JP2002075737A - Thin-film transformer and its manufacturing method - Google Patents
Thin-film transformer and its manufacturing methodInfo
- Publication number
- JP2002075737A JP2002075737A JP2000253728A JP2000253728A JP2002075737A JP 2002075737 A JP2002075737 A JP 2002075737A JP 2000253728 A JP2000253728 A JP 2000253728A JP 2000253728 A JP2000253728 A JP 2000253728A JP 2002075737 A JP2002075737 A JP 2002075737A
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- Japan
- Prior art keywords
- coil
- winding
- thin
- transformer according
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、電子機器、主とし
て通信装置などに使用される薄形電源に搭載されるスイ
ッチング電源用の薄形トランスおよびその製造方法に関
するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thin transformer for a switching power supply mounted on a thin power supply used in electronic equipment, mainly a communication device, and a method of manufacturing the same.
【０００２】[0002]
【従来の技術】近年、情報通信インフラ網が大きく、進
展する中で消費電力の増大が社会的問題となってきてい
る。特に通信装置は小形化と消費電力の低減要請とに応
えるため、給電方式は集中給電から分散給電へと推移し
ており、現在ではこれらの電源部には小形・薄形のオン
ボード電源が多く使用されている。一方、ＬＳＩの高速
化に伴う大電流化と消費電力削減のための低電圧化が急
速に進展しており、これらＬＳＩを駆動するオンボード
電源も低電圧化／大電流化対応が求められている。そし
てこれら薄形オンボード電源はさらなる小形化手段とし
てスイッチング周波数をより高い周波数で駆動する傾向
にある。特に電源部の主要構成部品であるトランスにお
いては高周波駆動に適した低損失、低ノイズでかつ小形
で安価な面実装タイプの薄形トランスが求められてい
る。これらの電源の開発ニーズに対応するため、巻線を
利用した積層タイプのコイルを使用した薄形トランスが
多く提案されている。2. Description of the Related Art In recent years, information communication infrastructure networks have been large, and with the progress thereof, an increase in power consumption has become a social problem. In particular, in order to respond to the demand for miniaturization and reduction in power consumption of communication equipment, the power supply system has shifted from centralized power supply to distributed power supply, and these power supply units now have many small and thin on-board power supplies. It is used. On the other hand, large currents and low voltage for power consumption reduction are rapidly progressing with high speed of LSIs, and on-board power supplies for driving these LSIs are also required to support low voltage / high current. I have. These thin on-board power supplies tend to drive the switching frequency at a higher frequency as a means for further miniaturization. In particular, for a transformer which is a main component of the power supply unit, a low-loss, low-noise, small-sized and inexpensive surface-mount thin transformer suitable for high-frequency driving is demanded. In order to meet the development needs of these power supplies, many thin transformers using laminated type coils using windings have been proposed.
【０００３】巻線を使用した従来の薄形トランスとして
は実開平４−９９８１８号公報、実開平６−７０２２３
号公報に示すようなスパイラルコイルを積層した構成の
もの、実開平４−１０５５２３号公報に示すようなコイ
ルベースにスパイラルコイルを積層してモールドした構
成のもの、実開平５−９５０２６号公報に示すようなコ
イルベースにスパイラルコイルを積層した構成のもの、
特開平８−３１６０５４号公報に示すような平角線スパ
イラルコイルを積層した構成のもの、特開平１０−３４
０８１９号公報に示すような平角導体の２層折り返し巻
きしたスパイラルコイルをコイルベース上に積層した構
成のもの、さらに最近では特開平１１−３０７３５６号
公報に示すようなフープ端子上でスパイラルコイルと銅
箔を積層接続してモールドする構成としたものなどがあ
る。A conventional thin transformer using a winding is disclosed in Japanese Utility Model Laid-Open No. 4-99818, Japanese Utility Model Laid-Open No. 6-70223.
Japanese Unexamined Patent Publication No. 5-95026 discloses a configuration in which spiral coils are stacked as shown in Japanese Unexamined Patent Publication No. 4-105523, a configuration in which spiral coils are stacked and molded on a coil base as disclosed in Japanese Utility Model Application Laid-Open No. 4-105523. With a configuration in which spiral coils are stacked on such a coil base,
Japanese Unexamined Patent Publication No. 10-34, which has a configuration in which rectangular spiral coils are stacked as shown in JP-A-8-316054.
No. 0819, a spiral coil formed by winding two layers of a rectangular conductor in a folded manner and laminated on a coil base, and more recently, a spiral coil and copper on a hoop terminal as disclosed in JP-A-11-307356. There is a configuration in which foils are connected by lamination and molded.
【０００４】これら、従来技術を参考にして１次、２次
巻線を複数個以上に分割して多積層とした場合に考えら
れる従来例を図１８、図１９に示す。Referring to these prior arts, FIGS. 18 and 19 show conventional examples that can be considered when the primary and secondary windings are divided into a plurality or more to be multi-layered.
【０００５】以下、従来例として図１８、図１９を用い
て説明する。A conventional example will be described below with reference to FIGS.
【０００６】図１８は従来の薄形トランスの積層から組
立までを説明する工程説明図、図１９は図１８の従来の
薄形トランスのコイル積層図である。図１８、図１９に
おいて１は１次主巻線、１ａは１次補助巻線、２は２次
主巻線、３は絶縁紙、４は端子、４ａは端子台、５は接
続部、６はコイルベース、７は絶縁樹脂、８はモールド
コイル、９は磁心を示している。FIG. 18 is a process explanatory diagram for explaining the steps from lamination to assembly of a conventional thin transformer, and FIG. 19 is a coil lamination diagram of the conventional thin transformer of FIG. 18 and 19, 1 is a primary main winding, 1a is a primary auxiliary winding, 2 is a secondary main winding, 3 is insulating paper, 4 is a terminal, 4a is a terminal block, 5 is a connection part, 6 Denotes a coil base, 7 denotes an insulating resin, 8 denotes a molded coil, and 9 denotes a magnetic core.
【０００７】図１８において巻線をスパイラル状に巻回
したコイルを１次主巻線１として２個、１次補助巻線１
ａとして２個を予め準備しておく。さらに薄板状の導体
を打抜き、或いはエッチングなどにより、製作した非巻
線タイプのコイルを２次主巻線２として４個準備してお
く。また、別工程において両端部に端子４をインサート
成型或いは圧入などで植設してなる端子台４ａ部を有す
るコイルベース６を準備しておく。次に図１９に示すよ
うにこれらの事前に準備した各々の巻線を両端に端子台
４ａ部を有するコイルベース６上に各々の巻線間に絶縁
紙３を挿入しながら、２次主巻線２、１次補助巻線１
ａ、１次補助巻線１ａ、２次主巻線２、１次主巻線１、
２次主巻線２、１次主巻線１、２次主巻線２の順で積層
する。その後、端子台４ａに植設した端子４に各々の巻
線の引出し線を配線し、半田付け、溶接などの方法によ
り、接続部５の部分で接続して積層コイルを完成させ
る。こうして完成した積層コイルの接続部５を覆うよう
に絶縁樹脂７で封止してコイル部の製作を完成して図１
８に示すモールドコイル８を完成させる。次に図１８に
示すようにモールドコイル８の上下から、磁心９を組み
込み、薄形トランスとして完成させる。In FIG. 18, two coils each having a spirally wound winding are used as a primary main winding 1 and two primary auxiliary windings 1 are provided.
Two are prepared in advance as a. Further, four non-winding type coils manufactured as punching main windings 2 are prepared by punching or etching a thin plate conductor. In a separate step, a coil base 6 having a terminal block 4a formed by inserting terminals 4 at both ends by insert molding or press fitting is prepared. Next, as shown in FIG. 19, the secondary main winding is carried out while inserting the insulating paper 3 between the respective windings on the coil base 6 having the terminal block 4a at both ends. Wire 2, primary auxiliary winding 1
a, primary auxiliary winding 1a, secondary main winding 2, primary main winding 1,
The secondary main winding 2, the primary main winding 1, and the secondary main winding 2 are stacked in this order. Thereafter, a lead wire of each winding is wired to the terminal 4 implanted in the terminal block 4a, and connected at the connection portion 5 by a method such as soldering or welding to complete a laminated coil. The completed coil part was completed by sealing with an insulating resin 7 so as to cover the connection part 5 of the completed laminated coil.
8 is completed. Next, as shown in FIG. 18, the magnetic core 9 is assembled from above and below the molded coil 8 to complete a thin transformer.
【０００８】[0008]
【発明が解決しようとする課題】しかしながら、従来例
を示す図１８、図１９の構成においてはコイルベース６
の上に多くのコイルを一度に積層して引出し部を端子４
に配線、接続する構成としているため、端子４の間隔が
狭いと配線、接続ができなくなるという作業上での致命
的な課題を有していた。また、２次主巻線２の引出し部
と端子４の接続部５のスペースも必要となるため、小形
化の弊害となるものであった。However, in the constructions shown in FIGS. 18 and 19 showing a conventional example, the coil base 6 is not provided.
A number of coils are stacked at a time on the
In this case, the wiring and connection are not performed. Therefore, if the interval between the terminals 4 is small, the wiring and connection cannot be performed. In addition, a space is required between the lead portion of the secondary main winding 2 and the connecting portion 5 of the terminal 4, which is a problem of downsizing.
【０００９】さらにこれら従来例を示す図１８、図１９
の構成においては積層、配線、接続するために端子４、
端子台４ａ、コイルベース６などの多くの部品が必要と
なり、原価面においても不利となるという課題を有して
いるものであった。FIGS. 18 and 19 show these conventional examples.
In the configuration of the above, terminals 4 for laminating, wiring and connecting,
Many components, such as the terminal block 4a and the coil base 6, are required, and there is a problem that the cost is disadvantageous.
【００１０】本発明は、上記課題を解決し、作業性の良
い、小形で安価なコイル多積層タイプの薄形トランスお
よびその製造方法を提供することを目的とする。An object of the present invention is to solve the above-mentioned problems and to provide a small and inexpensive multi-layer coil type thin transformer with good workability and a method of manufacturing the same.
【００１１】[0011]
【課題を解決するための手段】上記課題を解決するため
に本発明は、１次、２次主巻線の少なくともどちらか一
方は薄板状の非巻線コイルで形成し、この非巻線コイル
の上に他の巻線を形成して一対にした複巻線一体型コイ
ルを形成し、この複巻線一体型コイルを複数個積層して
多積層コイルを構成し、この多積層コイルの上下から、
磁心を組み込んだ構成としたものである。According to the present invention, at least one of a primary winding and a secondary winding is formed of a thin plate-shaped unwound coil. A multi-layer integrated coil is formed by forming another winding on top of the multi-layer integrated coil, and a plurality of the multi-layer integrated coil is laminated to form a multi-layer coil. From
It has a configuration incorporating a magnetic core.
