JPH04302112A - Electromagnetic devices and power supplies - Google Patents

Abstract

PURPOSE:To manufacture a printed coil having a general purpose property for the intended purpose and the number of turns of a coil pattern having the property of easy lamination and also having the property of obtaining creeping distance without fail. CONSTITUTION:A composite sheet 1 is formed by adjacently positioning insulating sheet parts 3a to 3e through the intermediary of bendable parts 2a to 2d. Coil patterns 5a to 5c are printed on the insulating sheet parts 3a to 3e. The bending parts 2a to 2d are bent respectively, and the insulating sheet parts 3a to 3e are overlapped with each other. The overlapped insulating sheet parts 3a to 3e are reinforced by an insulated reinforcement plate 7, and the insulation between the coils formed by the coil patterns 5a to 5c is secured.

Description

[Detailed description of the invention]

[Object of the invention]

0002

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic device and a power supply device comprising a printed coil having a coil pattern printed on an insulating sheet.

0003

2. Description of the Related Art Conventionally, a printed coil as an electromagnetic device has a structure in which a coil pattern 62 is printed on one or both sides of an insulating sheet 61 made of ceramic or synthetic resin, as shown in FIGS. 13 and 14. There is. When the coil patterns 62 are printed on both sides, the coil patterns 62 on both sides may be electrically connected through the through holes 63 provided in the insulating sheet 61 to form a printed coil 64.

Furthermore, in order to increase the number of coil turns by stacking the printed coils 64, as shown in FIGS. 15 and 16, the coil pattern 62 of each printed coil 64 is
A conductive connecting pin 65 connects the starting end and the ending end of the
Connect with etc.

[0005]

[Problems to be Solved by the Invention] Generally, when increasing the number of turns of the coil using the above conventional printed coil, each printed coil 64 is electrically connected using a connecting pin 65 as shown in FIG. , each printed coil 64
The connection terminal portions as the starting end and the terminal end of the printed coil 64 must overlap in the stacking direction of the printed coil 64, and a printed coil 64 having different coil patterns 62 printed thereon is required. Furthermore, as shown in FIG. 16, it is necessary to insert an insulating sheet 66 into the gap between each of the stacked printed coils 64, making the process of stacking and manufacturing the printed coils 64 complicated and time-consuming. Ta.

Furthermore, when manufacturing a transformer using this printed coil 64, it is necessary to prevent dielectric breakdown between the primary coil and the secondary coil. Therefore, in order to increase the creepage distance between the primary coil and the secondary coil, the distance between the outermost coil pattern 62 of the printed coil 64 and the peripheral edge of the insulating sheet 61 is increased. . However, when the creepage distance is increased in this way, the occupation rate of the coil in the transformer decreases, resulting in an increase in the size of the transformer.

Furthermore, in the conventional printed coil 64, since the starting end and the ending end of the coil pattern 62 are connection terminals for connecting to other electrical components, the number of turns of the coil pattern 62 is smaller than the number of turns of the printed coil 64. Fixed for each. Therefore, it was necessary to manufacture the printed coil 64 according to the number of turns of the coil pattern 62.

[0008] The object of the present invention was made in view of the above-mentioned problems, and has versatility in terms of the number of windings and uses of the coil pattern, facilitates lamination, and ensures that the creepage distance is maintained when a transformer is fabricated. It is an object of the present invention to provide an electromagnetic device and a power supply device that can increase the occupancy rate of a coil while reducing the energy consumption.

[Configuration of the invention]

0010

[Means for Solving the Problems] The electromagnetic device according to claim 1 includes a plurality of insulating sheet parts arranged adjacent to each other via flexible bending parts, a coil pattern printed on each of the insulating sheet parts, The bent portions are bent, the insulating sheet portions are overlapped, and the overlapping insulating sheet portions are reinforced with an insulating reinforcing plate.

[0011] In the electromagnetic device according to claim 2, a plurality of printed coils each having a different coil pattern printed on one side and the other side of an insulating sheet are formed, and each of these printed coils is formed on a side on which the same coil pattern is printed. are stacked facing each other, and the vicinity of the ends of the coil patterns of the opposing printed coils are electrically connected in the stacking direction of the printed coils, so that the direction of the magnetic field generated in each of the printed coils is aligned. .

