil device 1. Figs. 3A to 3E are diagrams schematically showing the manufacturing process of the coil device 1.

[0019] In the following description, the direction from the upper right to the lower left in FIG. 1 is referred to as the X direction, the direction from the upper left to the lower right as the Y direction, and the direction from the bottom to the top as the Z direction. The X, Y, and Z directions are perpendicular to each other. For convenience of explanation, the side indicated by the Z arrowhead is also referred to as the upper side, and the opposite side is also referred to as the lower side. Note that these directional names are used for convenience in explaining the relative positional relationships of components and do not indicate absolute directions. For example, the Z direction (up-down direction) does not necessarily have to be the vertical direction, but may be, for example, the horizontal direction.

[0020] The coil device 1 is a reactor for use in household electrical appliances such as washing machines and refrigerators. The coil device 1 is merely one example of an embodiment of the present invention. The configuration of the embodiment of the present invention is not limited to this and can be modified as appropriate. The coil device 1 is not limited to a reactor (inductor) and may be replaced with another device having a core, such as a transformer or a filter.

[0021] The coil device 1 includes a coil 10, a core 20, a fixture 30, and a bobbin 40. The coil device 1 is fixed to a substrate (not shown) by the fixture 30.

[0022] The coil 10 is a spirally wound conductor coated with insulation such as enamel. The coil 10 is wound around the outer periphery of the cylindrical portion 42 of the bobbin 40. The conductor wire is made of, for example, copper or aluminum. The coil 10 may be made of round wire or rectangular wire such as an edgewise coil. The coil 10 may also be made of a conductor in the form of foil or strip, such as a copper foil coil or copper strip coil.

[0023] The core 20 is an EI core made up of an I core 22 and an E core 24 butted against each other. The I core 22 is a first laminated core made up of a plurality of I-shaped plate cores 22a laminated in the X direction (stacking direction). The E core 24 is a second laminated core made up of a plurality of E-shaped plate cores 24a laminated in the X direction (stacking direction). In this embodiment, the plate cores 22a and 24a are made of, for example, silicon steel plates, taking into consideration the required inductance value and material costs. Note that, instead of silicon steel plates, other materials (for example, amorphous ribbons) may be used for the plate cores 22a and 24a.

[0024] The E core 24 comprises a center leg 24A, a pair of outer legs 24B disposed on either side thereof, and a connecting portion 24C connecting the center leg 24A and the pair of outer legs 24B. The center leg 24A is inserted into the hollow portion of the bobbin 40 around which the coil 10 is wound. The center leg 24A and the pair of outer legs 24B of the E core 24 are abutted against the top surface of the I core 22, thereby forming a magnetic path (more specifically, a closed magnetic path) for the magnetic flux generated by the coil 10.

[0025] The fixing bracket 30 is a bracket for fixing the coil 10, the core 20, and the bobbin 40 to a substrate. The fixing bracket 30 has a base 32 on which the core 20 is placed, a pair of rising portions 34 (first portions) that stand upright relative to the base 32 in the Z direction (direction perpendicular to the lamination direction) that is perpendicular to the lamination direction (X direction) of the plate-like cores 22a and 24a, and a screw hole 36 through which a screw for fastening the base 32 to the substrate is passed.

[0026] The fastening bracket 30 is formed, for example, by processing a single sheet of metal. Specifically, a portion of the metal sheet forming the base 32 is cut (the metal sheet is punched to form notches that penetrate the metal sheet in the Z direction, including notches 34a that are long in the X direction and notches 34b that extend in the Y direction from both ends of notch 34a toward the inside of the base 32). Of the rectangular portion surrounded on three sides by notch 34a and the pair of notches 34b, a portion 34c that is connected to the base 32 is bent at a right angle relative to the base 32. This forms the rising portion 34 that stands upright relative to the base 32. In other words, the rising portion 34 is formed by bending the portion 34c that is connected to the base 32 of the rectangular portion that represents the rising portion 34. Therefore, the base 32 and the rising portion 34 are formed integrally. In addition, a pair of screw holes 36 are formed by punching two locations in the metal sheet. The metal plate forming the fastening fitting 30 is, for example, a zinc-plated steel plate.