【００１２】また、薄板状の非巻線コイルとして非巻線
コイルとフレーム枠を一体化したフレームコイルとした
構成にしたものである。[0012] Further, as the thin plate-shaped non-winding coil, a frame coil is formed by integrating the non-winding coil and the frame.
【００１３】さらに薄板状の非巻線コイルとして端子と
非巻線コイルとフレーム枠を一体化した端子一体型フレ
ームコイルとした構成にしたものである。Further, as a thin plate-shaped non-winding coil, the terminal, the non-winding coil and the frame are integrated into a terminal-integrated frame coil.
【００１４】上記構成によって端子への配線・接続部が
複数に分割されるので端子間のピッチ間隔が狭くても作
業ができることとなり、多出力・多数端子の設計が可能
となる。また、自動化も容易となるものである。Since the wiring / connection portion to the terminal is divided into a plurality of parts by the above configuration, the work can be performed even if the pitch interval between the terminals is narrow, so that a multi-output and a large number of terminals can be designed. In addition, automation is easy.
【００１５】また、非巻線コイルとフレーム枠を一体化
したフレームコイルとしたため、薄板状の非巻線コイル
の引出し端子の接続スペースが不要となり、小形化でき
る。さらに端子一体型フレームコイルを採用したので端
子、端子台、コイルベース、或いはボビンなどの別部品
が不要となり、部品点数が削減できる。Further, since the non-winding coil and the frame are integrated into a frame coil, a space for connecting the lead terminals of the thin non-winding coil becomes unnecessary, and the size can be reduced. Further, the use of the terminal-integrated frame coil eliminates the need for separate components such as terminals, terminal blocks, coil bases, and bobbins, thereby reducing the number of components.
【００１６】この結果、作業性の良い、小形で安価なコ
イル多積層タイプの薄形トランスおよびその製造方法を
提供することが可能となるのである。As a result, it is possible to provide a small and inexpensive coil multi-stack type thin transformer with good workability and a method of manufacturing the same.
【００１７】[0017]
【発明の実施の形態】本発明の請求項１に記載の発明は
１次、２次主巻線の少なくともどちらか一方は薄板状の
非巻線コイルで形成し、この非巻線コイルの上に他の巻
線を形成して一対にした複巻線一体型コイルを形成し、
この複巻線一体型コイルを複数個積層して多積層コイル
を構成し、この多積層コイルの上下から、磁心を組み込
んだものであり、端子への配線・接続部が複数に分割さ
れるので端子間のピッチ間隔が狭くても作業ができるこ
ととなり、多出力・多数端子の設計が可能となる。ま
た、自動化も容易となるものである。DESCRIPTION OF THE PREFERRED EMBODIMENTS According to the first aspect of the present invention, at least one of the primary and secondary main windings is formed of a thin plate-shaped unwound coil. The other winding is formed to form a double winding integrated coil which is paired,
A multi-layered coil is constructed by laminating a plurality of these multi-winding integrated coils, and a magnetic core is incorporated from above and below the multi-layered coil. The work can be performed even if the pitch interval between the terminals is narrow, and it is possible to design a multi-output, multi-terminal. In addition, automation is easy.
【００１８】本発明の請求項２に記載の発明は請求項１
の構成に加えて薄板状の非巻線コイルとして非巻線コイ
ルとフレーム枠を一体化したフレームコイルとしたもの
であり、薄板状の非巻線コイルの引出し端子の接続スペ
ースが不要となり、小形化できる。The invention described in claim 2 of the present invention is claim 1
In addition to the above configuration, a thin-plate unwound coil is used as a frame coil that integrates a non-wound coil and a frame frame. Can be
【００１９】本発明の請求項３に記載の発明は請求項１
または２の構成に加えて薄板状の非巻線コイルとして端
子と非巻線コイルとフレーム枠を一体化した端子一体型
フレームコイルとしたものであり、端子、端子台、コイ
ルベース、或いはボビンなどの別部品が不要となり、部
品点数が削減できる。The third aspect of the present invention is the first aspect.
Or a terminal-integrated frame coil in which a terminal, an unwound coil, and a frame are integrated as a thin plate-shaped unwound coil in addition to the configuration of 2 above, such as a terminal, a terminal block, a coil base, or a bobbin. This eliminates the need for separate parts, thereby reducing the number of parts.
【００２０】本発明の請求項４に記載の発明は請求項２
または３の構成に加えてフレーム枠に位置決め用の基準
部を設けたものであり、基準部を利用して積層時の位置
決め、金型内での位置決め、など治具、金型設計時の規
準とできるため、各コイルの相対的な位置の作業バラツ
キを抑えることができるものである。The invention described in claim 4 of the present invention is claim 2.
Or, in addition to the configuration of 3, a frame frame is provided with a reference portion for positioning, and the reference portion is used for positioning during stacking, positioning in a mold, etc. Therefore, it is possible to suppress the work variation in the relative position of each coil.
【００２１】本発明の請求項５に記載の発明は請求項４
の構成に加えて基準部として穴を設けたものであり、積
層治具、金型内に穴に対応したピンをたてるだけで簡単
に位置決めの治具が実現できる。The invention according to claim 5 of the present invention is the invention according to claim 4.
In addition to the configuration described above, a hole is provided as a reference portion, and a positioning jig can be easily realized simply by setting pins corresponding to the holes in a lamination jig or a mold.
【００２２】本発明の請求項６に記載の発明は請求項４
または５の構成に加えてフレーム枠の基準部の位置を非
対称の位置に設けたものであり、１次、２次の方向性を
もたせることにより、積層方向の誤りを防止できる。The invention described in claim 6 of the present invention is claim 4.
Alternatively, in addition to the configuration of 5, the reference portion of the frame is provided at an asymmetrical position. By providing primary and secondary directions, an error in the stacking direction can be prevented.
【００２３】本発明の請求項７に記載の発明は請求項１
〜３のいずれか一つの構成に加えて１次主巻線、２次主
巻線をほぼ同一巻幅で１層巻としたものであり、１次巻
線間、２次巻線間では折り返し対向面がなくなるので近
接効果などによる高周波抵抗の増大を少なくできる。ま
た、各巻線の線間容量も少なくなり、低ノイズ化が達成
できる。さらに１次主巻線１１と２次主巻線１２は完全
に交互に積層された状態となるので１次、２次主巻線間
の距離は最小となること、かつ対向面積も最大限に確保
できることとなり、１次、２次主巻線の漏れインダクタ
ンス（Ｌｅ）も少なくできるため、巻線間の高結合化が
達成され、結果として低損失化、低ノイズ化、電源の高
効率化が達成される。The invention described in claim 7 of the present invention is claim 1
In addition to any one of the above-described configurations, the primary main winding and the secondary main winding are formed as a single-layer winding with substantially the same winding width. Since there is no facing surface, an increase in high-frequency resistance due to the proximity effect or the like can be reduced. Also, the line capacitance of each winding is reduced, and low noise can be achieved. Further, since the primary main winding 11 and the secondary main winding 12 are completely alternately stacked, the distance between the primary and secondary main windings is minimized, and the facing area is maximized. As a result, the leakage inductance (Le) of the primary and secondary main windings can be reduced, so that high coupling between the windings is achieved, resulting in low loss, low noise, and high efficiency of the power supply. Achieved.
【００２４】本発明の請求項８に記載の発明は請求項７
の構成に加えて補助巻線を１次、２次主巻線の最上層又
は最下層に配置したものであり、１次、２次主巻線の間
に余分な巻線を配置しないようにしたので、１次、２次
主巻線間の距離は最小、かつ安定するため、漏れインダ
クタンス（Ｌｅ）最小、巻線間結合は最大限に高めるこ
とができることに加えて性能のばらつきも小さくできる
ものである。The invention according to claim 8 of the present invention is the invention according to claim 7
In addition to the configuration described above, the auxiliary winding is arranged on the uppermost layer or the lowermost layer of the primary and secondary main windings, and no extra winding is arranged between the primary and secondary main windings. Therefore, the distance between the primary and secondary main windings is minimized and stable, so that the leakage inductance (Le) can be minimized, the coupling between the windings can be maximized, and the variation in performance can be reduced. Things.
【００２５】本発明の請求項９に記載の発明は請求項１
〜３のいずれか一つの構成に加えて積層コイル全体を絶
縁樹脂で封止したものであり、この積層コイルの隙間に
樹脂が流れ込むことにより、コイル部の均熱化が図れる
ため、温度上昇が低減できる。また、コイルとコイル
間、コイルと磁心間の絶縁も強化できることとなる。The ninth aspect of the present invention is the first aspect.
In addition to any one of the above-described configurations, the entire laminated coil is sealed with an insulating resin, and the resin flows into the gaps of the laminated coil, so that the coil portion can be heated so that the temperature rises. Can be reduced. In addition, insulation between the coils and between the coils and the magnetic core can be strengthened.
【００２６】本発明の請求項１０に記載の発明は請求項
９の構成に加えて絶縁樹脂でモールド成型して封止した
ものであり、成型工法を利用しているため、封止時間を
短縮でき、生産性が向上する。According to a tenth aspect of the present invention, in addition to the constitution of the ninth aspect, the present invention is formed by molding with an insulating resin and sealing. Since the molding method is used, the sealing time is shortened. And increase productivity.
【００２７】本発明の請求項１１に記載の発明は請求項
１〜３，９，１０のいずれか一つの構成に加えて１次ま
たは２次主巻線の少なくともどちらか一方の巻線を絶縁
皮膜付きの電線としたものであり、巻数が簡単に変更対
応できるので設計の自由度が広がる。According to an eleventh aspect of the present invention, in addition to any one of the first to third, ninth and tenth aspects, at least one of the primary and secondary main windings is insulated. It is a wire with a coating, and the number of turns can be changed easily, so the degree of freedom of design is expanded.
【００２８】本発明の請求項１２に記載の発明は請求項
１１の構成に加えて電線を丸電線としたものであり、巻
線材料コストの低減が達成できる。また、巻線のスピー
ドアップが図れ、作業性が向上する。According to a twelfth aspect of the present invention, in addition to the configuration of the eleventh aspect, the electric wire is a round electric wire, so that the cost of the winding material can be reduced. Further, the speed of the winding can be increased, and the workability is improved.
【００２９】本発明の請求項１３に記載の発明は請求項
１１の構成に加えて電線を３層絶縁皮膜付き電線とした
ものであり、高電圧入力に対しても充分な絶縁が保証で
きる。また、安全規格等への対応も簡単にできる。According to a thirteenth aspect of the present invention, in addition to the configuration of the eleventh aspect, the electric wire is an electric wire with a three-layer insulating film, and sufficient insulation can be ensured even at a high voltage input. In addition, it is possible to easily comply with safety standards and the like.