[0012] The electromagnetic device according to claim 3 includes a printed coil and a bobbin that sandwiches and stores the printed coil and is composed of a plurality of bobbin structures, and one of the bobbin structures is connected to the other of the bobbin structures. A joining protrusion is provided near a peripheral edge of a joint where the bobbin structures face each other and are joined, and the joining protrusions of the bobbin structures are joined to each other to sandwich the printed coil.

An electromagnetic device according to a fourth aspect of the present invention includes a coil pattern formed on an insulating sheet, and a plurality of conductor patterns formed on the insulating sheet and electrically insulated from each other, wherein the coil pattern and each of the conductors are electrically insulated from each other. The pattern is electrically connected to the pattern.

[0014] A power supply device according to a fifth aspect includes the electromagnetic device according to any one of claims 1 to 4.

[0015]

[Function] The electromagnetic device according to claim 1 includes a plurality of insulating sheet parts arranged adjacent to each other via flexible bending parts,
A coil pattern is printed on each insulating sheet portion, the bent portions are bent, the insulating sheet portions are overlapped, and the overlapping insulating sheet portions are reinforced with an insulating reinforcing plate, making it easy to connect. Coil patterns can be easily stacked without using pins. In addition, if a transformer is formed using the coil patterns of the overlapping insulating sheet parts, and the insulating sheet part that becomes the end of the coil formed by this coil pattern is reinforced with the reinforcing plate, the spaces between each coil are as described above. Reliably insulated with a reinforcing plate.

[0016] In the electromagnetic device according to claim 2, a plurality of printed coils are formed by printing different coil patterns on one side and the other side of an insulating sheet, and each of these printed coils is printed with the same coil pattern. The printed coils are stacked with their faces facing each other, and the ends of the coil patterns of the opposing printed coils are electrically connected in the stacking direction of the printed coils to align the directions of the magnetic fields generated in each printed coil. A plurality of printed coils can be easily stacked using only different types of printed coils.

An electromagnetic device according to a third aspect of the present invention includes a printed coil and a bobbin which sandwiches and stores the printed coil and is composed of a plurality of bobbin structures, and one of the bobbin structures is connected to the other of the bobbin structures. A joining protrusion is provided near the peripheral edge of the joint where the bobbin structures face each other and are joined, and the joining protrusions of these bobbin structures are joined to each other to sandwich the printed coil. When a printed coil stored and clamped is used in a transformer, the creepage distance of the printed coil can be set three-dimensionally by the joining protrusion of the bobbin structure.

[0018] In the electromagnetic device according to claim 4, the coil pattern formed on the insulating sheet and the plurality of conductor patterns formed on the insulating sheet and electrically insulated from each other are electrically connected to each other. By selecting a conductor pattern to be electrically connected to this coil pattern, the number of turns of the coil pattern can be changed.

[0019] Since the power supply device according to claim 5 is equipped with the electromagnetic device according to any one of claims 1 to 4,
It has versatility in use and can be manufactured inexpensively and compactly.

[0020]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment in which the electromagnetic device of the present invention is applied to a multilayer transformer will be described with reference to FIGS. 1 to 4.

In FIGS. 1 to 3, reference numeral 1 denotes a composite sheet, and this composite sheet 1 has a plurality of insulating layers sequentially inserted through folds 2a to 2d, each of which is an insulating and flexible folding portion. It is divided into seat parts 3a to 3e. Each of the insulating sheet parts 3a to 3e has an insertion opening 4 formed approximately in the center thereof, into which a core (not shown) is inserted. As shown in FIG. 2, this composite sheet 1 has folds 2a and 2d that can be valley-folded,
b and fold line 2c can be mountain-folded.

Further, as shown in FIG. 3, an electrically conductive metal foil is attached to the insulating sheet portion 3a to serve as a coil.
A C electric coil pattern 5a is formed on both sides,
The end portion 5aa of the coil pattern 5a for this IC power supply,
5ab can be connected to other electrical components at the terminal piece 6a.