[0027] The pair of rising portions 34 are plate-like portions that are wide in the X direction and tall in the Z direction, and are arranged facing each other with a gap in the Y direction. On the base 32, in the space within this gap (i.e., the space between the pair of rising portions 34), an I core 22 is arranged with its longitudinal direction oriented along the Y direction. The arrangement distance between the pair of rising portions 34 is only slightly wider than the longitudinal length of the I core 22. Therefore, when the I core 22 is arranged in the space, the end face 22b (first end face) of the I core 22, where the end faces of the plate-like cores 22a are aligned, and the rising portion 34 are positioned close to each other (positioned slightly apart in the Y direction).

[0028] The E core 24 is arranged on the upper surface of the I core 22 with the center leg 24A and the pair of outer leg portions 24B butting against each other. That is, the I core 22 and the E core 24 are stacked on the base 32 in the orthogonal direction (Z direction, the standing direction in which the rising portions 34 stand) in the order of the I core 22 and the E core 24.

[0029] The end face 24b (second end face) of the E core 24, where the end faces of the plate-shaped cores 24a are aligned, and the end face 22b of the I core 22 are located on the same plane. The end face of the core 20 consisting of the end face 22b and the end face 24b will be referred to as the "end face 20a."

[0030] In this embodiment, the I core 22, the E core 24, and the fixture 30 (more specifically, the rising portion 34) are joined together. For example, TIG welding or plasma welding is used to join these three parts, in which the base materials are heated to fuse them together and then solidify and join them as they cool. The joining of these three parts will be described in detail below.

[0031] Before welding, the rising portion 34 has a height H1 in the direction perpendicular to the lamination (Z direction) that is slightly (at most 2.5 mm) lower than the height H2 (see FIG. 3D) of the boundary between the end face 22b and the end face 24b before welding. Note that the height H2 of the boundary between the end face 22b and the end face 24b before welding is the same as the height H3 of the boundary 26 between the I core 22 and the E core 24 shown in FIG. 1. Heights H1 to H3 and a height H1' described below are heights from the mounting surface between the base 32 and the substrate.

[0032] When a welding machine melts the butt portion 28 of the I-core 22 and the E-core 24 (more specifically, the outer leg portion 24B), including the boundary between the end face 22b and the end face 24b, and the rising portion 34, the molten metal fuses together. When the fused I-core 22, outer leg portion 24B, and rising portion 34 cool and solidify, the three parts of the I-core 22, the E-core 24, and the fixture 30 are joined together.

[0033] That is, the fixing bracket 30 has a leading end close to the butt joint 28 between the I-core 22 and the E-core 24 (outer leg 24B), and has a rising portion 34 (first portion) formed along the lamination direction (X direction) of each of the plate-shaped cores 22a, 24a (in other words, having a width in the X direction, which is a direction perpendicular to the rising direction (Y direction)). The rising portion 34, whose height H1 in the direction perpendicular to the lamination (Z direction) is lower than the height H2 of the boundary between the end face 22b and the end face 24b on the end face 20a, is attached together with the butt joint 28, thereby joining the three parts of the I-core 22, the E-core 24, and the fixing bracket 30.

[0034] Whether or not the joining was performed using the rising portion 34 with a height H1 lower than the height H2 can be determined from the relationship between the height H1' of the rising portion 34 after solidification and the height H3 of the boundary 26 between the I core 22 and the E core 24. Specifically, if the joining was performed using the rising portion 34 with a height H1 lower than the height H2, the height H1' of the rising portion 34 after solidification will be only slightly higher than the height H3. Specifically, the height H1' will be only 1.5 mm to 2.5 mm higher than the height H3. Note that the height H1' of the rising portion 34 after solidification varies slightly in the width direction (X direction). Therefore, the height H1' here is, for example, the average value of the heights of the rising portion 34 at sample points (e.g., 10 points positioned at intervals of N mm) in the width direction (X direction).

