Coil apparatus and manufacturing method for the same

Details Coil apparatus and manufacturing method for the same Coil apparatus and manufacturing method for the same

2001-06-20

2003-02-04

Walczak, David J. (Department: 3729)

Metal working

Method of mechanical manufacture

Electrical device making

C029S832000, C029S602100, C336S196000, C361S760000, C361S761000

Reexamination Certificate

active

06513230

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to coil apparatuses capable of serving as transformers and choke coils and a method for manufacturing the same.
2. Description of the Related Art
FIG. 7A
is an exploded view of a coil apparatus.
FIG. 7B
is a sectional view taken along line
7
B—
7
B of the coil apparatus shown in
FIG. 7A. A
coil apparatus
1
shown in
FIGS. 7A and 7B
is incorporated in a circuit such as a DC-to-DC converter, and serves as a transformer or a choke coil. The coil apparatus
1
includes an electronic-part-mounting substrate
2
, a coil pattern group
3
formed on the electronic-part-mounting substrate
2
, a pair of core members
4
(
4
a
) and
4
(
4
b
), and a core-coupling unit
5
′.
The electronic-part-mounting substrate
2
carries electronic parts for forming a circuit, and a circuit pattern is formed on the electronic-part-mounting substrate
2
. The electronic-part-mounting substrate
2
is a multi-layered substrate including a plurality of substrate elements laminated on each other. For example, the plurality of substrate elements may be individually provided with coil patterns
7
which are disposed coaxially with each other, the coil patterns
7
forming the coil pattern group
3
. When the coil apparatus
1
is used as a transformer apparatus, at least one of the coil patterns
7
serves as a primary coil and the remainder serves as a secondary coil.
The pair of core members
4
(
4
a
) and
4
(
4
b
) shown in
FIGS. 7A and 7B
are made of a powdered magnetic material such as a ferrite by sintering. The core members
4
(
4
a
) and
4
(
4
b
) are E-type core members which individually include planar top plates
8
, each top plate
8
being provided with core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) projecting from one end, an intermediate part, and the other end, respectively, of the top plate
8
, whereby the cross-section of each core member
4
(
4
a
) or
4
(
4
b
) is E-shaped.
The electronic-part-mounting substrate
2
is provided with core-leg-passing through-holes
10
(
10
a
),
10
(
10
b
), and
10
(
10
c
) in an outside part, a central part, and the opposite outside part, respectively, of the coil pattern group
3
. As shown in
FIG. 7B
, the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of each core member
4
(
4
a
) or
4
(
4
b
) are inserted into the core-leg-passing through-holes
10
(
10
a
),
10
(
10
b
), and
10
(
10
c
), respectively, from the top or bottom side of the electronic-part-mounting substrate
2
. The core-legs
9
a,
9
b,
and
9
c
of the top core member
4
(
4
a
) come into contact with the respective core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the bottom core member
4
(
4
b
) at tips of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the respective core members
4
(
4
a
) and
4
(
4
b
).
The core-coupling unit
5
′ receives and couples the pair of core members
4
(
4
a
) and
4
(
4
b
) with each other, as shown in FIG.
7
B. The core-coupling unit
5
′ is formed by bending a metallic plate, and includes a top plate
12
, legs
13
(
13
a
) and
13
(
13
b
), and hooks
14
(
14
a
) and
14
(
14
b
). That is, the top plate
12
for covering the top plate
8
of the core member
4
(
4
a
) is bent in the standing direction of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) at the right and left ends of the top plate
12
, thereby forming the legs
13
(
13
a
) and
13
(
13
b
), and the legs
13
(
13
a
) and
13
(
13
b
) are individually bent toward the inside at the ends thereof, thereby forming the hooks
14
(
14
a
) and
14
(
14
b
).
The distance between the top plate
12
and the hooks
14
is substantially the same as a distance h between an outer surface
8
a
of the top plate
8
of the top core member
4
(
4
a
) and the outer surface
8
a
of the top plate
8
of the bottom core member