【００３０】本発明の請求項１４に記載の発明は請求項
１１の構成に加えて電線を平角電線としたものであり、
巻線の占積率を高められるので巻線抵抗の低減、即ち、
低損失化が達成できる。According to a fourteenth aspect of the present invention, in addition to the configuration of the eleventh aspect, the electric wire is a rectangular electric wire,
Since the space factor of the winding can be increased, the winding resistance can be reduced, that is,
Low loss can be achieved.
【００３１】本発明の請求項１５に記載の発明は請求項
１〜３，９，１０のいずれか一つの構成に加えて１次ま
たは２次主巻線の両方の巻線を薄板状の非巻線コイルで
形成したものであり、１次または２次主巻線の巻数が少
ない時でも巻線間の結合が高められる。また、大電流対
応可能とできる。According to a fifteenth aspect of the present invention, in addition to any one of the first to third, ninth, and tenth aspects, both the primary and secondary main windings are made of a thin plate-like non-winding. It is formed by winding coils, and the coupling between the windings is enhanced even when the number of turns of the primary or secondary main winding is small. In addition, a large current can be handled.
【００３２】本発明の請求項１６に記載の発明は請求項
１５の構成に加えて１次または２次主巻線の両方の巻線
をフレーム枠を一体化したフレームコイルで形成したも
のであり、大電流を流す主巻線の内部接続点がなくなる
ので信頼性が向上する。According to a sixteenth aspect of the present invention, in addition to the structure of the fifteenth aspect, both the primary and secondary main windings are formed by a frame coil having an integrated frame. In addition, since there is no internal connection point of the main winding through which a large current flows, the reliability is improved.
【００３３】本発明の請求項１７に記載の発明は請求項
１〜３，９，１０のいずれか一つの構成に加えて１次ま
たは２次主巻線の少なくともどちらか一方の巻線を平角
線のエッジワイズ巻コイルで形成したものであり、断面
積の大きく取れる平角電線を利用できるため、１次、ま
たは２次主巻線の巻数が比較的、多い場合でも大電流に
対応可能となり、設計の自由度が大きく広がる。According to a seventeenth aspect of the present invention, in addition to any one of the first to third, ninth, and tenth aspects, at least one of the primary and secondary main windings has a rectangular shape. Since it is formed by an edgewise wound coil of wire and a rectangular wire that can take a large cross-sectional area can be used, even if the number of turns of the primary or secondary main winding is relatively large, it is possible to cope with a large current, The degree of freedom in design is greatly expanded.
【００３４】本発明の請求項１８に記載の発明は請求項
１７の構成に加えて巻始めと巻終わりの引出し線先端部
に穴をあけたものであり、接続点としてやると共に基準
点として利用できるため、コイル積層時の位置決め精度
が向上し、性能ばらつきも少なくできるものである。According to an eighteenth aspect of the present invention, in addition to the structure of the seventeenth aspect, a hole is formed at the leading end of the lead wire at the start and end of winding, and is used as a connection point and used as a reference point. Therefore, the positioning accuracy at the time of coil lamination is improved, and the performance variation can be reduced.
【００３５】本発明の請求項１９に記載の発明は請求項
１〜３，９，１０のいずれか一つの構成に加えて１次ま
たは２次補助巻線の少なくともどちらか一方の巻線を丸
電線としたものであり、補助出力巻線に関して設計の自
由度向上、材料低減などの効果が得られるものである。According to a nineteenth aspect of the present invention, in addition to any one of the first to third, ninth, and tenth aspects, at least one of the primary and secondary auxiliary windings is rounded. It is an electric wire, and it is possible to obtain the effects of improving the degree of freedom of design and reducing the material for the auxiliary output winding.
【００３６】本発明の請求項２０に記載の発明は請求項
１〜３，９，１０のいずれか一つの構成に加えて１次ま
たは２次補助巻線の少なくともどちらか一方の巻線を非
巻線タイプの基板で形成したものであり、積層面の厚み
が安定するので性能ばらつきが低減できる。According to a twentieth aspect of the present invention, in addition to any one of the first to third, ninth, and tenth aspects, at least one of the primary and secondary auxiliary windings is non-winding. It is formed of a winding type substrate, and the thickness of the laminated surface is stabilized, so that the performance variation can be reduced.
【００３７】本発明の請求項２１に記載の発明は請求項
２０の構成に加えて非巻線タイプの基板としてエッチン
グ工法によるプリント基板で形成したものであり、エッ
チング工法によるプリント基板は汎用性が高いので調達
性向上、低コスト化が図れる。According to a twenty-first aspect of the present invention, in addition to the constitution of the twentieth aspect, the non-winding type substrate is formed by a printed circuit board by an etching method. Since it is high, procurement can be improved and cost can be reduced.
【００３８】本発明の請求項２２に記載の発明は請求項
２０または２１の構成に加えて基板上に２線輪以上の複
数線輪を形成したものであり、複数線輪であっても同一
層に形成できるため、コイルの積層厚みをアップしない
で補助出力が形成できる。また、複数線輪間の相対位置
も安定するので性能ばらつきを低減できる。According to a twenty-second aspect of the present invention, in addition to the constitution of the twentieth or twenty-first aspect, a plurality of two or more wire loops are formed on a substrate. Since it can be formed in one layer, an auxiliary output can be formed without increasing the laminated thickness of the coil. Further, the relative position between the plurality of wire loops is also stabilized, so that the performance variation can be reduced.
【００３９】本発明の請求項２３に記載の発明は請求項
１１〜１４，１９のいずれか一つの構成に加えて各巻線
を融着層付きとしたものであり、各巻線をした状態のま
まで固着ができるのでボビンレスでの巻線形成が容易に
実現できる。According to a twenty-third aspect of the present invention, in addition to any one of the eleventh to fourteenth aspects, each of the windings is provided with a fusion layer, and the respective windings are kept in a state of being wound. Thus, winding can be easily formed without a bobbin.
【００４０】本発明の請求項２４に記載の発明は請求項
２３の構成に加えて融着層をアルコール融着タイプの融
着層としたものであり、アルコール塗布するだけで簡単
に巻線の固着ができるため、設備化が容易となる。According to a twenty-fourth aspect of the present invention, in addition to the constitution of the twenty-third aspect, the fusion layer is a fusion layer of an alcohol fusion type. Since it can be fixed, it is easy to implement equipment.
【００４１】本発明の請求項２５に記載の発明は１次、
２次主巻線の少なくともどちらか一方は薄板状の非巻線
コイルで形成し、この非巻線コイルの上に他の巻線を形
成して一対にした複巻線一体型コイルを形成する第１の
工程とこの複巻線一体型コイルを複数個積層して多積層
コイルを形成する第２の工程とこの多積層コイルの上下
から、磁心を組み込む最終工程を有する製造方法とした
ものであり、第１の工程で複数個の複巻線一体型コイル
部に分割して配線・接続作業を行うので配線・接続の作
業性が各段に向上できる。また、第２の工程では複巻線
一体型コイルを複数個積層するだけで配線・接続作業が
ないので端子ピッチの小さい多数端子の製品でも問題な
く製造できる。According to a twenty-fifth aspect of the present invention, the primary,
At least one of the secondary main windings is formed of a thin plate-shaped non-winding coil, and another winding is formed on the non-winding coil to form a paired multi-winding integrated coil. The manufacturing method has a first step, a second step of laminating a plurality of the multi-winding integrated coils to form a multi-layer coil, and a final step of incorporating a magnetic core from above and below the multi-layer coil. In addition, in the first step, wiring and connection work is performed by dividing into a plurality of multi-winding integrated coil portions, so that the workability of wiring and connection can be improved in each step. In the second step, wiring and connection operations are not performed merely by laminating a plurality of multi-winding integrated coils, so that a multi-terminal product having a small terminal pitch can be manufactured without any problem.
【００４２】本発明の請求項２６に記載の発明は請求項
２５の構成に加えて複巻線一体型コイルを形成する第１
の工程において非巻線コイルの上に準備済みの巻線コイ
ルを積層して製作する製造方法としたものであり、巻線
コイル製作の工程を分離できるので簡単な巻線機で巻線
コイルを事前に製作・準備できるため、設備化コストが
低減できる。小ロット対応に向いた工程編成ができる。According to a twenty-sixth aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, the first aspect of the present invention for forming a multiple winding integrated coil is provided.
In this process, the prepared winding coil is laminated on the non-wound coil in the manufacturing process.The winding coil manufacturing process can be separated. Since it can be manufactured and prepared in advance, equipment costs can be reduced. Process organization suitable for small lots is possible.
【００４３】本発明の請求項２７に記載の発明は請求項
２６の構成に加えて予め、準備する巻線コイルの少なく
とも一方の面に絶縁紙を貼り付けて製作する製造方法と
したものであり、巻線形状の維持ができる。特に引出し
線の位置決めもできるので後工程でのコイル積層時の作
業性が向上する。According to a twenty-seventh aspect of the present invention, in addition to the constitution of the twenty-sixth aspect, there is provided a manufacturing method in which insulating paper is pasted on at least one surface of a winding coil to be prepared in advance. In addition, the winding shape can be maintained. In particular, since the lead wire can be positioned, workability in laminating the coil in a later step is improved.
【００４４】本発明の請求項２８に記載の発明は請求項
２５の構成に加えて複巻線一体型コイルを形成する第１
の工程において非巻線コイルの上に絶縁物を介して巻線
コイルを巻回して製作する製造方法としたものであり、
非巻線コイルの上に直巻きするため、自動化がやり易く
なり、大量生産に向いた工程編成ができる。また、積層
工程も削減できる。According to a twenty-eighth aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, a first aspect of the present invention for forming a multiple winding integrated coil is provided.
In the step of, the manufacturing method of winding and manufacturing the winding coil via an insulator on the non-winding coil,
Since it is wound directly on an unwound coil, automation is easy and the process organization suitable for mass production can be performed. Also, the number of laminating steps can be reduced.
【００４５】本発明の請求項２９に記載の発明は請求項
２５の構成に加えて薄板状の非巻線コイルをエッチング
で製作する製造方法としたものであり、ばりなしのコイ
ルとできるので品質が安定する。According to a twenty-ninth aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, the present invention is directed to a manufacturing method for manufacturing a thin plate-shaped non-winding coil by etching. Becomes stable.
【００４６】本発明の請求項３０に記載の発明は請求項
２５の構成に加えて薄板状の非巻線コイルを打ち抜きで
製作する製造方法としたものであり、生産性が向上する
ので大量生産が可能となる。According to a thirtieth aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, the present invention is directed to a manufacturing method in which a thin plate-shaped non-winding coil is manufactured by punching. Becomes possible.