[0035] By forming the rising portion 34 lower than the boundary between the end face 22b and the end face 24b in the direction perpendicular to the lamination (Z direction), the boundary between the end face 22b and the end face 24b is exposed without being covered by the rising portion 34 before welding. Therefore, the butt joint 28, including this boundary, is directly heated and melted by the arc heat. Because the butt joint 28 is directly heated, insufficient melting of the butt joint 28 is avoided, and the three parts of the I core 22, the E core 24, and the fastener 30 are firmly joined together.

[0036] In contrast, if the rising portion 34 is formed higher than the boundary between the end face 22b and the end face 24b in the direction perpendicular to the lamination (Z direction), or if the rising portion 34 is formed at the same height as the boundary, the boundary between the end face 22b and the end face 24b is covered by the rising portion 34 and is not exposed before welding. In these cases, the boundary is heated only indirectly by the arc heat via the rising portion 34. As a result, the butt joint 28 is insufficiently melted, making it difficult to ensure the joint strength of the I-core 22, the E-core 24, and the fastener 30.

[0037] Furthermore, if the rising portion 34 is made too low below the boundary between the end face 22b and the end face 24b in the direction perpendicular to the stacking direction (Z direction) (for example, if the difference between the height H1 and the height H2 exceeds 2.5 mm), the molten metal in the rising portion 34 and the molten metal in the outer leg portion 24B located away from it will not fuse sufficiently, making it difficult to ensure the joint strength between the E core 24 and the fixing bracket 30.

[0038] In this way, in the coil device 1 according to this embodiment, the I core 22, the E core 24, and the fixing bracket 30 are joined together by a single welding operation. Therefore, the coil device 1 can be produced with fewer welding steps than conventional coil devices.

[0039] The width W1 (dimension in the X direction) of the rising portion 34 before welding is smaller than or equal to the thickness T1 (dimension in the X direction) of the end surface 20a. Specifically, the width W1 of the rising portion 34 before welding is 50% to 100% of the thickness T1. The width W1' (dimension in the X direction) of the solidified portion 34' of the rising portion 34 is smaller than or substantially equal to the thickness T1. Note that the width W1' varies slightly in the height direction (Z direction). Therefore, the width W1' here is, for example, the average value of the widths of the portion 34' at sample points (e.g., 10 points positioned at intervals of M mm) in the height direction (Z direction).

[0040] The wider the width W1 of the rising portion 34 before welding, the wider the area over which the butt joint 28 and the rising portion 34 can be welded in the X direction. However, if the width W1 is greater than 100% of the thickness T1, the protruding portion of the rising portion 34 before welding that protrudes from the end surface 20a in the X direction beyond the butt joint 28 is unlikely to fuse with the butt joint 28. The protruding portion that does not fuse with the butt joint 28 flows and solidifies, for example, onto the base 32. This results in a poor appearance of the coil device 1. Furthermore, in order to increase the width W1, the fixing bracket 30 must be made from a large sheet metal.

[0041] The narrower the width W1 of the rising portion 34 before welding, the more easily the arc heat is transferred to the butt joint 28, causing the butt joint 28 to melt. However, if the width W1 is less than 50% of the thickness T1, it is not possible to ensure a sufficient welding allowance in the X direction between the butt joint 28 and the rising portion 34.

[0042] In view of these, it is more preferable that the width W1 of the rising portion 34 before welding is a width that is, for example, 50% or more and less than 100% of the thickness T1, which allows for both the ease of melting the butt joint portion 28 and ensuring a welding allowance in the X direction between the butt joint portion 28 and the rising portion 34.

