A choke coil for preventing harmonic distortions, used with home-use and industrial electronic apparatuses, is designed to reduce the apparatus size, reduce leakage fluxes and realize superior high-frequency characteristics. In order to achieve this object, there is provided a choke coil comprising a first magnetic core and a second magnetic core making up a closed magnetic circuit or an open magnetic circuit, a first coil, a second coil and a third coil, wherein the first coil is wound on the first magnetic core, the second coil is wound on the second magnetic core, and further the third coil is wound in such a manner as to cover the first magnetic core and the second magnetic core, and an inductance value required for preventing harmonic distortions is secured by the magnetic circuit configuration. At the same time, the function of a common-mode choke coil is provided to increase a coupling coefficient and reduce the system size and leakage fluxes.
A conventional choke coil for preventing harmonic distortions shown in FIGS. 32 to 34 is well known. FIGS. 32 to 34 show an exploded perspective view, a sectional view and an equivalent circuit respectively of a conventional choke coil used for preventing harmonic distortions.
In FIGS. 32 to 34, numeral 58 designates a U-shaped closed-circuit magnetic core made of a ferrite material, numeral 59 an EI-shaped closed-circuit magnetic core made of silicon steel sheets, numeral 60 a bobbin, numerals 61, 62 coils, numeral 63 a resin case, numeral 64 a shield case, numeral 65 a casting resin, numeral 66 partitioning flanges, numeral 67 a magnetic gap, character "C" a common-mode choke coil section and character "N" a normal-mode choke coil section.
The above-mentioned choke coil for preventing harmonic distortions is completed by combining the U-shaped closed-circuit magnetic core 58 of a ferrite material and the EI-shaped closed-circuit magnetic core 59 of silicon steel sheets, with the coils 61, 62 having the same number of turns wound on the bobbin 60 partitioned by the partitioning flange 66 in such a manner as to cover two magnetic cores 58, 59. In this configuration, as shown by the equivalent circuit of FIG. 34, two different closed-circuit magnetic cores 58, 59 constitute different magnetic circuits, and the normal-mode choke coil section "N" is configured mainly of the EI-shaped closed-circuit magnetic core 59 of silicon steel sheets while the common-mode choke coil section "C" is constructed mainly of the U-shaped closed-circuit magnetic core 58 of a ferrite material. The magnetic gap 67 provided on the middle limb of the EI-shaped magnetic core 59 made of silicon steel sheets is for improving the magnetic saturation characteristic of the normal-mode choke coil section "N".
For a choke coil for preventing harmonic distortions, the important problem is generally how to secure a very large inductance value on the order of several mH in normal mode and reduce the package space and weight at the same time. The conventional choke coil for preventing harmonic distortions shown in FIG. 32 can secure a normal-mode inductance value required for preventing harmonic distortions, while at the same time having the function of a common-mode choke coil. Therefore, prevention of both harmonic distortions and EMI is possible, and also the common-mode choke coil thus far arranged in the filter block of the power circuit can be eliminated, thereby leading to the additional advantage of reducing the package space.
In the conventional choke coil for preventing harmonic distortions, however, due to the configuration of the magnetic circuit thereof, the coil 61 and the coil 62 cannot be arranged closely to each other and are separated by the width of the middle limb of the EI-shaped magnetic core 59 of silicon steel sheets. As a result, the coupling coefficient between the coils 61 and 62 of the common-mode choke coil section "C" is reduced, so that the magnetic core 58 of a ferrite material is liable to be magnetically saturated. It is thus necessary to select a material of a high saturation flux density for the magnetic core 58. Generally, materials of a high saturation flux density have a low magnetic permeability, leading to the disadvantage of an increased size of the common-mode choke coil section "C". Also, in the normal-mode choke coil section "N", a great amount of leakage fluxes are generated from the magnetic gap 67 provided on the middle limb of the EI-shaped magnetic core 59 of silicon steel sheets, thereby posing the problem of an adverse effect on the other parts.
DISCLOSURE OF INVENTION
In order to solve the above-mentioned problem, a choke coil according to the present invention comprises a first magnetic core and a second magnetic core making up a closed magnetic circuit or an open magnetic circuit, a first coil, a second coil and a third coil, wherein the first coil is wound on the first magnetic core, the second coil is wound on the second magnetic core, and the third coil is wound in such a manner as to cover at least portions of the first and second magnetic cores.