A coil pattern 5b made of a conductive metal foil serving as the primary coil of the transformer is formed over both sides of the insulating sheet portions 4b and 4c, and the end portions 5ba and 5bb of this coil pattern 5b are as follows: It can be electrically connected to the power supply side through the terminal piece portion 5b. On the other hand, the coil pattern 5c is made of a conductive metal foil as a secondary coil of the transformer, and the insulating sheet portion 4d
, 4e, and the ends 5ca, 5cb of this coil pattern 5c can be connected to other electrical components at terminal piece portions 6c. The surface layer of each of the insulating sheet parts 3a to 3e on which the coil patterns 5a, 5b, and 5c are formed is coated with an insulating resin (not shown).

Further, reinforcing plates 7 having substantially the same shape as the insulating sheet parts 3a to 3e and having insulating properties are attached to the back sides of the insulating sheet parts 4b and 4c, respectively, to constitute a printed coil 8.

Next, the operation of this embodiment will be explained.

Fold line 2a and fold line 2 of the composite sheet 1
d is valley-folded, and fold line 2b and fold line 2c are folded into a mountain fold, and a gap between the insulating sheet portion 3b and the insulating sheet portion 3c formed by the mountain-folding of the fold line 2b is formed by the valley-folding of the fold line 2d. Overlapping insulation sheet portion 3d,
3e is inserted by mountain folding along the fold line 2c, this composite sheet is inserted into the insulating sheet portion 3 from above as shown in FIG.
c, the insulating sheet part 3d, the insulating sheet part 3e, the insulating sheet part 3b, and the insulating sheet part 3a are laminated in this order.

[0027] In the state in which the insulating sheet parts 3a to 3e are laminated, the secondary coil constituted by the coil pattern 5c is sandwiched between the primary coil constituted by the coil pattern 5b, and then laminated. A reinforcing plate 7 is interposed between the insulating sheet parts 3b and 3e where the primary coil and the secondary coil face each other, and between the insulating sheet parts 3c and 3d, respectively. Therefore, the reinforcing plate 7 can maintain the insulation distance required according to safety standards between the primary coil and the secondary coil.

As described above, according to the above structure, the plurality of insulating sheet parts 3a to 3 on which the coil patterns 5a to 5c are formed
A transformer can be manufactured by stacking coils without using connection pins, simply by folding the composite sheet 1 made of e and overlapping each of the insulating sheet parts 3a to 3e.

Furthermore, since the reinforcing plate 7 is attached to the insulating sheet parts 3a to 3e in advance, when overlapping each of the insulating sheet parts 3a to 3e, the reinforcing plate 7 and the insulating sheet parts 3a to 3e are aligned. Because it becomes unnecessary,
A transformer can be manufactured by simply overlapping each of the insulating sheet parts 3a to 3e.

The composite sheet 1 is not limited to the shape shown in FIG. 1, but also has insulating sheet portions 3a, 3b,
3c are sequentially arranged in series via the folds 2a and 2b, and the insulating sheet parts 3e and 3d are arranged via the fold 2d, and the insulating sheet parts 3b and 3e are adjacent to each other, and the insulating sheets part 3c and insulating sheet part 3
The insulating sheet portion 3c and the insulating sheet portion 3d may be arranged and configured such that the insulating sheet portions 3c and 3d are connected to each other via the fold line 2c so that the insulating sheet portions 3c and 3d are adjacent to each other.

Although the above embodiment has been explained using a transformer consisting of a primary coil and a secondary coil, the present invention is not limited to this, and each coil pattern 5a to 5a is
5c are electrically connected and stacked on top of each other, the insulating sheet portion 3a
You may form one coil from ~3e.

Next, a second embodiment in which the electromagnetic device of the present invention is applied to a printed coil will be described with reference to FIGS. 5 to 7.