[0043] 4 is an enlarged side view of the vicinity of the rising portion 34 of the coil device 1. The rising portion 34 is formed by partially cutting and bending a metal plate in an area closer to the center of the base portion 32 than a portion 34c corresponding to its base (in other words, within the area where the core 20 is placed). As a result, as shown in FIG. 4, the center of curvature C of the portion 34c (the bent portion formed by bending a part of the metal plate) is located on the opposite side of the rising portion 34 from the core 20.

[0044] 5 is an enlarged side view of the vicinity of rising portion 134 of coil device 101 according to the comparative example. In the comparative example, rising portion 134 is formed by partially cutting and bending a metal plate in an area closer to the outside of base portion 132 than portion 134c corresponding to its base (in other words, outside the area where core 120 is placed). As a result, as shown in FIG. 5, portion 134c has a bent shape in which center of curvature C' is located closer to core 120 than rising portion 134.

[0045] In the comparative example, even if an attempt is made to bring rising portion 134 into contact with core 120, portion 134c mechanically interferes with core 120 (portion 134c comes into contact with core 120), and therefore, as shown in Fig. 5, substantially the entire rising portion 134 must be positioned away from end face 120a of core 120 by at least the radius of curvature of portion 134c. The wider the gap between end face 120a and rising portion 134 (in other words, the wider the air layer between butt portion 128 and rising portion 134), the more difficult it becomes for the molten metals in butt portion 128 and rising portion 134 to fuse together.

[0046] In contrast, in this embodiment, portion 34c does not mechanically interfere with core 20, and therefore, as shown in Fig. 4, substantially the entire rising portion 34 can be disposed in contact with end face 20a of core 20. Compared to the comparative example, the gap between butt portion 28 and rising portion 34 can be made smaller, which makes it easier to fuse the molten metals of butt portion 28 and rising portion 34 together.

[0047] In this embodiment, the rising portion 34 is formed by partially cutting and bending the metal plate within the area where the core 20 is placed, thereby reducing the size (area) of the metal plate and material costs compared to when the rising portion 34 is formed outside the area where the core 20 is placed.

[0048] In this embodiment, the I core 22 is disposed on the base 32, and the E core 24 is disposed on the I core 22. The height in the Z direction of the I core 22 is shorter than the length in the Z direction of the outer leg 24B. Therefore, compared to a configuration in which the I core 22 is disposed on the E core 24, the height position of the abutting portion 28 relative to the base 32 can be lowered. By lowering the height position of the abutting portion 28, the height of the rising portion 34 can be reduced, and therefore the fixing bracket 30 can be made from a smaller sheet metal.

[0049] Next, a method for manufacturing the coil device 1 will be described with reference to Figures 3A to 3E. Note that the method for manufacturing the coil device 1 described below is merely an example. The method for manufacturing the coil device 1 is not limited to a method of carrying out the steps shown in Figures 3A to 3E, and can be modified as appropriate.

[0050] 3A, a portion of the metal plate constituting base 32 is cut away in an area closer to the center of base 32 than portion 34c, forming notch 34a and a pair of notches 34b. In addition, a pair of screw holes 36 are formed by punching out two locations in the metal plate.

[0051] 3B, the portion 34c is bent at a right angle to the base portion 32. As a result, the rising portion 34 that stands upright relative to the base portion 32 is formed.

[0052] 3C, on the base 32, all of the plate cores 22a constituting the I core 22 are arranged side by side in the stacking direction (X direction) with their longitudinal directions aligned along the Y direction between a pair of rising portions 34, without any gaps between them (in other words, all of the plate cores 22a are stacked in the stacking direction with their longitudinal directions aligned along the Y direction). The multiple plate cores 22a arranged side by side in the stacking direction are clamped and fixed by a jig such as a clamp so that the plate cores 22a do not separate on the base 32.