4
(
4
b
) when the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the top core member
4
(
4
a
) are in contact with the respective core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the bottom core member
4
(
4
b
) at tips of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the core members
4
(
4
a
) and
4
(
4
b
), as shown in FIG.
7
B. As shown in
FIG. 7B
, the core-coupling unit
5
′ couples the core members
4
(
4
a
) and
4
(
4
b
) with each other, the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the respective core members
4
(
4
a
) and
4
(
4
b
) being in contact with each other at the tips of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
), so that the core members
4
(
4
a
) and
4
(
4
b
) are clamped at the left and right ends thereof by the top plate
12
and the hooks
14
(
14
a
) and
14
(
14
b
), respectively. The core members
4
(
4
a
) and
4
(
4
b
) are coupled with each other so as to be movable relative to each other in directions ∝ (backward and forward) shown in
FIG. 7A. A
width W in the backward and forward directions of each core-leg-passing through-hole
10
(
10
a
),
10
(
10
b
), or
10
(
10
c
) is set greater than a width w of each core-leg
9
(
9
a
),
9
(
9
b
), or
9
(
9
c
) of the core member
4
(
4
a
) or
4
(
4
b
) so that the core members
4
(
4
a
) and
4
(
4
b
) can move backward and forward.
The coil apparatus shown in
FIGS. 7A and 7B
is formed, for example, as described below. The core members
4
(
4
a
) and
4
(
4
b
) are disposed at the top and bottom sides, respectively, of the electronic-part-mounting substrate
2
provided with the coil pattern group
3
and the core-leg-passing through-holes
10
(
10
a
),
10
(
10
b
), and
10
(
10
c
). The core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the top core member
4
(
4
a
) are inserted into the corresponding core-leg-passing through-holes
10
(
10
a
),
10
(
10
b
), and
10
(
10
c
), respectively, of the electronic-part-mounting substrate
2
from the topside thereof, and the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the bottom core member
4
(
4
b
) are inserted into the corresponding core-leg-passing through-holes
10
(
10
a
),
10
(
10
b
), and
10
(
10
c
), respectively, of the electronic-part-mounting substrate
2
from the bottom side thereof, so that the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the respective top and bottom core members
4
(
4
a
) and
4
(
4
b
) come into contact with each other at the tips thereof.
The legs
13
(
13
a
) and
13
(
13
b
) of the core-coupling unit
5
′ are inserted, from the top of the core members
4
(
4
a
) and
4
(
4
b
) coupled with each other so that the respective core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) are in contact with each other at the tips thereof, into the left core-leg-passing through-hole
10
(
10
a
) at the outer side of the core-leg
9
(
9
a
) and the right core-leg-passing through-hole
10
(
10
c
) at the other outer side of the core-leg
9
(
9
c
), respectively.
The core-coupling unit
5
′ thus coupling the core members
4
(
4
a
) and
4
(
4
b
) with each other is incorporated into the electronic-part-mounting substrate
2
. That is, the core members
4
(
4
a
) and
4
(
4
b
), by being thus incorporated into the electronic-part-mounting substrate
2
, are mounted on the coil pattern group
3
in such a manner that the core members
4
(
4
a
) and
4
(
4
b
) clamp the electronic-part-mounting substrate
2
at a part of the coil pattern group
3
from the top and bottom sides of the electronic-part-mounting substrate
2
.
Then, the coupled core members
4
(
4
a
) and
4
(
4
b
) are slid backward and forward relative to each other, so as to rub against each other at a contact part between the core members
4
(
4
a
) and
4
(
4
b
), that is, at the tips of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) of the respective core members
4
(
4
a
) and
4
(
4
b
). By thus rubbing the tips of the core-legs
9
(
9
a
),
9
(
9
b
), and
9
(
9
c
) with each other (by performing core-rubbing), an effect described below can be obtained.
As described above, since the core members
4
(
4
a
) and
4
(
4
b
) are made

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