As described above, the third coil is wound in such a manner as to cover the first and second magnetic cores, and therefore the coupling coefficient between coils becomes high in the common-mode choke coil section "C". As a result, the common-mode choke coil section "C" can be reduced in size. In the normal-mode choke coil section "N", on the other hand, the leakage fluxes generated from the magnetic gap can be blocked by coils. Thus, a compact choke coil for preventing harmonic distortions having the function of a high-performance common-mode choke coil can be provided with low cost and high quality.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a model perspective view of a choke coil according to an embodiment of the present invention,
FIG. 2 is a diagram showing a magnetic circuit of the same embodiment,
FIG. 3 is a model perspective view of a development example of the embodiment shown in FIG. 1,
FIG. 4 is a perspective view showing a choke coil according to a further embodiment,
FIG. 5 is a model perspective view of the choke coil shown in FIG. 4,
FIG. 6 is a sectional view of the same choke coil,
FIG. 7 is a model perspective view of the development example of the embodiment shown in FIG. 4,
FIGS. 8(a) and 8(b) are a model perspective view and a diagram showing a magnetic circuit respectively of a choke coil according to another embodiment,
FIG. 9 is a model perspective view of a development example of the embodiment shown in FIG. 1,
FIG. 10 is a model perspective view of a development example of the embodiment shown in FIG. 8,
FIG. 11 is a perspective view of another embodiment of the invention,
FIG. 12 is a model plan view of the same embodiment,
FIG. 13 is a diagram for comparing the frequency characteristics between the embodiment of FIG. 11 and a reference,
FIG. 14 is a perspective view of another embodiment of the invention,
FIG. 15 is a model plan view of the same embodiment,
FIG. 16 is a diagram for comparing the frequency characteristics between the embodiment of FIG. 14 and a reference,
FIG. 17 is a model plan view of a development example according to the embodiment shown in FIG. 14,
FIG. 18 is a diagram showing a magnetic circuit of another embodiment,
FIG. 19 is a perspective view of the same embodiment,
FIG. 20 is a model perspective view of the same embodiment,
FIG. 21 is a diagram showing a punching layout of the U-shaped laminated iron cores,
FIG. 22 is a diagram showing a magnetic circuit of a choke coil according to another embodiment,
FIG. 23 is a diagram showing a magnetic circuit of a choke coil according to another embodiment,
FIGS. 24(a), 24(b) and 24(c) are diagrams showing a magnetic circuit, an enlarged view of a limb of the essential parts and a sectional view taken in line X-X' in FIG. 25(b) respectively according to another embodiment,
FIG. 25 is a perspective view of the same embodiment,
FIG. 26 is a model perspective view of the same embodiment,
FIG. 27 is a diagram showing a magnetic circuit as a development example of the embodiment shown in FIG. 24(a),
FIGS. 28(a) and 28(b) are a model diagram and a beat characteristic diagram respectively of the laminated iron cores having embossments,
FIGS. 29(a) and 29(b) are a model diagram of laminated iron cores having embossments and a characteristic diagram showing the relation between the inductance, the laminated iron cores and leakage fluxes, respectively,
FIG. 30 is a diagram showing a magnetic circuit of the development example shown in FIG. 24(a),
FIG. 31 is a diagram showing a magnetic circuit of the development example shown in FIG. 24(a),
FIG. 32 is an exploded perspective view of a conventional choke coil,
FIG. 33 is a sectional view of the same choke coil, and
FIG. 34 is a diagram showing an equivalent circuit of the same embodiment.
BEST MODE FOR CARRYING OUT THE INVENTION
(Embodiment 1)
An embodiment of the invention is described below with reference to the accompanying drawings. In FIGS. 1 to 3, those component parts having the same configuration as the conventional circuits shown in FIGS. 32, 33 and 34 are denoted by the same reference numerals respectively and will not be described again. First, a model perspective view of a choke coil for preventing harmonic distortions, a magnetic circuit thereof and a model perspective view of a development example of the embodiment of FIG. 1 are shown respectively in FIGS. 1 to 3. In FIGS. 1 to 3, numeral 1 designates a first magnetic core providing a single-rectangle-shaped closed-circuit magnetic core made of a U-shaped ferrite material, numeral 2 a second magnetic core providing a single-rectangle-shaped magnetic circuit core made of U-shaped silicon steel sheets, numeral 3a a first coil, numeral 4a a second coil, numeral 5a a third coil, numeral 7 a magnetic gap, character "A" a line current, character F.sub.1 magnetic fluxes generated by the first coil 3a, character F.sub.2 magnetic fluxes generated by the second coil 4a, and character F.sub.3 magnetic fluxes generated by the third coil 5a.
The configuration of the first embodiment is described in detail. First, the first coil 3a is wound on one of the limbs of the first magnetic core 1, and the second coil 4a on one of the limbs of the second magnetic core 2. Further, the third coil 5a is wound between the limbs in such a manner as to cover the first coil 3a and the second coil 4a. The partitioned winding may be employed as a winding method in order to improve the high frequency characteristics.
The first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5a wound on the first coil 3a are positioned in such a direction that the magnetic fluxes F.sub.1 and F.sub.3 are offset with each other in the particular limb with respect to the line current "A", thereby configuring a common-mode choke coil section "C" similar to the equivalent circuit of FIG. 34 described with reference to the prior art. Also, the second coil 4a wound on one of the limbs of the second magnetic core 2 and the third coil 5a wound on the second coil 4a have the magnetic fluxes F.sub.2 and F.sub.3 thereof positioned in such a direction as not to be offset with each other in the particular limb with respect to the line current "A", thereby mainly constituting a normal-mode choke coil section "N" similar to the equivalent circuit of FIG. 34 described with reference to the prior art. The circuit according to the embodiment is completed by connecting the first coil 3a and the second coil 4a. The butted surface of one of the limbs of the second magnetic core 2 may be provided with a magnetic gap for improving the normal-mode magnetic saturation characteristic.
As described above, according to the embodiment under consideration, the equivalent circuit of the invention can be configured of the same circuit as the conventional equivalent circuit shown in FIG. 34. Therefore, the same normal-mode inductance value required for a choke coil for preventing harmonic distortions can be secured as in the prior art while at the same time providing the function of a common-mode choke coil. For this reason, EMI as well as harmonic distortions can be prevented, and the common-mode choke coil thus far provided in the filter block of the power circuit can be eliminated, resulting in a reduced package space.