In FIGS. 5 and 6, reference numeral 11 denotes an insulating sheet, and an insertion opening 12 is formed in the center of the insulating sheet 11, into which a core (not shown) is inserted. Also, one side 13a and the other side 13b of this insulating sheet 11
Different coil patterns 14a and 14b made of conductive metal sheets are formed on each side, and the coil patterns 14a and 14b on each side are formed on the insulating sheet 11.
The coil patterns 14a and 14b are electrically connected through through holes 15 formed in the coil patterns 14a and 14b so that the directions of the magnetic fields generated by the coil patterns 14a and 14b are aligned. And one side 13
A connecting terminal hole 16a is formed near the end of the coil pattern 14a on the other side 13b, and a connecting terminal hole 16b is formed near the end of the coil pattern 14b on the other side surface 13b. Furthermore, the connection terminal holes 16a and 16b formed on each surface 13a and 13b are arranged so that, for example, when one side surface 13a of each of the two insulating sheets 11 is stacked facing each other, they overlap at one point. The printed coil 17 is formed by forming the printed coil 17.

Next, the operation of this embodiment will be explained.

When a plurality of printed coils 17 are electrically connected and stacked, for example, as shown in FIG. When these printed coils 17 are made to face each other, connection terminal holes 16b and 16b for electrically connecting the coil patterns 14a and 14b of these printed coils 17 overlap at one point in the stacking direction of these printed coils 17.

Therefore, when the connecting terminal hole 16b of one printed coil 17 and the connecting terminal hole 16b of the other printed coil 17 are connected via the conductive connecting terminal pin 18, the connecting terminal hole 16b of one printed coil 17 and the connecting terminal hole 16b of the other printed coil 17 are connected. The other printed coil 17 is electrically connected, and the number of turns of the coil is increased to align the directions of the magnetic fields generated in each printed coil 17. Further, as the terminal portions of the electrically connected and stacked printed coils 17, the connecting terminal hole portion 16a of one printed coil 17 and the connecting terminal hole portion 16a of the other printed coil 17 each have conductivity. Connecting the terminal pins 19 allows connection to other electronic components.

According to the above configuration, it is not necessary to fabricate two types of printed coils with different coil patterns and to stack and connect these printed coils, but it is possible to use a plurality of printed coils 17 of one type to form the same coil. pattern 1
The direction of the magnetic field generated in each printed coil 17 can be aligned by simply stacking the surfaces 13a and 13b on which the printed coils 4a and 14b are opposed to each other and electrically connecting them.

[0038] Therefore, by simply using a plurality of printed coils 17, a laminated coil can be easily manufactured.

Next, a third embodiment in which the electromagnetic device of the present invention is applied to a transformer will be described with reference to FIGS. 8 and 9.

In FIG. 8, a printed coil 17 is constructed in the same manner as in the second embodiment, and a plurality of printed coils 17 are stacked and electrically connected to form a coil 21. The coil 21 is held between and housed within the bobbin 22.

The bobbin 22 is approximately donut-shaped with an insertion hole 23 formed in the center into which a core (not shown) is inserted, and is made up of a plurality of bobbin structures 24 whose joints are perpendicular to the direction in which the core is inserted. It is configured. As shown in FIG.
A joining protrusion 26 protrudes along this peripheral edge. The coil 21 is placed inside one bobbin structure 24.
When the other bobbin structure 24 is joined to the one bobbin structure 24 after fitting, the one bobbin structure 2
The joint protrusion 26 of the fourth bobbin structure 24 and the joint protrusion 26 of the other bobbin structure 24 are joined to each other without leaving a gap, and sandwich the coil 21 therebetween.

A transformer (not shown) is constructed using a plurality of coils held between the bobbins.

Next, the operation of this embodiment will be explained.

The creepage distance L for ensuring the insulation state between each coil of the transformer is as follows: If the width of the joint protrusion 26 is a and the height is b, the joint protrusions 26 of the opposing joint parts 25 are Since they are joined, the interval between adjacent joining protrusions 26 is a
Therefore, L=4a+4b.

Therefore, the joint protrusion 26 of the joint 25 can equivalently increase the creepage distance from the coil 21 to the outer surface of the bobbin 22, so that even though the width of the joint is 4a, , it is possible to secure a creepage distance L that is longer than the width 4a of this joint portion. For this reason,
There is no need to increase the size of the bobbin 22 in order to ensure the creepage distance L, and the bobbin 22 can be configured to be smaller than the coil 21.

[0046] According to the above structure, the bobbin 22 that holds the coil 21 can be made smaller while ensuring a long creepage distance, so that the transformer made of the coil 21 can be made smaller.