【００４７】本発明の請求項３１に記載の発明は請求項
２５の構成に加えて巻線コイルを融着層付きの絶縁電線
で形成する製造方法としたものであり、巻線コイルは巻
線した状態のままで固着できるため、巻線単体での形状
保持ができることとなり、非巻線コイルの上にこの巻線
を積層して簡単に複巻線一体型コイルを製作できる。According to a thirty-first aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, the present invention is directed to a manufacturing method of forming a winding coil with an insulated wire having a fusion layer. Since the coil can be fixed as it is, the shape of the coil alone can be maintained, and this coil can be laminated on the non-coiled coil to easily produce a multi-coil integrated coil.
【００４８】本発明の請求項３２に記載の発明は請求項
３１の構成に加えて融着層をアルコール融着タイプの融
着層として巻線形成と同時にアルコール融着する製造方
法としたものであり、巻線機にアルコール塗布装置を取
り付けるだけで巻線と同時に固着ができるので巻線と融
着工程が一体化できることとなり、熱融着などに比べて
熱硬化設備、硬化工程が不要となり、製造工程が簡素化
できるものである。According to a thirty-second aspect of the present invention, in addition to the constitution of the thirty-first aspect, a manufacturing method is provided in which the fusion layer is formed as an alcohol fusion type fusion layer, and the alcohol is simultaneously formed with the windings. Yes, simply by attaching an alcohol coating device to the winding machine, the winding can be fixed simultaneously with the winding, so that the winding and the fusion process can be integrated, eliminating the need for thermosetting equipment and curing process compared to heat fusion, etc. The manufacturing process can be simplified.
【００４９】本発明の請求項３３に記載の発明は請求項
２５の構成に加えて巻線コイルを非巻線タイプの基板で
形成する製造方法としたものであり、巻線コイルの巻線
作業、引出しリードの配線、巻付け作業、等がなくな
り、作業工数が削減できる。According to a thirty-third aspect of the present invention, in addition to the constitution of the twenty-fifth aspect, a manufacturing method for forming a wound coil on a non-winding type substrate is provided. In addition, wiring and winding work of the lead lead are eliminated, and the number of working steps can be reduced.
【００５０】本発明の請求項３４に記載の発明は請求項
２５の構成に加えて第２の工程と最終工程の間に多積層
コイルを絶縁樹脂で封止する第３の工程を設けた製造方
法としたものであり、積層コイルの外形形状が安定する
ため、後工程での磁心の組み込みも容易となる。According to a thirty-fourth aspect of the present invention, in addition to the structure of the twenty-fifth aspect, a manufacturing method is provided in which a third step of sealing the multi-layered coil with an insulating resin is provided between the second step and the final step. Since the outer shape of the laminated coil is stabilized, it is easy to incorporate the magnetic core in a later step.
【００５１】以下、本発明の実施の形態について図面を
用いて具体的に説明する。Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
【００５２】（実施の形態１）本発明の第１の実施の形
態について図１〜図７を用いて説明する。(Embodiment 1) A first embodiment of the present invention will be described with reference to FIGS.
【００５３】図１（ａ）〜（ｇ）は、本発明の第１の実
施の形態を示す薄形トランスの工程説明図、図２（ａ）
〜（ｃ）は本発明の第１の実施の形態における各々の複
巻線一体型コイルを形成する第１の工程の説明図、図
３、図４、図５は本発明の第１の実施の形態における各
々の複巻線一体型コイルの完成図、図６は本発明の第１
の実施の形態における多積層コイルを形成する第２の工
程の説明図、図７は治具を利用した多積層コイルの積層
方法を示す説明図、図８は本発明の第１の実施の形態に
おけるモールドコイルの外観図、図９はモールド金型を
利用したモールドコイルの封止例を示す説明図、図１０
は本発明の第１の実施の形態を示す薄形トランスの組立
図、図１１は本発明の第１の実施の形態を示す薄形トラ
ンスの完成図である。図１〜図１１において１０は端子
一体型フレームコイル、１０ａはフレーム枠、１０ｂは
１次引出し端子、１０ｃは２次引出し端子、１０ｄは基
準穴、１０ｅは位置決めピン、１１は１次主巻線、１１
ａは１次補助巻線、１１ｂは１次引出しリード線、１２
は２次主巻線、１２ａは２次補助巻線、１３は絶縁紙、
１４は複巻線一体型コイル、１５は多積層コイル、１５
ａは積層治具、１６は絶縁樹脂、１７はモールドコイ
ル、１７ａはモールド金型、１８は磁心、１９は引出し
端子接続部を示している。FIGS. 1 (a) to 1 (g) are explanatory diagrams showing the steps of a thin transformer according to a first embodiment of the present invention, and FIGS.
FIGS. 3A to 3C are explanatory views of a first step of forming each of the multi-winding integrated coils in the first embodiment of the present invention, and FIGS. 3, 4 and 5 are first views of the first embodiment of the present invention. FIG. 6 is a completed view of each of the multi-winding integrated coils in the form of FIG.
FIG. 7 is an explanatory view of a second step of forming a multi-layered coil in the embodiment, FIG. 7 is an explanatory view showing a method of laminating the multi-layered coil using a jig, and FIG. 8 is a first embodiment of the present invention. , FIG. 9 is an explanatory view showing an example of sealing a molded coil using a mold, and FIG.
FIG. 11 is an assembly view of a thin transformer according to the first embodiment of the present invention, and FIG. 11 is a completed view of the thin transformer according to the first embodiment of the present invention. 1 to 11, reference numeral 10 denotes a terminal-integrated frame coil, 10a denotes a frame, 10b denotes a primary lead terminal, 10c denotes a secondary lead terminal, 10d denotes a reference hole, 10e denotes a positioning pin, and 11 denotes a primary main winding. , 11
a is the primary auxiliary winding, 11b is the primary lead wire, 12
Is a secondary main winding, 12a is a secondary auxiliary winding, 13 is insulating paper,
14 is a double winding integrated coil, 15 is a multi-layer coil, 15
a is a laminating jig, 16 is an insulating resin, 17 is a molded coil, 17a is a mold, 18 is a magnetic core, and 19 is a lead terminal connecting portion.
【００５４】図１において従来例を示す図１８と大きく
異なる点は端子一体型リードフレームコイル１０を発明
した点、この端子一体型リードフレームコイル１０を利
用して３個の複巻線一体型コイル１４を形成した点、こ
の３個の複巻線一体型コイルを積層して多積層コイル１
５を形成した点であるが、以下、図２〜図１１を利用し
て順次、説明する。FIG. 1 is largely different from FIG. 18 showing a conventional example in that the terminal-integrated lead frame coil 10 is invented. 14, the three multi-coil integrated coils are laminated to form a multi-layer coil 1
5 is formed, and will be sequentially described below with reference to FIGS.
【００５５】図２に示すようにまず、巻線をスパイラル
状に巻回し、上下を絶縁紙１３で挟み込んで形成した１
次主巻線１１を２個、巻線を巻回しないで製作する非巻
線タイプの基板からなる１次補助巻線１１ａと２次補助
巻線１２ａを各１個を予め、準備しておく。さらに薄板
状の導体をエッチング、或いは打抜きなどにより、製作
した端子一体型フレームコイル１０を３枚準備してお
く。この端子一体型フレームコイル１０は非巻線タイプ
の２次主巻線１２とフレーム枠１０ａを一体化してフレ
ームコイルを形成し、このフレームコイルに１次引出し
端子１０ｂ、２次引出し端子１０ｃも一体形成して端子
と２次主巻線１２とフレーム枠１０ａの３点を完全に一
体化した構成とした点が従来と大きく異なる点である。
次にこれら予め準備した各々の巻線をこれも予め準備し
ておいた各々の端子一体型フレームコイル１０と組み合
せて順次、積層して図３、図４、図５に示すように引出
し端子接続部１９において配線、接続し、３種類の複巻
線一体型コイル１４を製作する。この時、端子一体型フ
レームコイル１０に形成した１次引出し端子１０ｂ、２
次引出し端子１０ｃは上部に配置される巻線の引出し位
置を考慮しながら、必要最小限の端子数に設定してい
る。As shown in FIG. 2, first, the winding is wound in a spiral shape, and is formed by sandwiching the upper and lower sides with insulating paper 13.
Two primary auxiliary windings 11a and one secondary auxiliary winding 12a made of a non-winding type substrate manufactured without winding the two main windings 11 are prepared in advance. . Further, three frame-integrated terminal coils 10 manufactured by etching or punching a thin plate conductor are prepared. The terminal-integrated frame coil 10 is formed by integrating a non-winding type secondary main winding 12 and a frame 10a to form a frame coil, and a primary lead terminal 10b and a secondary lead terminal 10c are also integrated with the frame coil. The point that the three points of the terminal, the secondary main winding 12, and the frame 10a are completely integrated is significantly different from the related art.
Next, these pre-prepared windings are combined with the pre-prepared respective terminal-integrated frame coils 10 and sequentially laminated, and as shown in FIG. 3, FIG. 4, and FIG. In the part 19, wiring and connection are performed to manufacture three types of multi-winding integrated coils 14. At this time, the primary lead terminals 10b, 2
The number of the next extraction terminals 10c is set to the minimum necessary number in consideration of the extraction position of the winding disposed above.
【００５６】次に図６に示すように図２、図３、図４、
図５の工程で製作した３種類の複巻線一体型コイル１４
を順次積層して図７に示すような多積層コイル１５を製
作していく。この時、フレーム枠に基準穴１０ｄを設け
ており、積層治具１５ａにはこの基準穴１０ｄに対応し
た位置決めピン１０ｅを設けている。Next, as shown in FIG. 6, FIGS.
Three types of double-winding integrated coils 14 manufactured in the process of FIG.
Are sequentially laminated to produce a multi-layer coil 15 as shown in FIG. At this time, a reference hole 10d is provided in the frame, and a positioning pin 10e corresponding to the reference hole 10d is provided in the stacking jig 15a.
【００５７】さらに図８に示すように図６、図７の工程
で準備した多積層コイル１５を絶縁樹脂１６で封止して
モールドコイル１７を製作する。図９はモールド金型１
７ａを利用したモールドコイル１７の封止例を示してお
り、このモールド金型１７ａにもフレーム枠１０ａに設
けた基準穴１０ｄに対応した位置決めピン１０ｅを設け
てある。Further, as shown in FIG. 8, the multilayer coil 15 prepared in the steps of FIGS. 6 and 7 is sealed with an insulating resin 16 to produce a molded coil 17. Fig. 9 shows the mold 1
An example of sealing the molded coil 17 using the mold coil 7a is shown, and a positioning pin 10e corresponding to the reference hole 10d provided in the frame 10a is also provided in the mold 17a.
【００５８】最後に図１０に示すように完成したモール
ドコイル１７の上下から、磁心１８を組み込んで図１１
に示すようなコイル多積層型の薄形トランスを完成させ
るのである。Finally, as shown in FIG. 10, magnetic cores 18 are assembled from above and
Thus, a multi-layer coil type thin transformer as shown in FIG.