Further, with the common-mode choke coil section "C" according to the present embodiment, the first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5a have a structure of double layers of windings, so that the magnetic fluxes F.sub.1, and F.sub.3 are offset with each other in this limb with respect to the line current "A". The coupling between the coils can thus be improved. As a result, the magnetic saturation characteristic of the magnetic core 1 is improved, and the inductance value can be set freely without regard to the number of turns or the setting of the magnetic circuit of the normal-mode choke coil section "N" by changing the sectional area of the magnetic core 1. Also, a material of high permeability can be selected instead of the conventional low-permeability material with a high saturation flux density, with the result that an inductance value about two or three times larger than in the prior art can be secured, thereby permitting a remarkable decrease in size. The improved coupling coefficient reduces the leakage fluxes.
In addition, with both the common- and normal-mode choke coil sections "C" and "N". the winding width of each coil can be accommodated in a single limb, and therefore a longer coil can be wound than in the prior art. In the case where a partitioned winding structure is employed, a multi-partitioned winding becomes possible, and therefore it is possible to provide a coil smaller in stray capacity than the prior art with an improved high-frequency characteristic.
In the above-mentioned embodiment, a choke coil is completed by connecting the first coil 3a and the second coil 4a. As an alternative method, the second coil 4a and the third coil 5a may be connected to equal effect. This applies to the embodiments described below.
The choke coil according to another embodiment shown in FIG. 3 has a configuration similar to the embodiment of FIG. 1 and will not be described again.
In the description of the second to seventh embodiments that follows, the same component parts as those of the first embodiment will be designated by the same reference numerals as those of the first embodiment respectively and will not be described again.
In the choke coil shown in FIG. 3, the same effect as the above-described case can, of course, be obtained by a configuration in which silicon steel sheets are used for the first magnetic core 1 and a ferrite material for the second magnetic core 2, a normal-mode choke coil section N is formed by the first coil 3a and the third coil 5a, and a common-mode choke coil section C is formed by the second coil 4a and the third coil 5a, with the first coil 3a connected to the second coil 4a or the first coil 3a to the third coil 5a.
(Embodiment 2)
Further, FIGS. 4 to 7 show a perspective view, a model perspective view, a sectional view and a model perspective view of a development example, respectively, of a choke coil for preventing harmonic distortions according to a second embodiment of the invention. The same component parts as those in FIG. 1 are designated by the same reference numerals as in FIG. 1, wherein numerals 3, 4, 5 designate bobbins and numeral 6 partitioning flanges. In FIGS. 4-6, the normal-mode choke coil section and the common-mode choke coil section are designated by N and C, respectively, while the first, second and third magnetic fluxes are shown in FIG. 6 as F1, F2 and F3 respectively.
First, a first coil 3a is wound on one of the limbs of a first magnetic core 1 through a bobbin 3 partitioned by the partitioning flanges 6. One of the limbs of a second magnetic core 2 is wound with a second coil 4a through the bobbin 4 partitioned by the partitioning flanges 6. Further, a third coil 5c is wound in such a position as to cover the other limb of the second magnetic core 2 and the aforementioned one of the limbs of the first magnetic core 1 through the bobbin 5 partitioned by the partitioning flanges 6.
The first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5c wound on the first coil 3a are positioned in such a direction that the magnetic fluxes offset each other in the same limb with respect to the line current. The second coil 4a wound on one of the limbs of the second magnetic core 2 and the third coil 5c wound on the othe limb thereof, on the other hand, are wound in such a direction that the magnetic fluxes thereof do not offset each other in the closed-circuit magnetic core with respect to the line current. In this way, a circuit similar to the equivalent circuit of FIG. 34 is formed, while at the same time constituting the common-mode choke coil section "C" and the normal-mode choke coil section "N". The choke coil is completed by connecting the first coil 3a and the second coil 4a. Magnetic gaps 7 for improving the magnetic saturation characteristic in normal mode are uniformly formed on the butted surfaces of the two limbs of the second magnetic core 2.
As shown in the figures and described throughout this specification, magnetic gaps 7 can be provided as noted above in various locations in the coil. Thus, the cores are not limited to closed-circuit magnetic cores, but can instead by open-circuit magnetic cores.
As described above, according to the present embodiment, an equivalent circuit of the invention can be configured of the same circuit as the conventional equivalent circuit shown in FIG. 34. Therefore, the same inductance value in normal mode required for a choke coil for preventing harmonic distortions can be secured as in the prior art, and also the function of a common-mode choke coil can be added. As a result, EMI can be prevented as well as harmonic distortions, and the common-mode choke coil so far used in the filter block of the power circuit can be eliminated for a saving of package space.
Furthermore, with the common-mode choke coil section "C", the first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5c are constructed in two layers. The magnetic fluxes are offset in this limb with respect to the line current, and therefore the coupling between coils can be improved. Consequently, the magnetic saturation characteristic of the magnetic core 1 is improved, and the inductance value can be freely set without regard to the number of turns or the setting of the magnetic circuit of the normal-mode choke coil section "N" by changing the sectional area of the magnetic core 1. Also, a high-permeability material may be used in place of the conventional material low in permeability and high in saturation flux density as the magnetic core 1, and therefore an inductance value about two or three times as high as the prior art can be secured, thereby contributing to a considerable size reduction.
With the normal-mode choke coil section "N", on the other hand, the two limbs of the second magnetic core 2 are enclosed in a complete core-type structure by the second coil 4a and the third coil 5c respectively wound on them. The magnetic gaps 7 provided for the purpose of improving the magnetic saturation in normal mode are also enclosed. Further, these magnetic gaps 7 are formed uniformly on the butted surfaces of the limbs, so that the magnetic fluxes in the magnetic core 2 can be made uniform and the leakage magnetic fluxes considerably reduced. The magnetic fluxes after reduction are about one fifth of the conventional structure without a shield case, and about one fourth of the conventional one with a shield case. As a result, the adverse effect on other parts, and in the case of television set, a fatal defect of picture fluctuations, can be prevented to a considerable degree.