Next, a fourth embodiment in which the electromagnetic device of the present invention is applied to a printed coil will be described based on FIGS. 10 and 11.

In FIG. 10, reference numeral 31 denotes an insulating sheet, and an insertion hole 32 is formed in the center of the insulating sheet 31, into which a core (not shown) is inserted. A coil pattern 34 is formed on the surface portion 33 of the insulating sheet 31 using a conductive metal foil.
A plurality of linear conductive patterns 36 that are insulated from each other are formed on the back surface portion 35 of the device 1 . Further, each conductive pattern 36 is electrically connected to the coil pattern 34 through a through hole 37 provided in the insulating sheet 31 to form a printed coil 38.

Next, the operation of this embodiment will be explained.

One of the plurality of conductive patterns 36 is selected, and the end of the conductive pattern 36 that is not connected to the through hole is connected to the end of the coil pattern 34 that is electrically connected to the conductive pattern 36. By doing so, the number of turns of the coil formed by the coil pattern 34 and the conductive pattern 36 can be changed.

As described above, according to the above structure, the number of turns of the coil formed by the coil pattern 34 and the conductive pattern 36 can be changed by selecting a plurality of conductive patterns 36. The number of times can be adjusted.

Although the printed coil 38 has the coil pattern 34 or the conductive pattern 36 formed on both sides, the present invention is not limited to this, and the coil pattern 34 may be formed only on one side of the insulating sheet, and at least three of the coil patterns 34 It is also possible to change the number of turns of the coil by providing two or more connecting terminals and selecting two of them as the ends of the coil.

Next, a fifth embodiment in which the electromagnetic device of the present invention is applied to a transformer will be explained based on FIG. 12.

In FIG. 12, 41 is a laminated core, and this laminated core 41 is composed of an E-type laminated core 42 and an I-type laminated core 43.
The central leg portion 44 is provided with an air gap (not shown).

Among the coils wound around this laminated iron core 41, the coil wound to cover the air gap of the central leg portion 44 of the laminated iron core 41 has a coil pattern 34 formed on the insulating sheet 31. A plurality of printed coils 38 are stacked and electrically connected. This printed coil 38 has the same structure as the printed coil 38 of the fourth embodiment, and the insertion hole 32 formed in the center of the insulating sheet 31 is connected to the center leg portion 44 of the laminated core 41.
It is formed in a shape that can be inserted into and fixed to the central leg piece 44. Then, the plurality of printed coils 38
A coil 45 is inserted and fixed into the central leg portion 44 of the laminated core 41 so as to cover the air gap, thereby forming a transformer.

Next, the operation of this embodiment will be explained.

The coil 45 consisting of a plurality of printed coils 38 is installed so as to cover the air gap of the central leg portion 44 of the laminated core 41, so that when the transformer is in operation, a frequency of 1 MHz or more generated in the transformer is Noise terminal noise can be reduced.

[0058]

According to the electromagnetic device according to claim 1, connecting pins can be connected by simply bending a flexible bending portion and overlapping a plurality of insulating sheet portions each having a coil pattern formed thereon. Coils can be easily stacked without using. Furthermore, if a reinforcing plate having an insulating property that reinforces the insulating sheet portion is inserted between the stacked coils to reinforce the stacked insulating sheet portions, the coils can be reliably insulated.

According to the electromagnetic device according to claim 2, it is possible to use a plurality of printed coils of one type to form a surface on which the same coil pattern is formed, without having to produce printed coils on which two different types of coil patterns are formed. By simply stacking them facing each other and electrically connecting them, the direction of the magnetic field generated in each printed coil can be aligned. Therefore, the printed coil can have versatility in its uses.

According to the electromagnetic device according to claim 3, the connecting protrusions of the mutually opposing joint parts of the bobbin components constituting the bobbin allow the printed coil held and housed in the bobbin to reach the outer surface of the bobbin. Since the creepage distance can be equivalently increased three-dimensionally, a creepage distance longer than the width of the joint can be secured. Therefore, there is no need to increase the size of the bobbin to ensure a long creepage distance, and the bobbin can be configured to be small with respect to the coil while ensuring a long creepage distance. Therefore,
For example, when creating a transformer consisting of this coil and a bobbin, the occupancy rate of the coil in the transformer is increased,
This transformer can be downsized.