[0053] The center leg 24A of the E core 24 is inserted into the hollow portion of the bobbin 40 around which the coil 10 is wound. Next, as shown in FIG. 3D, the center leg 24A and the pair of outer leg portions 24B of the E core 24 are butted against the upper surface of the I core 22. All of the plate-shaped cores 24a that make up the E core 24 are previously fixed together by welding. Specifically, the center leg portions 24A of all of the plate-shaped cores 24a that make up the E core 24 are previously joined by welding.

[0054] 3E, the rising portion 34 and the butt portion 28 are attached together to join the I core 22, the E core 24, and the fixture 30. To ensure a welding allowance in the X direction between the butt portion 28 and the rising portion 34, for example, the rising portion 34 has a width W1 equal to the thickness T1 of the end face 20a. To achieve both ease of melting of the butt portion 28 and ensuring a welding allowance, for example, the rising portion 34 may have a width W1 that is 50% or more but less than 100% of the thickness T1 of the end face 20a. To ensure that the butt portion 28, including the boundary between the end face 22b and the end face 24b, is directly heated and melted by arc heat, the rising portion 34 has a height H1 that is lower than the height H2 of this boundary (but at most 2.5 mm lower).

[0055] The above is a description of exemplary embodiments of the present invention. The embodiments of the present invention are not limited to those described above, and various modifications are possible within the scope of the technical concept of the present invention. For example, configurations that appropriately combine embodiments explicitly shown as examples in the specification or obvious embodiments are also included in the embodiments of the present invention.

[0056] FIG. 6 is an enlarged side view of the vicinity of the rising portion 34 of the coil device 1 according to a modified example of the present invention. As described in the above embodiment, the arrangement interval between the pair of rising portions 34 is slightly wider than the longitudinal length of the I core 22. Therefore, when the I core 22 is arranged between the pair of rising portions 34, a gap is formed between the end surface 22b of the I core 22 and the rising portion 34. The wider this gap, the more difficult it is for the molten metals at the butt portion 28 and the rising portion 34 to fuse together. Therefore, as shown in FIG. 6 , the root portion 34c of the rising portion 34 may be plastically deformed during or before welding so as to tilt slightly toward the butt portion 28 from a position perpendicular to the base portion 32 (in other words, a state bent at a right angle to the base portion 32). In other words, the rising portion 34 may be raised at an angle relative to the base portion 32 so that at least a portion (specifically, the tip of the rising portion 34) is close to the butt portion 28. This allows the gap between the butted portion 28 and the rising portion 34 to be reduced.

[0057] The wider the width W1 of the rising portion 34, the higher the rigidity of the rising portion 34, making it more difficult to plastically deform the rising portion 34 toward the butt portion 28. Therefore, the rising portion 34 may be divided into multiple pieces in the X direction (in other words, multiple narrow rising portions 34 lined up in the X direction). Forming multiple narrow rising portions 34 makes it easier to plastically deform the rising portion 34 toward the butt portion 28, and also ensures a welding allowance in the X direction between the butt portion 28 and the rising portion 34. [Explanation of symbols]

[0058] 1 Coil device 20 cores 22 I-core (first laminated core) 22a I-type plate core (plate core) 24 E-core (second laminated core) 24a E-type plate core (plate core) 28 Butt joint 30 Fixing bracket 32 Base 34 Rising Section (Part 1)