The shield case 64 which has conventionally been used for preventing leakage fluxes is also eliminated, with the result that the insulating case 63 and the casting resin 65 can be done without. The cost is thus considerably reduced and the frequency characteristics improved. In the common- and normal-mode choke coil sections "C" and "N", the winding width of each coil can be accommodated in a single limb. The coil can thus be wound longer than in the prior art. When a partitioned winding structure is employed, therefore, a multi-partitioned winding is made possible, and a coil smaller in stray capacity than in the prior art is provided with an improved frequency characteristic.
A model perspective view of a choke coil for preventing harmonic distortions according to an embodiment of the invention is also shown in FIG. 7. This embodiment has a magnetic circuit configured in the same way as and has the same effect as the second embodiment of the invention.
(Embodiment 3)
FIGS. 8(a) and 8(b) show choke coils for preventing harmonic distortions according to a third embodiment of the invention. The third embodiment will be described with reference to the same reference numerals attached as in the embodiment of FIG. 1. First, a first coil 3a is wound on one of the limbs of a first magnetic core 1, and a second coil 4a on one of the limbs of a second magnetic core 2. The second magnetic core 2 is positioned inside a magnetic circuit of the first magnetic core 1 on one of the limbs of which the first coil 3a is wound. Further, a third coil 5b is wound in such a position as to cover the other limb of the first magnetic core 1 and the other limb of the second magnetic core 2. The partitioned winding may be employed as a method of winding to improve the high frequency characteristic.
The first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5b wound on the other limb thereof are positioned in such a direction that the magnetic fluxes F.sub.1 and F.sub.3 offset each other in the closed-circuit magnetic core with respect to the line current "A". Also, the second coil 4a wound on one of the limbs of the second magnetic core 2 and the third coil 5b wound on the other limb thereof are positioned in such a direction that the magnetic fluxes F.sub.2 and F.sub.3 do not offset each other in this closed-circuit magnetic core with respect to the line current "A". In this way, a circuit similar to the equivalent circuit of FIG. 34 is formed, while at the same time making up a common-mode choke coil section "C" and a normal-mode choke coil section "N". The choke coil is then completed by connecting the first coil 3a and the second coil 4a. When it is desired to provide a magnetic gap in order to improve the magnetic saturation characteristic in normal mode, such magnetic gaps 7 are formed uniformly in the butted surfaces of the two limbs of the second magnetic core 2.
As described above, according to this embodiment, the equivalent circuit of the invention can be configured with the same circuit as the conventional equivalent circuit shown in FIG. 34. Therefore, the same normal-mode inductance value can be secured as in the prior art as required for a choke coil for preventing harmonic distortions. At the same time, the function of a common-mode choke coil can be added. As a consequence, EMI can be prevented as well as harmonic distortions, and the common-mode choke coil that has thus far been provided in the filter block of the power circuit can be eliminated for a saving of package space.
Furthermore, in the normal-mode choke coil section "N", the two limbs of the second magnetic core 2 are enclosed in a complete core-type structure of the second coil 4a and the third coil 5b wound thereon respectively, and so are the magnetic gaps 7 formed for improving the magnetic saturation in normal mode. In addition, the uniform provision of the magnetic gaps 7 on the butted surfaces of the limbs secures uniform magnetic fluxes within the magnetic core 2 and thereby considerably reduces the leakage fluxes. In particular, as the second magnetic core 2 is positioned inside the magnetic path of the first magnetic core 1 which makes up the common-mode choke coil section "C", the shield effect on the leakage fluxes is obtained.
Consequently, a shield case 64 which has so far been used to prevent leakage fluxes can be eliminated from the choke coil for preventing harmonic distortions. This makes it possible to eliminate the insulating case 63 and the casting resin 65 for a considerable cost reduction. This elimination has no adverse effect on the other parts and prevents picture fluctuations of the television set or the like.
Furthermore, with the common- and normal-mode choke coils "C" and "N", each limb can be accommodated by the winding width of a single coil, and therefore a longer coil can be wound than in the prior art. In the case where the partitioned winding structure is employed, therefore, a multi-partitioned winding is made possible, and as compared with the prior art, a coil with a small stray capacity can be provided for an improved high-frequency characteristic.
Also, according to an embodiment of the invention, characteristics required of normal and common modes can be selected by combining magnetic materials having different magnetic properties such as permalloy, iron dust, Sendust or amorphous, by combining at least three types of magnetic materials or by setting a desired geometry in order to achieve a high permeability, a high magnetic saturation power and a high frequency from the first magnetic core and the second magnetic core.
In particular, although only the structure of a single-rectangle-shaped closed-circuit magnetic core is shown as the first and second magnetic cores, a double-hung rectangle or a triple-hung rectangle as shown in FIGS. 9 and 10 may be used for the closed-circuit magnetic cores to achieve a further improved effect.
The embodiments shown in FIGS. 9 and 10 will be described. These embodiments represent an application of the embodiments of FIGS. 1 and 8, respectively, in which corresponding parts are replaced by a double-hung rectangular closed magnetic circuit 1a of a ferrite material, a second magnetic core 2a having a double-hung rectangular closed magnetic circuit made of silicon-steel sheets and a second magnetic core 2b having a triple-hung rectangular closed magnetic circuit, respectively. In this configuration, the first magnetic core la has the magnetic fluxes thereof dispersed as compared with the structure having a single-rectangle-shaped closed magnetic circuit.