According to the electromagnetic device according to the fourth aspect, by selecting a plurality of conductive patterns, the number of turns of the coil formed by the coil patterns and the conductive patterns can be changed. Therefore, in the printed coil, the number of turns of the coil can be adjusted, so that the number of turns of the coil can be varied.

According to the power supply device according to claim 5, since it is provided with the electromagnetic device according to claims 1 to 4, it has versatility in use and can be easily manufactured in a small size and at low cost. can.

[Brief explanation of the drawing]

FIG. 1 is a perspective view showing a first embodiment in which an electromagnetic device of the present invention is applied to a laminated transformer, and illustrating a state in which insulating sheet portions are overlapped.

FIG. 2 is a configuration diagram of a composite sheet made of the same insulating sheet portion as above.

FIG. 3(A) is a surface view of a printed coil made of the same composite sheet. (B) is a back view of a printed coil made of the same composite sheet.

FIG. 4 is a configuration diagram of a composite sheet having a different shape from the above.

FIG. 5 is a surface view of one side of a printed coil showing a second embodiment of the electromagnetic device of the present invention.

FIG. 6 is a back view of the printed coil as the other side.

FIG. 7 is a perspective view illustrating a state in which the printed coils are stacked.

FIG. 8 is an exploded perspective view of a printed coil and a bobbin that sandwiches and stores the printed coil, showing a third embodiment of the electromagnetic device of the present invention.

FIG. 9 is a cross-sectional view of the opposing joint portions of the bobbin components of the same bobbin.

FIG. 10 is a surface view of a printed coil showing a fourth embodiment of the electromagnetic device of the present invention.

FIG. 11 is a back view of the printed coil shown above.

FIG. 12 is a perspective view of a portion of a transformer showing a fifth embodiment of the electromagnetic device of the present invention.

FIG. 13 is a surface view of a conventional printed coil.

FIG. 14 is a back view of the printed coil shown above.

FIG. 15 is an exploded perspective view of a portion of a conventional laminated printed coil.

FIG. 16 is a perspective view of the printed coil laminated as above.

[Explanation of symbols]

2a to 2d Folds 3a to 3e as bending parts
Insulating sheet parts 5a to 5c Coil pattern 7 Reinforcement plate 8 Printed coil 11 as an electromagnetic device
Insulating sheet 13a One side 13b Other side 14a Coil pattern 14b Coil pattern 17 Printed coil 21 as an electromagnetic device
Coil 22 as a printed coil Bobbin 24 Bobbin structure 25 Joint portion 26 Joint protrusion 31 Insulating sheet 34 Coil pattern 36 Conductive pattern

Claims (5)

[Claims] 1. A plurality of insulating sheet parts are placed next to each other through flexible bending parts, a coil pattern is printed on each of the insulating sheet parts, and the bending part is bent to form the insulating sheet part. An electromagnetic device characterized in that the overlapping insulating sheet parts are reinforced with an insulating reinforcing plate. [Claim 2] A plurality of printed coils each having a different coil pattern printed on one side and the other side of an insulating sheet are formed, and these printed coils are stacked with the sides on which the same coil pattern is printed facing each other. An electromagnetic device characterized in that the vicinity of the ends of the coil patterns of the opposing printed coils are electrically connected in the stacking direction of the printed coils, so that the direction of the magnetic field generated in each of the printed coils is aligned. 3. A bobbin comprising a printed coil and a plurality of bobbin structures that sandwich and store the printed coil, wherein one of the bobbin structures is opposed to the other of the bobbin structures. An electromagnetic device characterized in that a joining protrusion is provided near a peripheral edge of a joining part to be joined, and the joining protrusions of the bobbin structure are joined to each other to sandwich the printed coil. 4. A coil pattern formed on an insulating sheet, and a plurality of conductor patterns formed on the insulating sheet and electrically insulated from each other, the coil pattern and each of the conductor patterns being electrically connected. An electromagnetic device characterized by: 5. A power supply device comprising the electromagnetic device according to claim 1.