【００５９】以上、本発明の実施の形態１を示す図１〜
図１１の構成によれば、１次主巻線１１、２次主巻線１
２の少なくともどちらか一方は薄板状の非巻線コイルで
形成し、この非巻線コイルの上に他の巻線を形成して一
対にした複巻線一体型コイル１４を形成し、この複巻線
一体型コイルを複数個積層して多積層コイル１５を構成
し、この多積層コイル１５の上下から、磁心１８を組み
込んだので配線・接続部が複数に分割されるので端子間
のピッチ間隔が狭くても作業ができることとなり、多出
力・多数端子の設計が可能となる。また、自動化も容易
となるなどの効果がでる。The first embodiment of the present invention is described above with reference to FIGS.
According to the configuration of FIG. 11, the primary main winding 11, the secondary main winding 1
At least one of the coils 2 is formed of a thin plate-shaped unwound coil, and another winding is formed on the unwound coil to form a pair of multi-winding integrated coils 14. A multi-layer coil 15 is formed by laminating a plurality of winding-integrated coils. Since the magnetic core 18 is incorporated from above and below the multi-layer coil 15, the wiring / connection portion is divided into a plurality. Work can be performed even when the width is small, and it is possible to design a multi-output and multi-terminal. Further, effects such as easy automation can be obtained.
【００６０】また、２次主巻線１２とフレーム枠１０ａ
を一体化したフレームコイルとしたため、薄板状の２次
主巻線１２の引出し端子１０ｃの接続スペースが不要と
なり、小形化できる。The secondary main winding 12 and the frame 10a
Are integrated into a frame coil, so that a space for connecting the lead terminal 10c of the thin-plate-shaped secondary main winding 12 becomes unnecessary, and the size can be reduced.
【００６１】さらに１次引出し端子１０ｂ、或いは２次
引出し端子１０ｃと２次主巻線１２とフレーム枠１０ａ
を一体化した端子一体型フレームコイル１０としたの
で、端子、端子台、コイルベース、或いはボビンなどの
別部品が不要となり、部品点数が削減できる。Further, the primary lead terminal 10b or the secondary lead terminal 10c, the secondary main winding 12, and the frame 10a
Are integrated into a terminal-integrated frame coil 10, so that separate components such as terminals, terminal blocks, coil bases, and bobbins are not required, and the number of components can be reduced.
【００６２】これらの結果、作業性の良い、小形で安価
なコイル多積層タイプの薄形トランスを提供することが
可能となるのである。As a result, it is possible to provide a small and inexpensive coil multi-stack type thin transformer with good workability.
【００６３】また、フレーム枠１０ａに位置決め用の基
準部を設けたので基準部を利用してコイル積層治具、金
型設計時の基準点とできることとなり、製造時、各コイ
ルの相対的な位置バラツキを抑えることができるもので
ある。Further, since the positioning reference portion is provided on the frame 10a, the reference portion can be used as a reference point for designing the coil laminating jig and the mold. Variation can be suppressed.
【００６４】さらに基準部として穴１０ｄを設けたので
積層治具、金型に穴１０ｄに対応したピン１０ｅをたて
るだけで簡単に位置決めの治具が製作できる。Further, since the hole 10d is provided as a reference portion, a positioning jig can be easily manufactured only by setting a pin 10e corresponding to the hole 10d on a lamination jig or a mold.
【００６５】また、フレーム枠１０ａの基準穴１０ｄの
位置を非対称の位置に設けて１次、２次の方向性をもた
せてやれば、積層方向の誤りを防止できる。If the reference hole 10d of the frame 10a is provided at an asymmetrical position so as to have primary and secondary directions, an error in the stacking direction can be prevented.
【００６６】なお、本発明の実施の形態１を示す図１〜
図１１においては１次主巻線１１、２次主巻線１２をほ
ぼ同一巻幅で１層巻としているので１次主巻線間、２次
主巻線間では折り返し対向面がなくなるため、近接効果
などによる高周波抵抗の増大を少なくできる。また、各
巻線の線間容量も少なくなり、低ノイズ化が達成でき
る。さらに１次主巻線１１と２次主巻線１２は完全に交
互に積層された状態となるので１次主巻線１１と２次主
巻線１２の距離は最小となること、かつ対向面積も最大
限に確保できることとなり、１次、２次主巻線の漏れイ
ンダクタンス（Ｌｅ）も少なくできるため、巻線間の高
結合化が達成され、結果として低損失化、低ノイズ化、
電源の高効率化が達成される。FIGS. 1 to 3 show the first embodiment of the present invention.
In FIG. 11, since the primary main winding 11 and the secondary main winding 12 are wound in a single layer with substantially the same winding width, there is no folded facing surface between the primary main windings and between the secondary main windings. An increase in high-frequency resistance due to the proximity effect or the like can be reduced. Also, the line capacitance of each winding is reduced, and low noise can be achieved. Further, since the primary main winding 11 and the secondary main winding 12 are completely alternately stacked, the distance between the primary main winding 11 and the secondary main winding 12 is minimized, and the facing area is reduced. And the leakage inductance (Le) of the primary and secondary main windings can be reduced, so that high coupling between the windings is achieved, resulting in low loss, low noise,
High efficiency of the power supply is achieved.
【００６７】また、１次補助巻線１１ａ、２次補助巻線
１２ａを最上層に配置して１次、２次主巻線の間に余分
な巻線を配置しないようにしたので１次、２次主巻線間
の距離は最小、かつ安定するため、漏れインダクタンス
（Ｌｅ）最小、巻線間結合は最大限に高めることができ
ることに加えて性能のばらつきも小さくできる。The primary auxiliary winding 11a and the secondary auxiliary winding 12a are arranged on the uppermost layer so that no extra winding is arranged between the primary and secondary main windings. Since the distance between the secondary main windings is minimum and stable, the leakage inductance (Le) can be minimized, the coupling between windings can be maximized, and variations in performance can be reduced.
【００６８】なお、１次補助巻線１１ａは最下層に配置
してもその効果は同じである。さらに補助巻線が２次側
であっても同様の配置をすれば、同じ効果が得られる。The effect is the same even if the primary auxiliary winding 11a is arranged in the lowermost layer. Furthermore, the same effect can be obtained if the same arrangement is made even when the auxiliary winding is on the secondary side.
【００６９】さらに１次主巻線１１は絶縁皮膜付きの電
線としたので巻数が簡単に変更対応できるので設計の自
由度が広がる。この場合、１次または２次主巻線の少な
くともどちらか一方の巻線を絶縁皮膜付きの電線として
やれば、設計の自由度は広がり、その効果は同じものが
得られる。Furthermore, since the primary main winding 11 is an electric wire with an insulating film, the number of windings can be easily changed, so that the degree of freedom in design is widened. In this case, if at least one of the primary and secondary main windings is formed as an electric wire with an insulating film, the degree of freedom of design is widened and the same effect can be obtained.
【００７０】また、１次主巻線１１は絶縁皮膜の表面に
融着層を有するように構成しており、巻線を巻装した状
態のままで融着層を固着できるのでボビンレスでの巻線
形成が容易に実現できる。Further, the primary main winding 11 is configured to have a fusion layer on the surface of the insulating film, and the fusion layer can be fixed while the winding is wound. Line formation can be easily realized.
【００７１】さらにこれら巻線の融着層はアルコール融
着タイプの融着層としており、アルコール塗布するだけ
で簡単に巻線の固着ができるため、設備化が容易となる
ものである。Further, the fusion layer of these windings is a fusion layer of an alcohol fusion type, and the winding can be easily fixed only by applying an alcohol, thereby facilitating installation.
【００７２】また、本発明の実施の形態１を示す図８、
図９のように多積層コイル１５全体を絶縁樹脂１６で封
止したので多積層コイル１５の隙間に絶縁樹脂１６が流
れ込むことにより、コイル部の均熱化が図れるため、温
度上昇が低減できる。また、コイルとコイル間、コイル
と磁心１８間の絶縁も強化できることとなる。FIG. 8 showing the first embodiment of the present invention,
Since the entire multi-layer coil 15 is sealed with the insulating resin 16 as shown in FIG. 9, the insulating resin 16 flows into the gap between the multi-layer coils 15, so that the coil portion can be made uniform in temperature and the temperature rise can be reduced. Further, insulation between the coils and between the coils and the magnetic core 18 can be strengthened.
【００７３】さらに絶縁樹脂１６でモールド成型して封
止する工法を利用しているため、封止時間を短縮でき、
生産性が向上する。Further, since the method of molding and sealing with the insulating resin 16 is used, the sealing time can be shortened.
Productivity is improved.
【００７４】また、本発明の実施の形態１を示す図１〜
図１１において１次補助巻線１１ａ、２次補助巻線１２
ａとして非巻線タイプの基板を使用しているが、巻線を
巻回したコイルに比べて表面の仕上り具合に凹凸が少な
く、積層面の厚みが安定しているので性能バラツキが低
減できる。FIGS. 1 to 3 show the first embodiment of the present invention.
In FIG. 11, a primary auxiliary winding 11a and a secondary auxiliary winding 12
Although a non-winding type substrate is used as a, the unevenness of the surface finish is smaller than that of a coil wound with a winding, and the thickness of the laminated surface is stable, so that the performance variation can be reduced.
【００７５】非巻線タイプの基板としてはガラエポ基板
などが一般的であるが、セラミックなどの別の基板であ
ってもよい。さらに非巻線コイルの形成法に関してはエ
ッチング、印刷、蒸着などがあるが、あえて限定する必
要はない。A non-winding type substrate is generally a glass epoxy substrate or the like, but may be another substrate such as a ceramic substrate. Further, the method of forming the non-wound coil includes etching, printing, vapor deposition, etc., but it is not necessary to limit the method.
【００７６】特にエッチングで製作したガラエポ基材の
プリント基板などを使用すれば、汎用性も高いので調達
性向上、低コスト化が図れるという効果が生まれる。In particular, when a printed circuit board made of a glass epoxy substrate manufactured by etching is used, the versatility is high, so that the effect of improving procurement and reducing costs can be achieved.
【００７７】また、この基板上に２線輪以上の非巻線コ
イルを同一層に形成してやれば、コイルの積層厚みはア
ップしないで多くの補助出力が形成できることとなり、
トランス設計の自由度が大きくなる。また、これら複数
線輪間の相対位置も安定するので性能バラツキは低減で
きる。Further, if unwound coils of two or more wire loops are formed on the same layer on this substrate, a large number of auxiliary outputs can be formed without increasing the lamination thickness of the coils.
The degree of freedom in transformer design increases. In addition, since the relative position between the plurality of wire loops is also stabilized, the performance variation can be reduced.