Further, as described with reference to the aforementioned embodiments, the first, second and third coils can of course be formed of a copper wire or a copper foil or other foil material as a winding with an equal effect.
(Embodiment 4)
A fourth embodiment of the invention is described below with reference to FIGS. 11 and 12. The perspective view and the model plan view of FIGS. 11 and 12 show a choke coil more specifically on the basis of the first embodiment shown in FIGS. 4 and 5.
In FIGS. 11 and 12, a first bobbin 8 is mounted closely without any air gap on one of the limbs of the first magnetic core 1 made of a ferrite material, and a first coil 3a is wound through the first bobbin 8. A second bobbin 9 is mounted with an air gap by a support member 11 on one of the limbs of the second magnetic core 2 made of silicon steel sheets. The second coil 4a is wound through the bobbin 9. The third bobbin 10 is formed with an air gap by the support member 11 in such a manner as to cover the outer side of the first bobbin 8 and the other limb of the magnetic core 2, and the third coil 5c is wound through the third bobbin 10.
The first coil 3a wound on one of the limbs of the first magnetic core 1 and the third magnetic coil 5c wound on the first coil 3a are positioned in such a direction as to offset the magnetic fluxes thereof each other by the same limb with respect to the line current, thereby configuring a common-mode choke coil section "C". Also, the second coil 4a wound on the one of the limbs of the second magnetic core 2 and the third coil 5c wound on the other limb are positioned in such a direction that the magnetic fluxes thereof do not offset each other in a closed-circuit magnetic core with respect to the line current, thereby configuring a normal-mode choke coil section "N".
More specifically, according to the embodiment described above, the first coil 3a is wound closely on the first magnetic core 1 through the first bobbin 8 without any air gap being formed.
A choke coil with the first coil 3a closely attached to the first magnetic core 1 without any air gap is compared with a reference of the same pair not closely attached to each other in Table 1 in terms of the result of temperature increase under the load of the stray capacity and the rated current.
TABLE 1
______________________________________
Temperature
Stray capacity
increase
______________________________________
Choke coil of 16.5 pF 48.3 K
embodiment 1
Reference 20.7 pF 54.3 K
______________________________________
As is obvious from Table 1, the choke coil according to this embodiment has a superior advantage in reducing the stray capacity. In a common choke coil (not shown), a close arrangement of the coil and the magnetic core without any air gap increases the stray capacity between therebetween and deteriorates the frequency characteristic. The coil and the magnetic core, therefore, are generally detached as in the case of reference. Conversely, however, in the case of a choke coil of a two-core three-winding structure such as the one according to this embodiment, it has become apparent that the stray capacity can be reduced by closely attaching the coil and the magnetic core without any air gap being formed therebetween. As a consequence, the frequency characteristic of the impedance of the common-mode choke coil section "C" especially requiring a high-frequency characteristic can be effectively improved. The result of improvement is shown in FIG. 13.
Also, since the first bobbin 8 is attached closely to the first magnetic core 1 of a ferrite material without any air gap, the heat generated in the first coil 3a is efficiently transmitted from the bobbin to the magnetic core, thereby reducing the temperature increase.
As described above, according to this embodiment, the first coil 3a wound on one of the limbs of the first magnetic core 1 of a ferrite core material forming a common-mode choke coil section "C" is closely attached to the first bobbin 8 without any air gap being formed therebetween, and therefore the stray capacity can be reduced for an improved frequency characteristic while at the same time reducing the temperature increase.
(Embodiment 5)
FIGS. 14 and 15 are a perspective view and a model plan view respectively of a choke coil according to a fifth embodiment of the invention. This embodiment basically represents an attempt to improve the embodiment shown in FIGS. 11 and 12. The configuration of this embodiment is different from that of the fourth embodiment in that a support member 11 in contact with the outside of the first bobbin 8 and the limbs of the second magnetic core 2 of silicon steel sheets are eliminated so that the first coil 3a is closely attached to the magnetic core without any air gap therebetween.
More specifically, according to this embodiment, the first coil 3a is closely attached to the first magnetic core 1 through the first bobbin 8a without any air gap therebetween, the second coil 4a is also closely attached to the second magnetic core 2 through the second bobbin 9a without any air gap, and the third coil 5c is closely attached to the second magnetic core 2 through the third bobbin 10a without any air gap therebetween.
The result of temperature increase of the choke coil according to the embodiment is compared with a reference in Table 2 below under the load of the stray capacity and the rated current.
TABLE 2
______________________________________
Temperature
Stray capacity
increase
______________________________________
Embodiment 2 14.3 pF 49.7 K
Prior art 20.7 pF 54.3 K
______________________________________
As obvious from Table 2, the choke coil according to this embodiment has a superior advantage in stray capacity. As a result, the frequency characteristic of impedance of the common-mode choke coil section "C" is also improved, as the result thereof is shown in FIG. 16.
Also, the temperature increase is reduced as compared with the reference in view of the fact that the first bobbin 8a is closely attached to the first magnetic core 1, and the second bobbin 9a and the third bobbin 10a to the second magnetic core 2 without forming any air gap, thereby allowing heat to be transmitted from the bobbin to the magnetic core. Further, the choke coil is reduced in size by the size of the support member 11 removed, and the amount of copper wires can be reduced by about 10% for a reduced cost.
As explained above, according to this embodiment, the second coil 4a and the third coil 5c wound on the limbs of the second magnetic core 2 of silicon steel sheets as well as the first magnetic core 1 of a ferrite material making up the common-mode choke coil section "C" of the fourth embodiment are closely attached to the first magnetic core 1 or the second magnetic core 2 without any air gap being formed therebetween. The stray capacity is thus reduced for an improved frequency characteristic, thereby reducing the temperature increase, the size and the cost.