Claims

1. a laminated core formed by laminating a plurality of plate-shaped cores, the core having a first laminated core and a second laminated core butted against each other; a fixture for fixing the core to a substrate; Equipped with The fixing bracket is a base on which the core is placed; a first portion that is formed by bending a portion of the sheet metal forming the base and that stands up relative to the base, the first portion being close to the butt portion of the first laminated core and the second laminated core and having a width in a direction perpendicular to the standing direction in which the first laminated core and the second laminated core stand up relative to the base, the first portion having a width in a lamination direction of the plate-like cores of each laminated core, By joining the first portion and the butted portion together, three portions, i.e., the first portion, the first laminated core, and the second laminated core, are joined together, a center of curvature of a bent shape formed by bending a portion of the metal plate is located on an opposite side of the core with respect to the first portion; the first laminated core and the second laminated core each have a first end face and a second end face aligned with an end face of the plate-like core, a width of the first portion in the lamination direction is substantially equal to a thickness of an end face of the core, the end face being made up of the first end face and the second end face, in the lamination direction; the first laminated core and the second laminated core are stacked on the base in the standing direction, the first portion, the height of which in the standing direction is lower than the height of the boundary between the first end face and the second end face, is attached to the butted portion, thereby joining the three portions together, The difference between the height of the boundary and the height of the first portion before welding is within 2.5 mm. Coil device.

2. a laminated core formed by laminating a plurality of plate-shaped cores, the core having a first laminated core and a second laminated core butted against each other; a fixture for fixing the core to a substrate; Equipped with The fixing bracket is a base on which the core is placed; a first portion that is formed by bending a portion of the sheet metal forming the base and that stands up relative to the base, the first portion being close to the butt portion of the first laminated core and the second laminated core and having a width in a direction perpendicular to the standing direction in which the first laminated core and the second laminated core stand up relative to the base, the first portion having a width in a lamination direction of the plate-like cores of each laminated core, By joining the first portion and the butted portion together, three portions, i.e., the first portion, the first laminated core, and the second laminated core, are joined together, a notch penetrating the metal plate, the notch representing the first portion being formed in the metal plate, and the first portion is formed in a shape that stands up relative to the base portion by bending a portion of the portion representing the first portion by the notch that is connected to the base portion; the first laminated core and the second laminated core each have a first end face and a second end face aligned with an end face of the plate-like core, a width of the first portion in the lamination direction is substantially equal to a thickness of an end face of the core, the end face being made up of the first end face and the second end face, in the lamination direction; the first laminated core and the second laminated core are stacked on the base in the standing direction, the first portion, the height of which in the standing direction is lower than the height of the boundary between the first end face and the second end face, is attached to the butted portion, thereby joining the three portions together, The difference between the height of the boundary and the height of the first portion before welding is within 2.5 mm. Coil device.

3. a laminated core formed by laminating a plurality of plate-shaped cores, the core having a first laminated core and a second laminated core butted against each other; a fixture for fixing the core to a substrate; Equipped with The fixing bracket is a base on which the core is placed; a first portion that is formed by bending a portion of the sheet metal forming the base and that stands up relative to the base, the first portion being close to the butt portion of the first laminated core and the second laminated core and having a width in a direction perpendicular to the standing direction in which the first laminated core and the second laminated core stand up relative to the base, the first portion having a width in a lamination direction of the plate-like cores of each laminated core, By joining the first portion and the butted portion together, three portions, i.e., the first portion, the first laminated core, and the second laminated core, are joined together, the first portion stands at an oblique angle relative to the base portion so that at least a portion of the first portion is adjacent to the abutting portion; the first laminated core and the second laminated core each have a first end face and a second end face aligned with an end face of the plate-like core, a width of the first portion in the lamination direction is substantially equal to a thickness of an end face of the core, the end face being made up of the first end face and the second end face, in the lamination direction; the first laminated core and the second laminated core are stacked on the base in the standing direction, the first portion, whose height in the standing direction is lower than the height of the boundary between the first end face and the second end face on the end face of the core, is attached to the butted portion, thereby joining the three portions together, The difference between the height of the boundary and the height of the first portion before welding is within 2.5 mm. Coil device.

4. the first laminated core is disposed on the base, and the second laminated core is disposed on the first laminated core; The coil device according to any one of claims 1 to 3.

5. The core is an EI core consisting of the first laminated core which is an I core and the second laminated core which is an E core. The coil device according to any one of claims 1 to 4.

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