【００７８】これら本発明の実施の形態１を示す図１〜
図１１の製造方法として１次、２次主巻線の少なくとも
どちらか一方は薄板状の非巻線コイルで形成し、この非
巻線コイルの上に他の巻線を形成して一対にした複巻線
一体型コイル１４を形成する第１の工程とこの複巻線一
体型コイルを複数個積層して多積層コイル１５を形成す
る第２の工程とこの多積層コイル１５の上下から、磁心
１８を組み込む最終工程としたものであり、第１の工程
で複数個の複巻線一体型コイル１４に分割して配線・接
続作業を行うので配線・接続の作業性が各段に向上でき
る。また、第２の工程では複巻線一体型コイル１４を複
数個積層するだけで配線・接続作業がないので端子ピッ
チの小さい多数端子の製品でも問題なく製造できる。FIGS. 1 and 2 show the first embodiment of the present invention.
As a manufacturing method in FIG. 11, at least one of the primary and secondary main windings is formed by a thin plate-shaped unwound coil, and another winding is formed on the unwound coil to form a pair. The first step of forming the multiple-winding integrated coil 14 and the second step of stacking a plurality of the multiple-winding integrated coils to form a multi-layer coil 15 and the magnetic core from above and below the multi-layer coil 15 This is a final step in which the wiring 18 is incorporated. In the first step, the wiring and connection work is performed by dividing the coil into a plurality of multi-winding integrated coils 14, so that the workability of wiring and connection can be improved in each step. In the second step, wiring and connection work are not required only by laminating a plurality of multi-coil integrated coils 14, so that a multi-terminal product having a small terminal pitch can be manufactured without any problem.
【００７９】また、複巻線一体型コイル１４を形成する
第１の工程において非巻線コイルの上に準備済みの巻線
コイルを積層して製作する製造方法としたので巻線コイ
ル製作工程が分離できるため、簡単な巻線機で巻線コイ
ルを事前に製作・準備できることとなり、設備化コスト
が低減できる、小ロット対応に向いた工程編成ができ
る、などの効果が生まれる。Further, in the first step of forming the multi-winding integrated coil 14, the manufacturing method is such that the prepared winding coil is laminated and manufactured on the non-winding coil. Since the coil can be separated, the winding coil can be manufactured and prepared in advance with a simple winding machine, so that effects such as reduction in equipment cost and formation of a process suitable for small lots can be obtained.
【００８０】さらに予め、準備した１次主巻線１１の上
下を絶縁紙１３で挟み込んで形成した製造方法としたの
で巻線形状の維持ができる。特に引出し線の位置決めも
できるので後工程でのコイル積層時の作業性が向上す
る。なお、この絶縁紙１３は少なくとも一方の面に貼り
付けて製造してやってもその効果に変わりはない。Furthermore, the manufacturing method is such that the upper and lower sides of the prepared primary main winding 11 are sandwiched between insulating papers 13 in advance, so that the winding shape can be maintained. In particular, since the lead wire can be positioned, workability in laminating the coil in a later step is improved. It should be noted that even if the insulating paper 13 is manufactured by attaching it to at least one surface, the effect is not changed.
【００８１】また、複巻線一体型コイル１４を形成する
第１の工程において非巻線コイルの上に絶縁物を介して
巻線コイルを巻回して製作する製造方法としてやること
により、非巻線コイルの上に直巻きできるため、自動化
がやり易くなり、大量生産に向いた工程編成ができる。
また、積層工程も削減できる。なお、ここで非巻線コイ
ルを絶縁するための絶縁物としては絶縁紙、絶縁フィル
ム、絶縁コーティングなど機能を満たせば、何でもよ
い。In the first step of forming the multi-winding integrated coil 14, a non-wound coil is produced by winding the wound coil on the non-wound coil via an insulator. Since it can be wound directly on a wire coil, automation can be easily performed, and process organization suitable for mass production can be performed.
Also, the number of laminating steps can be reduced. Here, as the insulator for insulating the non-wound coil, any material can be used as long as it satisfies the functions such as insulating paper, insulating film, and insulating coating.
【００８２】また、薄板状の非巻線コイルをエッチング
で製作する製造方法としてやれば、ばりなしのコイルと
できるので品質が安定する。Further, if a thin plate-shaped non-wound coil is manufactured by etching, a coil without burrs can be obtained, so that the quality is stabilized.
【００８３】さらに薄板状の非巻線コイルを打ち抜きで
製作する製造方法としてやれば、生産性が向上するので
大量生産が可能となる。Further, if the manufacturing method is to manufacture a sheet-shaped unwound coil by punching, productivity is improved, and mass production becomes possible.
【００８４】また、巻線コイルを融着層付きの絶縁電線
で形成する製造方法としたことにより、巻線コイルは巻
線した状態のままで固着できるため、巻線単体での形状
保持ができることとなり、非巻線コイルの上にこの巻線
を積層して簡単に複巻線一体型コイル１４を製作でき
る。In addition, by adopting a manufacturing method in which the winding coil is formed of an insulated wire with a fusion layer, the winding coil can be fixed in a wound state, so that the shape of the winding alone can be maintained. By stacking this winding on the non-wound coil, the multiple winding integrated coil 14 can be easily manufactured.
【００８５】さらに融着層をアルコール融着タイプの融
着層として巻線形成と同時にアルコール融着する製造方
法としたので巻線機にアルコール塗布装置を取り付ける
だけで巻線と同時に固着ができるので巻線と融着工程が
一体化できることとなり、熱融着などに比べて熱硬化設
備、硬化工程が不要となり、製造工程が簡素化できるも
のである。Further, since the fusion layer is formed as an alcohol fusion type fusion layer and the winding is formed and the alcohol is fused at the same time, the winding can be fixed simultaneously with the winding simply by attaching an alcohol coating device to the winding machine. Since the winding and the fusion step can be integrated, a thermosetting facility and a curing step are not required as compared with the heat fusion or the like, and the manufacturing process can be simplified.
【００８６】また、本発明の実施の形態１を示す図１〜
図１１に使用した１次主巻線１１の巻線コイルを非巻線
タイプの基板で形成する製造方法としてやれば、巻線コ
イルの巻線作業、引出しリードの配線、巻付け作業等が
なくなり、作業工数が削減できるという効果も生まれる
ものである。FIGS. 1 to 3 show the first embodiment of the present invention.
If the manufacturing method in which the winding coil of the primary main winding 11 used in FIG. 11 is formed on a non-winding type substrate is used, the winding work of the winding coil, the wiring of the lead lead, the winding work, etc. are eliminated. This also has the effect of reducing the number of work steps.
【００８７】さらに多積層コイルを製作する第２の工程
（図６、図７）と磁心を組み込む最終工程（図１０）の
間に多積層コイル１５を絶縁樹脂で封止する第３の工程
（図８、図９）を設けた製造方法としたことにより、多
積層コイルの外形形状が安定するため、後工程での磁心
の組み込みも容易となる。Further, a third step of sealing the multi-layered coil 15 with an insulating resin between the second step of manufacturing the multi-layered coil (FIGS. 6 and 7) and the final step of incorporating the magnetic core (FIG. 10) 8 and 9), the outer shape of the multi-layer coil is stabilized, so that the magnetic core can be easily incorporated in a later step.
【００８８】（実施の形態２）次に本発明の第２の実施
の形態について図１２を用いて説明する。図１２は、本
発明の薄形トランスの第２の実施の形態を示す積層コイ
ル構成図である。図１２において２０は丸電線を示して
いる。(Embodiment 2) Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 12 is a configuration diagram of a laminated coil showing a second embodiment of the thin transformer of the present invention. In FIG. 12, reference numeral 20 denotes a round electric wire.
【００８９】基本的な構成は本発明の第１の実施の形態
を示す図１〜図１１と同一である。大きく異なる点は１
次補助巻線１１ａ、２次補助巻線１２ａを非巻線タイプ
の基板を使用しないで絶縁皮膜付きの丸電線２０を使用
して全ての巻線コイルを丸電線２０で形成した点であ
る。The basic structure is the same as that shown in FIGS. 1 to 11 showing the first embodiment of the present invention. The major difference is 1
The second auxiliary winding 11a and the secondary auxiliary winding 12a do not use a non-winding type substrate, but use a round electric wire 20 with an insulating film and form all the winding coils with the round electric wire 20.
【００９０】以上、本発明の第２の実施の形態を示す図
１２の構成によれば、全ての巻線コイルに丸電線２０を
使用しているので巻線材料コストの低減が達成できる。
また、巻線のスピードアップが図れ、作業性が向上す
る。As described above, according to the configuration of FIG. 12 showing the second embodiment of the present invention, since the round electric wires 20 are used for all the winding coils, the cost of the winding material can be reduced.
Further, the speed of the winding can be increased, and the workability is improved.
【００９１】さらに図１２においては１次補助巻線１１
ａと２次補助巻線１２ａのみは丸電線を使用しており、
補助出力巻線に関して設計の自由度向上、材料低減など
の効果が得られるものである。なお、この補助巻線に関
しては少なくともどちらか一方の巻線を丸電線２０とし
てやれば、この効果は得られるものである。Further, in FIG. 12, the primary auxiliary winding 11
a and the secondary auxiliary winding 12a only use round electric wires,
With respect to the auxiliary output winding, effects such as improvement in design flexibility and material reduction can be obtained. This effect can be obtained if at least one of the auxiliary windings is formed as the round electric wire 20.
【００９２】また、図１２において１次又は２次巻線の
少なくともどちらか一方の巻線を３層絶縁皮膜付き電線
としてやることにより、高い電圧の入力に対しても１次
と２次間の充分な絶縁が保てる。また、各国安全規格等
への対応も容易となる。Further, in FIG. 12, at least one of the primary and secondary windings is formed as an electric wire with a three-layer insulating film, so that even if a high voltage is input, the primary and secondary windings can be interposed. Sufficient insulation can be maintained. It also facilitates compliance with safety standards in each country.
【００９３】（実施の形態３）次に本発明の第３の実施
の形態について図１３を用いて説明する。図１３は本発
明の薄形トランスの第３の実施の形態を示す積層コイル
構成図である。図１３において基本的な構成は本発明の
第２の実施の形態を示す図１２と同一である。大きく異
なる点は全ての巻線コイルとして平角電線２１を使用し
た点であり、巻線の占積率を高められるので巻線抵抗の
低減、即ち、低損失化が達成できるものである。(Embodiment 3) Next, a third embodiment of the present invention will be described with reference to FIG. FIG. 13 is a configuration diagram of a laminated coil showing a third embodiment of a thin transformer according to the present invention. The basic configuration in FIG. 13 is the same as that in FIG. 12 showing the second embodiment of the present invention. The major difference is that the flat wire 21 is used as all the winding coils. Since the space factor of the windings can be increased, the winding resistance can be reduced, that is, the loss can be reduced.