The temperature increase can be further reduced by mounting a support member 11 on the third bobbin 10b in contact with the outside of the first bobbin 8a and thus allowing heat to be dissipated into the atmosphere, as shown in FIG. 17.
(Embodiment 6)
FIGS. 18 to 20 show other embodiments of the invention which are basically intended to improve the performance of the embodiments shown in FIGS. 4 and 5.
In FIGS. 18 to 20, a first coil 3a is wound on one of the limbs of a first magnetic core 1 of a U-shaped ferrite, and a second magnetic coil 4a is wound on one of the limbs of a second magnetic core 2c of U-shaped laminated iron cores. Further, a third coil 5c is wound in such a manner as to cover the other limb of the second magnetic ore 2c and one of the limbs of the first magnetic core 1.
The fist coil 3a wound on one of the limbs of he first magnetic core 1 and the third coil 5c wound on he first coil 3a are positioned in such a direction that the magnetic fluxes F.sub.4 are offset in the same limb with respect to the line current "A". thereby constructing a common-mode choke coil section "C". Also, the second coil 4a wound on one of the limbs of the second magnetic core 2c and the third coil 5c wound on the other limb are arranged in such a position that the magnetic fluxes F.sub.5 are generated in one direction with respect to the line current "A". thereby configuring a normal-mode choke coil section "N" for preventing harmonic distortions. A choke coil is completed by connecting the first coil 3a and the second coil 4a.
FIG. 21 shows a punching layout of U-shaped laminated iron cores making up the second magnetic core 2c shown in FIGS. 18 to 20. The iron core band plate is punched out in such a layout that the difference in length between the limbs 17, 18 of the U-shaped iron core 2cl is at least equal to the width of the yoke 19, the width of the window 20 at least equal to the width of the limbs 17, 18, the shorter limb 18 of one of two sheets as a set is combined with the window 20 of the other sheet, and all the limbs 17, 18 are parallel with respect to the direction of pressure-rolling the iron core band plate. First, pilot holes 12 are formed, followed by forming caulking separation holes 13. This operation is performed on one of, say, ten laminations. Further, the U-shaped laminated iron cores not formed with the caulking separation holes 13 are formed with caulking protrusions 14. The U-shaped iron core portion 2cl shown by hatching is thus finally punched down, and simultaneously with the lamination, the protrustions and the reverse-side recesses of the upper and lower caulking protrusions 14 laid one on the other are fitted into each other, thereby integrating core sheets in the required number of, say, 10. The other separated U-shaped iron core portion 2cl not shown by hatching is moved to a stopper 16 to the right by a mechanical chuck or a permanent magnet 15 and then integrated by a predetermined number of sheets.
Instead of adding the process of forming the caulking separation holes 13 as described above, the punch may be driven so deep as to punch through and form the caulking separation holes 13 without forming the caulked protrusions 14 for each predetermined number of sheets. Further, the caulked protrusions 14 may be fitted with each other for each predetermined number of sheets without forming the caulking separation holes 13.
Especially, the number, position and the orientation of the pilot holes 12 and the caulked protrusions shown above are only an example and can be determined most appropriately from the viewpoint of productivity and characteristics.
The aforementioned laminated iron cores are shaped into U-shapes, with one of the limbs of each iron cores made shorter than the other limb thereof. Two sheets of iron cores can thus be combined as a pair at the time of punching, thereby saving the punching loss.
Further, the iron core band plate is punched out in such a layout that all the limbs 17, 18 are parallel with respect to the direction of pressure-rolling the iron core band plate, and therefore, lamination can be made on an automatic machine after punching out, therefore leading to a very high production efficiency. Also, with regard to the choke properties, as the direction of magnetic fluxes and the direction of pressure-rolling are the same in the limbs 17, 18, there is the advantage of obtaining a large inductance.
Since the balance between the lengths of the limbs 17 and 18 is lost, however, it was feared that a great amount of leakage fluxes may be generated due to the fact that the magnetic gaps where the fringing leakage fluxes are generated are displaced from the center of the coil winding and the leakage fluxes originating from the two limbs fail to offset each other in a balanced way at the crossing point thereof. According to this embodiment, however, the leakage fluxes can be considerably reduced by winding the coil on the two limbs of the second magnetic core 2c made of laminated iron cores. As a result, the use of the choke coil with TV or the like does not cause any fatal defect of picture fluctuations, and it could be confirmed that it is not necessary to take the expensive measure for magnetic shield.
It is thus possible to provide an inexpensive magnetic core made of laminated iron cores making up the essential parts with reduced leakage fluxes.
Although the foregoing description of the embodiment has dealt with a choke coil in which the third coil 5c is wound in such a position as to cover the first and second magnetic cores 1 and 2c, other methods can be used as far as the choke coil uses laminated iron cores. FIGS. 22 and 23 show embodiments of the choke coil having such a structure. The shape of the laminated iron cores according to this embodiment is also described in detail with reference to FIGS. 22 and 23.
In FIG. 22, the difference between a limb 17 and a limb 18 of a magnetic core 2d made of U-shaped laminated iron cores is made equal to the width of a yoke 19, and the width of a window 20 is made equal to that of the limbs 17, 18. The ends of the two limbs 17, 18 of the iron cores are butted to each other with magnetic gaps 7 formed therebetween, so that a closed magnetic circuit is formed making up a magnetic core including single-phase double-limb laminated iron cores. A coil 3 is wound continuously on the two limbs of the magnetic core 2d in such a manner that magnetic fluxes F.sub.6 are generated in a direction with respect to a line current "A", thereby completing a choke coil. The limbs 17, 18 and the magnetic gaps 7 are wound with the coil 3 thereby to reduce leakage fluxes.
In FIG. 23, a coil 4 is wound on each of the two limbs of a magnetic core 2d made of the same laminated iron cores as that in FIG. 1 in such a manner that magnetic fluxes F.sub.7 are generated in a direction with respect to the line current "A", thereby completing a choke coil.
Also, according to the above-mentioned embodiments, as compared with the choke coil shown in FIG. 22, the choke coil shown in FIGS. 18 and 23 has such a coil winding structure that the choke coil can be inserted in the two sides of an AC input line, whereby noises can be attenuated (EMI prevented) in a frequency range of several hundred kHz. This is by reason of the fact that the choke coil shown in FIG. 22 which has such a coil winding structure that the choke coil can be inserted in only one side of the AC line and therefore noises are passed from the other line.
Table 3 shows the noise attenuation for 150, 500 and 700 kHz of the choke coils shown in FIGS. 22 and 23 according to the above-mentioned embodiments.
TABLE 3
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150 kHz 500 kHz 700 kHz
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Choke coil
-58 dB -30 dB -30 dB
described in
FIG. 22
Choke coil
-62 dB -32 dB -31 dB
described in
FIG. 23
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It is found that the noise attenuation of the choke coil shown in FIG. 23 is greater by 1 to 4 dB than that shown in FIG. 22.
(Embodiment 7)
Another embodiment of the invention will be explained below with reference to FIGS. 24(a) to 26. This embodiment is aimed at an improved performance of the embodiment shown in FIG. 5.
In FIGS. 24(a) to 26, numeral 2e designates a second magnetic core made of U-shaped laminated iron cores, characters F.sub.8, F.sub.9 magnetic fluxes, and characters "O", "P" embossments for fixing the laminated iron cores. First, a first coil 3a is wound on one of the limbs of the first magnetic core 1 of a U-shaped ferrite. A second coil 4a is wound on one of the limbs of the second magnetic core 2e made of U-shaped laminated iron cores fixed by the embossments "O", "P". Further, a third coil 5c is wound in such a position as to cover the other limb of the second magnetic core 2e and one of the limbs of the first magnetic core 1. The first coil 3a wound on one of the limbs of the first magnetic core 1 and the third coil 5c wound on the first coil 3a are positioned in a such a direction that the magnetic fluxes F.sub.8. are offset in the particular limb with respect to a line current "A", thereby making up a common-mode choke coil section "C". Also, the second coil 4a wound on one of the limbs of the second magnetic core 2e and the third coil 5c wound on the other limb are positioned in such a manner that the magnetic fluxes F.sub.9 are generated in a direction with respect to the line current "A", thereby configuring a normal-mode choke coil section N for preventing harmonic distortions. The first coil 3a and the second coil 4a are connected to complete a choke coil.
The second magnetic core 2e is such that the difference in length between the two limbs 21 thereof is equal to the width of a yoke 22, and therefore, at the time of punching an iron core, two iron cores sheets can be combined as a pair, thereby saving the punching loss.
The second iron core 2e is laminated and fixed by means of V-shaped embossments "O", "P", for example, formed on the front and back of a multiplicity of iron core sheets punched out in a predetermined shape. The embossments "0", "P" are provided one each on each side of the yoke 22 and the limb 21 wound with the coil. Further, the embossments "P" formed on the limb 21 wound with the coil has the longitudinal side of the profile thereof oriented in the direction orthogonal to the flowing magnetic fluxes F.sub.9, while the embossments "O" on the two sides of each yoke 22 is formed inclined inward toward each other as viewed from the window 23.
According to the above-mentioned embodiment, explanation was made about a choke coil for preventing harmonic distortions having the function of an anti-EMI common-mode choke coil. The above-mentioned embossments, however, can be applied also to normal choke coils as well.
Explanation will be made below with reference to FIG. 27.
In FIG. 27, U-shaped laminated iron cores are fixed by embossments "Q", "R", and a magnetic gap 7 for improving the magnetic saturation characteristics is formed on each of the butted surfaces between the two limbs 24 of each iron core. In this way, a closed-circuit magnetic core 2f made of laminated iron cores is formed, and a coil 5 is wound on each of the two limbs of the magnetic core thereby to complete a choke coil.
The magnetic core 2f made of laminated iron cores is laminated and fixed by V-shaped embossments "M", "N", for example, formed on the front and back sides respectively of a multiplicity of iron core sheets punched out into a predetermined shape. The embossments "Q", "R" are provided one each on the two sides of the yoke 25 and the limb 24 wound with a coil. Further, the embossment "N" formed on the limb 24 wound with the coil 5 has the longitudinal sides of the profile thereof oriented orthogonal to the direction of the flowing magnetic fluxes F.sub.10. In FIGS. 24 and 27, the embossments "O", "P", "Q", "R" are formed one each on the two sides of the yokes 22, 25 and the limbs 21, 24. Further, the embossments "P", "R" are formed on the limbs 21, 24 wound with the coils with the longitudinal sides of the profile thereof orthogonal to the flowing magnetic fluxes F.sub.10. As far as the embossments are formed in this way, the embossments may assume any shape.