【００９４】（実施の形態４）次に本発明の薄形トラン
スの第４の実施の形態について図１４を用いて説明す
る。図１４は本発明の薄形トランスの第４の実施の形態
を示す積層コイル構成図である。図１４において基本的
な構成は本発明の第１の実施の形態を示す図１〜１１の
構成と同じであるが、大きく異なる点は１次主巻線１１
を薄板状の非巻線コイル２２で形成した点であり、結果
として２次主巻線１２と併せて両方の巻線を薄板状の非
巻線コイル２２で形成したことになる。Embodiment 4 Next, a fourth embodiment of the thin transformer of the present invention will be described with reference to FIG. FIG. 14 is a configuration diagram of a laminated coil showing a thin transformer according to a fourth embodiment of the present invention. The basic configuration in FIG. 14 is the same as the configuration in FIGS.
Is formed by the thin plate-shaped non-winding coil 22. As a result, both the windings are formed by the thin plate-shaped non-winding coil 22 together with the secondary main winding 12.
【００９５】この構成により、１次または２次主巻線の
巻数が少ない時でも１次と２次巻線間の対向面積が確保
できるので高結合とできる。また、断面積も確保できる
ので大電流対応も容易となる。With this configuration, even when the number of turns of the primary or secondary main winding is small, a facing area between the primary and secondary windings can be ensured, so that high coupling can be achieved. In addition, since a cross-sectional area can be secured, it is easy to handle a large current.
【００９６】（実施の形態５）次に本発明の薄形トラン
スの第５の実施の形態について図１５を用いて説明す
る。図１５は本発明の薄形トランスの第５の実施の形態
を示す積層コイル構成図である。図１５において基本的
には本発明の第４の実施の形態を示す図１４と同一であ
る。大きく異なる点は図１４における１次主巻線１１と
２次主巻線１２の両方の巻線をフレーム枠を一体化した
フレームコイル２３とした点である。(Embodiment 5) Next, a fifth embodiment of the thin transformer of the present invention will be described with reference to FIG. FIG. 15 is a configuration diagram of a laminated coil showing a fifth embodiment of a thin transformer according to the present invention. FIG. 15 is basically the same as FIG. 14 showing the fourth embodiment of the present invention. The major difference is that both windings of the primary main winding 11 and the secondary main winding 12 in FIG. 14 are frame coils 23 having an integrated frame.
【００９７】この構成によれば、大電流を流す１次主巻
線１１、２次主巻線１２の両方の巻線のコイル内部での
接続点がなくなるので、信頼性が向上する。According to this configuration, there is no connection point in the coil between the primary main winding 11 and the secondary main winding 12 through which a large current flows, so that the reliability is improved.
【００９８】（実施の形態６）次に本発明の薄形トラン
スの第６の実施の形態について図１６、図１７を用いて
説明する。図１６は本発明の第６の実施の形態で使用す
るコイル図、図１７は本発明の第６の実施の形態を示す
積層コイル構成図であり、２４はエッジワイズ巻コイ
ル、２４ａは穴を示している。(Embodiment 6) Next, a sixth embodiment of the thin transformer according to the present invention will be described with reference to FIGS. FIG. 16 is a coil diagram used in the sixth embodiment of the present invention, and FIG. 17 is a configuration diagram of a laminated coil showing the sixth embodiment of the present invention. 24 is an edgewise wound coil, and 24a is a hole. Is shown.
【００９９】図１６、図１７において基本的な構成は本
発明の第１の実施の形態を示す図１〜図１１と同じであ
る。大きく異なる点は１次主巻線１１として図１６に示
すような平角電線をエッジワイズ巻きしたコイルを使用
して端子一体型フレームコイル１０と積層した点であ
る。The basic structure in FIGS. 16 and 17 is the same as in FIGS. 1 to 11 showing the first embodiment of the present invention. A major difference is that a coil formed by winding a rectangular electric wire edgewise as shown in FIG. 16 as the primary main winding 11 is laminated on the terminal-integrated frame coil 10.
【０１００】この構成によれば、断面積の大きく取れる
平角電線を利用できるため、１次主巻線１１の巻数が比
較的多い場合でも大電流に対応可能となり、設計の自由
度が大きく広がる。なお、１次主巻線１１と２次主巻線
１２はどちらか一方の巻線をエッジワイズ巻コイル２４
としてやることによって本発明の効果が得られることは
いうまでもない。According to this configuration, a rectangular electric wire having a large cross-sectional area can be used, so that even when the number of turns of the primary main winding 11 is relatively large, it is possible to cope with a large current and the degree of freedom in design is greatly expanded. One of the primary main winding 11 and the secondary main winding 12 is formed by an edgewise winding coil 24.
Needless to say, the effect of the present invention can be obtained by doing so.
【０１０１】また、このエッジワイズ巻コイルの巻始め
と巻終わりの引出し線先端部に穴２４ａを設けてやり、
端子一体型フレームコイル１０に設けた端子を挿入して
やることにより、接続点としてやると共に位置決めの基
準点としても利用できるため、コイル積層時の位置決め
精度が向上し、性能ばらつきも少なくできるものであ
る。A hole 24a is provided at the leading end of the lead wire at the beginning and end of winding of this edgewise wound coil.
By inserting the terminal provided in the terminal-integrated frame coil 10, it can be used as a connection point and can also be used as a reference point for positioning, so that the positioning accuracy at the time of coil lamination can be improved and performance variations can be reduced.
【０１０２】[0102]
【発明の効果】以上のように本発明によれば、配線・接
続部が複数に分割されるので端子間のピッチ間隔が狭く
ても作業ができることとなり、多出力・多数端子の設計
が可能となる。さらに自動化も容易となるなどの効果が
でる。また、非巻線コイル１２とフレーム枠１０ａを一
体化したフレームコイルとしたため、薄板状の非巻線コ
イル１２の引出し端子１０ｃの接続スペースが不要とな
り、小形化できる。As described above, according to the present invention, since the wiring / connection portion is divided into a plurality of parts, the work can be performed even if the pitch interval between the terminals is narrow, and it is possible to design a multi-output and many terminals. Become. Further, effects such as easy automation can be obtained. Further, since the non-winding coil 12 and the frame 10a are integrated into a frame coil, a space for connecting the lead terminals 10c of the thin non-winding coil 12 becomes unnecessary, and the size can be reduced.
【０１０３】さらに端子一体型フレームコイル１０を採
用したので、端子、端子台、コイルベース、或いはボビ
ンなどの別部品が不要となり、部品点数が削減できる。Further, the use of the terminal-integrated frame coil 10 eliminates the need for separate components such as terminals, terminal blocks, coil bases, and bobbins, thereby reducing the number of components.
【０１０４】このことにより、作業性の良い、小形で安
価なコイル多積層タイプの薄形トランスおよびその製造
方法を提供するという目的を達成できるのである。As a result, it is possible to achieve the object of providing a compact and inexpensive multi-layer coil type thin transformer with good workability and a method of manufacturing the same.
【図１】本発明の第１の実施の形態を示す薄形トランス
の工程説明図FIG. 1 is a process explanatory view of a thin transformer showing a first embodiment of the present invention.
【図２】本発明の第１の実施の形態における第１の工程
の説明図FIG. 2 is an explanatory diagram of a first step according to the first embodiment of the present invention.
【図３】本発明の第１の実施の形態における各々の複巻
線一体型コイルの完成図FIG. 3 is a completed view of each of the double-wound integrated coils according to the first embodiment of the present invention.
【図４】本発明の第１の実施の形態における各々の複巻
線一体型コイルの完成図FIG. 4 is a completed view of each of the multiple winding integrated coils according to the first embodiment of the present invention.
【図５】本発明の第１の実施の形態における各々の複巻
線一体型コイルの完成図FIG. 5 is a completed view of each of the multiple-winding integrated coils according to the first embodiment of the present invention.
【図６】本発明の第１の実施の形態における第２の工程
の説明図FIG. 6 is an explanatory view of a second step in the first embodiment of the present invention.
【図７】本発明の第１の実施の形態における多積層コイ
ルの積層方法を示す説明図FIG. 7 is an explanatory diagram showing a method for laminating a multi-layer coil according to the first embodiment of the present invention.
【図８】本発明の第１の実施の形態におけるモールドコ
イルの外観図FIG. 8 is an external view of a molded coil according to the first embodiment of the present invention.
【図９】本発明の第１の実施の形態におけるモールドコ
イルの封止例を示す説明図FIG. 9 is an explanatory diagram showing an example of sealing a molded coil according to the first embodiment of the present invention.
【図１０】本発明の第１の実施の形態を示す薄形トラン
スの組立図FIG. 10 is an assembly view of a thin transformer showing the first embodiment of the present invention.
【図１１】本発明の第１の実施の形態を示す薄形トラン
スの完成図FIG. 11 is a completed view of a thin transformer showing the first embodiment of the present invention.
【図１２】本発明の薄形トランスの第２の実施の形態を
示す積層コイルの構成図FIG. 12 is a configuration diagram of a laminated coil showing a thin transformer according to a second embodiment of the present invention;
【図１３】本発明の薄形トランスの第３の実施の形態を
示す積層コイルの構成図FIG. 13 is a configuration diagram of a laminated coil showing a thin transformer according to a third embodiment of the present invention.
【図１４】本発明の薄形トランスの第４の実施の形態を
示す積層コイルの構成図FIG. 14 is a configuration diagram of a laminated coil showing a thin transformer according to a fourth embodiment of the present invention;
【図１５】本発明の薄形トランスの第５の実施の形態を
示す積層コイルの構成図FIG. 15 is a configuration diagram of a laminated coil showing a fifth embodiment of a thin transformer according to the present invention.
【図１６】本発明の第６の実施の形態で使用するコイル
図FIG. 16 is a coil diagram used in a sixth embodiment of the present invention.
【図１７】本発明の第６の実施の形態を示す積層コイル
構成図FIG. 17 is a configuration diagram of a laminated coil showing a sixth embodiment of the present invention.
【図１８】従来の薄形トランスの積層から組立までを説
明する工程説明図FIG. 18 is a process explanatory view for explaining a conventional thin transformer from lamination to assembly.
【図１９】従来の薄形トランスのコイル積層図FIG. 19 is a coil stack diagram of a conventional thin transformer.