Also, with the fixedly fitted surfaces of the embossments "O", "P", "Q", "R", the embossments formed on each lamination iron sheets may be sequentially overlaid and engaged with each other in a punch die and taken out in an integrated half-caulked state. The resulting assembly is pressured again in the direction of lamination again into a completely caulked state. As an alternative method, each lamination iron sheet formed with embossments may be punched and at the same time caulked completely in a die sequentially into complete products.
The advantage of the above-mentioned configuration will be explained below with reference to FIGS. 28(a) to 29(b).
FIG. 28(a) is a model diagram showing laminated iron cores having embossments according to the prior art and those according to this embodiment. The embossments formed for the purpose of fixing laminated iron cores according to the prior art have the longitudinal sides of the profile thereof formed parallel to the magnetic fluxes in order to minimize the reduction in magnetic characteristics in view of the fact that the embossments increase the magnetic reluctance against the magnetic fluxes flowing in the laminated iron cores for deteriorated magnetic characteristics, make it necessary to increase the size of the choke coil to secure the required inductance, increase the loss for an increased temperature rise and increase leakage fluxes, resulting in deteriorated characteristics of the choke coil. In contrast, the embossments according to this embodiment have the longitudinal sides of the profile thereof formed orthogonal to the magnetic fluxes.
FIG. 28(b) shows the vibration acceleration (beat) of a magnetic core of a model choke coil sample in which the U-shaped iron cores laminated by the embossments make up a closed-circuit magnetic core with a magnetic gap formed, and a coil is wound on the limbs of the magnetic core.
Comparison shows that, the number of embossments being the same, the vibration acceleration of the laminated iron cores according to this embodiment is about 10% lower than that of the prior art. This indicates that the beat of the laminated iron cores can be effectively suppressed by the embossments according to the present embodiment. This is considered due to the table structure (with a great vibration suppression ability) of the embossments that can be fixed with a large area with respect to the flow of magnetic fluxes, which embossments are formed on the limbs wound with the coil of a closed-circuit magnetic core made of laminated iron cores, i.e., where the magnetic flux density is highest in the laminated iron cores and there are generated magnetostrictive vibrations and normal vibrations in the direction of attraction by the excitation current constituting a cause of the beat.
This structure is very effective for a choke coil laden with the problem of beat of the magnetic core made of laminated iron cores such as those used for a choke coil for preventing harmonic distortions, in which the beat is caused by the magnetic fluxes induced by a large pulse input current flowing in the AC line.
It is feared, however, that the structure of the embossments according to the embodiment, in spite of a high vibration suppression ability thereof, may have the disadvantages of a considerably increased magnetic reluctance compared with the prior-art embossments against the magnetic fluxes flowing in the laminated iron cores, reduced magnetic characteristics, a reduced inductance required for the choke coil characteristics, an increased loss for a considerable temperature rise and increased leakage fluxes.
FIGS. 29(a) and 29(b) show the inductance value, the temperature increase of the laminated iron cores and the leakage fluxes of a choke coil sample identical to the one shown in FIG. 28.
It is seen that the inductance value, the temperature increase of the laminate iron cores and the leakage fluxes of a choke coil using the laminated iron cores according to the present embodiment as a magnetic core are substantially the same as those of the prior art. This is considered due to the fact that in the case of a choke coil requiring a magnetic gap to be formed in the magnetic paths of a closed-circuit magnetic core of laminated iron cores in order to improve the magnetic saturation characteristics, the magnetic characteristic of the laminated iron cores is determined by the particular magnetic gap. It thus became apparent that the characteristics of the choke coil are not deteriorated by the deterioration of the magnetic characteristic of the laminated iron cores according to the embodiment against our fear.
Further, in FIG. 28, it became obvious that the vibration acceleration (beat) of the laminated iron cores according to the present embodiment is substantially constant with four or more embossments and that the vibration acceleration of the laminated iron cores having four embossments according to the embodiment is smaller than that of the conventional one with five embossments.
From the above-mentioned fact, the number of embossments formed for the purpose of fixing the laminations of the laminated iron cores used for the choke coil according to the present embodiment is most appropriate and can display the advantage of coupling the laminated iron cores firmly.
It was feared that the arrangement and structure of the embossments having a great ability of suppressing magnetic vibrations may considerably increase the magnetic reluctance against the magnetic fluxes flowing in the laminated iron cores as compared with the conventional structure of embossments, and the resultant deterioration of the magnetic characteristics may necessitate a bulky structure in order to secure the required inductance, or increase the loss for an increased temperature, increase leakage fluxes or otherwise considerably deteriorate the choke coil characteristics. In spite of this fear, in the case of a choke coil requiring a magnetic gap for improving the magnetic saturation characteristic within the magnetic paths of the closed-circuit magnetic core made of laminated iron cores, the magnetic characteristics of the laminated iron cores are determined by the particular magnetic gap and therefore the deterioration of the characteristics is avoided.
In other words, an embossed protrusion structure which has so far been prohibited for the reason of characteristics in fixing a laminated iron core is positively introduced and optimized to obtain the advantage that the beats of the magnetic core can be reduced without deteriorating the choke characteristics.
Also, as shown in FIGS. 24(b) and 24(c), the sides of the embossments arranged longitudinally of the profile thereof for fitting and holding the cores are oriented necessarily in parallel to the end surfaces of the cores making up the magnetic gap 7. Even when the embossments "O", "P", "M", "N" are pressed without using any guide, therefore, there occurs any displacement toward the end surfaces and the gap accuracy can thus be secured. Further, in the case where the embossments "O" are formed on the two sides of the yoke 2 in inwardly-inclined fashion to each other as viewed from the window 23, the accuracy along the width of the limbs 21 can also be secured, thereby obviating such inconvenien