１ １次主巻線 １ａ １次補助巻線 ２ ２次主巻線 ３ 絶縁紙 ４ 端子 ４ａ 端子台 ５ 接続部 ６ コイルベース ７ 絶縁樹脂 ８ モールドコイル ９ 磁心 １０ 端子一体型フレームコイル １０ａ フレーム枠 １０ｂ １次引出し端子 １０ｃ ２次引出し端子 １０ｄ 基準穴 １０ｅ 位置決めピン １１ １次主巻線 １１ａ １次補助巻線 １１ｂ １次引出しリード線 １２ ２次主巻線 １２ａ ２次補助巻線 １３ 絶縁紙 １４ 複巻線一体型コイル １５ 多積層コイル １５ａ 積層治具 １６ 絶縁樹脂 １７ モールドコイル １７ａ モールド金型 １８ 磁心 １９ 引出し端子接続部 ２０ 丸電線 ２１ 平角電線 ２２ 薄板状の非巻線コイル ２３ フレームコイル ２４ エッジワイズ巻コイル ２４ａ 穴 DESCRIPTION OF SYMBOLS 1 Primary main winding 1a Primary auxiliary winding 2 Secondary main winding 3 Insulating paper 4 Terminal 4a Terminal block 5 Connection part 6 Coil base 7 Insulating resin 8 Mold coil 9 Magnetic core 10 Terminal integrated frame coil 10a Frame frame 10b Primary extraction terminal 10c Secondary extraction terminal 10d Reference hole 10e Positioning pin 11 Primary main winding 11a Primary auxiliary winding 11b Primary extraction lead wire 12 Secondary main winding 12a Secondary auxiliary winding 13 Insulating paper 14 Double Wound integrated coil 15 Multi-layered coil 15a Laminating jig 16 Insulating resin 17 Mold coil 17a Mold 18 Magnetic core 19 Leader terminal connection part 20 Round wire 21 Flat wire 22 Thin non-winding coil 23 Frame coil 24 Edgewise Wound coil 24a hole
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.7 識別記号 ＦＩ テーマコート゛(参考） Ｈ０１Ｆ 31/00 Ｊ (72)発明者 大村 勝規 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 (72)発明者 中出 祐二 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 (72)発明者 伊藤 実 大阪府門真市大字門真1006番地 松下電器 産業株式会社内 Ｆターム(参考） 5E070 AA11 AB02 AB10 BA08 CA01 CA03 CA11 CA12 CB01 CB13 CB16 CB18 DA11 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 7 Identification code FI Theme coat ゛ (Reference) H01F 31/00 J (72) Inventor Katsunori Oka 1006 Ojidoma, Kadoma City, Osaka Matsushita Electric Industrial Co., Ltd. ( 72) Inventor Yuji Nakade 1006 Kazuma Kadoma, Kadoma City, Osaka Prefecture Inside Matsushita Electric Industrial Co., Ltd. (72) Inventor Minoru 1006 Kadoma Kadoma, Kadoma City Osaka Prefecture AB10 BA08 CA01 CA03 CA11 CA12 CB01 CB13 CB16 CB18 DA11
Claims (34)
一方は薄板状の非巻線コイルで形成し、この非巻線コイ
ルの上に他の巻線を形成して一対にした複巻線一体型コ
イルを形成し、この複巻線一体型コイルを複数個積層し
て多積層コイルを構成し、この多積層コイルの上下か
ら、磁心を組み込んだ薄形トランス。At least one of the primary and secondary main windings is formed of a thin plate-shaped non-winding coil, and another winding is formed on the non-winding coil to form a pair. A thin-type transformer that forms a multi-layer coil by laminating a plurality of multi-layer coils by forming a multi-layer coil, and forming a multi-layer coil from above and below the multi-layer coil.
ルとフレーム枠を一体化したフレームコイルとした請求
項１記載の薄形トランス。2. The thin transformer according to claim 1, wherein the non-winding coil is a frame coil in which the non-winding coil and the frame are integrated.
線コイルとフレーム枠を一体化した端子一体型フレーム
コイルとした請求項１または２記載の薄形トランス。3. The thin transformer according to claim 1, wherein the thin plate-shaped unwound coil is a terminal-integrated frame coil in which a terminal, an unwound coil, and a frame are integrated.
た請求項２または３記載の薄形トランス。4. The thin transformer according to claim 2, wherein a reference portion for positioning is provided on the frame.
薄形トランス。5. The thin transformer according to claim 4, wherein a hole is provided as a reference portion.
置に設けた請求項４または５記載の薄形トランス。6. The thin transformer according to claim 4, wherein the position of the reference portion of the frame is provided at an asymmetric position.
で１層巻とした請求項１〜３のいずれか一つに記載の薄
形トランス。7. The thin transformer according to claim 1, wherein the primary main winding and the secondary main winding are formed in a single-layer winding with substantially the same winding width.
は最下層に配置した請求項７記載の薄形トランス。8. The thin transformer according to claim 7, wherein the auxiliary winding is arranged on the uppermost layer or the lowermost layer of the primary and secondary main windings.
求項１〜３のいずれか一つに記載の薄形トランス。9. The thin transformer according to claim 1, wherein the entire laminated coil is sealed with an insulating resin.
請求項９記載の薄形トランス。10. The thin transformer according to claim 9, wherein the transformer is molded and sealed with an insulating resin.
ちらか一方の巻線を絶縁皮膜付きの電線とした請求項１
〜３，９，１０のいずれか一つに記載の薄形トランス。11. The electric wire with an insulating coating on at least one of the primary and secondary main windings.
-The thin transformer according to any one of-3, 9, and 10.
薄形トランス。12. The thin transformer according to claim 11, wherein the electric wire is a round electric wire.
求項１１記載の薄形トランス。13. The thin transformer according to claim 11, wherein the electric wire is an electric wire with a three-layer insulating film.
の薄形トランス。14. The thin transformer according to claim 11, wherein the electric wire is a rectangular electric wire.
薄板状の非巻線コイルで形成した請求項１〜３，９，１
０のいずれか一つに記載の薄形トランス。15. The method according to claim 1, wherein both of the primary and secondary main windings are formed of thin, unwinding coils.
0. The thin transformer according to any one of 0.
フレーム枠を一体化したフレームコイルで形成した請求
項１５記載の薄形トランス。16. The thin transformer according to claim 15, wherein both of the primary and secondary main windings are formed by a frame coil having an integrated frame.
ちらか一方の巻線を平角線のエッジワイズ巻コイルで形
成した請求項１〜３，９，１０のいずれか一つに記載の
薄形トランス。17. The thin film according to claim 1, wherein at least one of the primary and secondary main windings is formed by a rectangular wire edgewise wound coil. Shape transformer.
穴をあけた請求項１７記載の薄形トランス。18. The thin transformer according to claim 17, wherein a hole is formed at the leading end of the lead wire at the beginning and end of the winding.
どちらか一方の巻線を丸電線とした請求項１〜３，９，
１０のいずれか一つに記載の薄形トランス。19. The method according to claim 1, wherein at least one of the primary and secondary auxiliary windings is a round electric wire.
11. The thin transformer according to any one of 10.
どちらか一方の巻線を非巻線タイプの基板で形成した請
求項１〜３，９，１０のいずれか一つに記載の薄形トラ
ンス。20. The thin type according to claim 1, wherein at least one of the primary and secondary auxiliary windings is formed of a non-winding type substrate. Trance.
工法によるプリント基板で形成した請求項２０記載の薄
形トランス。21. The thin transformer according to claim 20, wherein the non-winding type substrate is formed by a printed circuit board by an etching method.
した請求項２０または２１記載の薄形トランス。22. The thin transformer according to claim 20, wherein a plurality of two or more wire loops are formed on the substrate.
〜１４，１９のいずれか一つに記載の薄形トランス。23. The winding according to claim 11, wherein each winding is provided with a fusion layer.
20. The thin transformer according to any one of claims 14 to 19.
層とした請求項２３記載の薄形トランス。24. The thin transformer according to claim 23, wherein the fusion layer is an alcohol fusion type fusion layer.
か一方は薄板状の非巻線コイルで形成し、この非巻線コ
イルの上に他の巻線を形成して一対にした複巻線一体型
コイルを形成する第１の工程とこの複数線一体型コイル
を複数個積層して多積層コイルを形成する第２の工程と
この多積層コイルの上下から、磁心を組み込む最終工程
を有する薄形トランスの製造方法。25. At least one of the primary and secondary main windings is formed of a thin plate-shaped non-winding coil, and another winding is formed on the non-winding coil to form a pair. A first step of forming a winding-integrated coil, a second step of laminating a plurality of the multi-wire integrated coils to form a multi-layer coil, and a final step of incorporating a magnetic core from above and below the multi-layer coil Of manufacturing a thin transformer having the same.
工程において非巻線コイルの上に準備済みの巻線コイル
を積層して製作した請求項２５に記載の薄形トランスの
製造方法。26. The method for manufacturing a thin transformer according to claim 25, wherein in the first step of forming the multi-winding integrated coil, the prepared winding coil is laminated on the non-winding coil. .
も一方の面に絶縁紙を貼り付けて製作した請求項２６記
載の薄形トランスの製造方法。27. The method for manufacturing a thin transformer according to claim 26, wherein said winding coil is prepared by attaching insulating paper to at least one surface of said winding coil.
工程において非巻線コイルの上に絶縁物を介して巻線コ
イルを巻回して製作した請求項２５に記載の薄形トラン
スの製造方法。28. The thin transformer according to claim 25, wherein in the first step of forming the multi-winding integrated coil, the winding coil is wound on the non-winding coil via an insulator. Production method.
製作した請求項２５に記載の薄形トランスの製造方法。29. The method of manufacturing a thin transformer according to claim 25, wherein the thin plate-shaped unwound coil is manufactured by etching.
作した請求項２５に記載の薄形トランスの製造方法。30. The method for manufacturing a thin transformer according to claim 25, wherein the thin non-winding coil is manufactured by punching.
形成した請求項２５に記載の薄形トランスの製造方法。31. The method for manufacturing a thin transformer according to claim 25, wherein the winding coil is formed of an insulated wire having a fusion layer.
層として巻線形成と同時にアルコール融着した請求項３
１記載の薄形トランスの製造方法。32. The method according to claim 3, wherein the fusing layer is an alcohol fusing type fusing layer, and the fusing layer is formed by fusing alcohol at the same time as winding.
2. The method for producing a thin transformer according to 1.
成した請求項２５に記載の薄形トランスの製造方法。33. The method for manufacturing a thin transformer according to claim 25, wherein the winding coil is formed of a non-winding type substrate.
イルを絶縁樹脂で封止する第３の工程を設けた請求項２
５に記載の薄形トランスの製造方法。34. A method according to claim 2, wherein a third step of sealing the multi-layer coil with an insulating resin is provided between the second step and the final step.
6. The method for producing a thin transformer according to 5.
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| JP2000253728A JP3551135B2 (en) | 2000-08-24 | 2000-08-24 | Thin transformer and method of manufacturing the same |
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|---|---|---|---|
| JP2000253728A JP3551135B2 (en) | 2000-08-24 | 2000-08-24 | Thin transformer and method of manufacturing the same |
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