Common mode choke coil

Abstract

A common mode choke coil includes a core, and first and second coils opposed to each other and wound on the core. The core can have a square shape, or an elongated shape having a long axis and a short axis when viewed in a direction along a central axis of the core. Each of the first and second coils is a single-layer coil. An area of a cross-section of the core taken perpendicular to a circumferential direction of the core is constant in the circumferential direction of the core. The cross-section of the core has a quadrilateral shape.

Claims

1. A common mode choke coil comprising: a core having an elongated shape having a long axis and a short axis when viewed in a direction along a central axis of the core; and a first coil and a second coil opposed to each other and wound on the core, wherein the first coil and the second coil each include a plurality of wire members that are separate, rod-like, and connected to each other, the plurality of wire members includes bent wire members each having a substantially U shape, and separate, rod-like, first straight wire members each extending in a substantially straight line, the bent wire members and the first straight wire members are alternately connected to be wound on the core, and the first straight wire members are directly attached to only the bent wire members, the first coil and the second coil are opposed to each other in a short axis direction of the elongated shape and wound on the core in a long axis direction of the elongated shape, the first coil and the second coil are located further inside than an outermost end of the core in the long axis direction of the core when viewed in the direction along the central axis of the core, when Φdw<2Rin and (lz+2Φdw+2Cc-p)≥2Rin, (Φdw+2Cc-p)>2Rin, and when Φdw≥2Rin and (lz+2Φdw+2Cc-p)≥2Rin, (4−π)Φdw+4Cp-p<(2π−4)Cc-p+2(4−π)Rin, where Φdw is a coil diameter, Cc-p is a clearance between an inner surface of the core and the coil, Cp-p is a coil clearance, lz is a minimum distance between the first coil and the second coil in an inner area of the core, and Rin is a radius of curvature of an inner corner of the core.

2. The common mode choke coil according to claim 1, further comprising: a case housing the core, the case having a rectangular shape when viewed in the direction along the central axis of the core, wherein the core is housed in the case with the long axis of the core extending in a direction along one side of the case.

3. The common mode choke coil according to claim 2, wherein the case has an oblong shape when viewed in the direction along the central axis of the core, and the core is housed in the case with the long axis of the core extending in a long axis direction of the case.

4. The common mode choke coil according to claim 2, further comprising: ferrite beads each having a tubular shape at corners of the case, the ferrite beads being connected to the first coil and the second coil, wherein second straight wire members are disposed in the ferrite beads.

5. The common mode choke coil according to claim 1, wherein the first coil and the second coil do not intersect with the long axis of the core when viewed in the direction along the central axis of the core.

6. A common mode choke coil comprising: a core having an elongated shape having a long axis and a short axis when viewed in a direction along a central axis of the core; and a first coil and a second coil opposed to each other and wound on the core, wherein the first coil and the second coil each include a plurality of wire members that are separate, rod-like, and connected to each other, the plurality of wire members includes bent wire members each having a substantially U shape, and separate, rod-like, first straight wire members each extending in a substantially straight line, the separate, rod-like, first straight wire members not being printed wires, and the bent wire members and the first straight wire members are alternately connected to be wound on the core, the first coil and the second coil are opposed to each other in a short axis direction of the elongated shape and wound on the core in a long axis direction of the elongated shape, the first coil and the second coil are located further inside than an outermost end of the core in the long axis direction of the core when viewed in the direction along the central axis of the core, when Φdw<2Rin and (lz+2Φdw+2Cc-p)≥2Rin, (Φdw+2Cc-p)>2Rin, and when Φdw≥2Rin and (lz+2Φdw+2Cc-p)≥2Rin, (4−π)Φdw+4Cp-p<(2π−4)Cc-p+2(4−π)Rin, where Φdw is a coil diameter, Cc-p is a clearance between an inner surface of the core and the coil, Cp-p is a coil clearance, lz is a minimum distance between the first coil and the second coil in an inner area of the core, and Rin is a radius of curvature of an inner corner of the core.

7. The common mode choke coil according to claim 6, further comprising: a case housing the core, the case having a rectangular shape when viewed in the direction along the central axis of the core, wherein the core is housed in the case with a long axis of the core extending in a direction along one side of the case.

8. The common mode choke coil according to claim 7, wherein the case has an oblong shape when viewed in the direction along the central axis of the core, and the core is housed in the case with the long axis of the core extending in a long axis direction of the case.

9. The common mode choke coil according to claim 7, further comprising: ferrite beads each having a tubular shape at corners of the case, the ferrite beads being connected to the first coil and the second coil, wherein second straight wire members are disposed in the ferrite beads.

10. The common mode choke coil according to claim 6, wherein the first coil and the second coil do not intersect with the long axis of the core when viewed in the direction along the central axis of the core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an upper perspective view of a common mode choke coil according to a first embodiment of the disclosure;

(2) FIG. 2 is a lower perspective view of the common mode choke coil;

(3) FIG. 3 is an upper perspective view illustrating an inside of the common mode choke coil;

(4) FIG. 4 is an exploded perspective view of the common mode choke coil;

(5) FIG. 5 is a plan view of the common mode choke coil;

(6) FIG. 6A is a plan view of a common mode choke coil including a circular core;

(7) FIG. 6B is a plan view of a common mode choke coil including a core having an elongated shape;

(8) FIG. 7 is a plan view of a common mode choke coil according to a second embodiment of the disclosure; and

(9) FIG. 8 is a plan view of a known coil component.

DESCRIPTION OF EMBODIMENTS

(10) Hereinafter, the disclosure is described in detail by referring to illustrated embodiments.

First Embodiment

(11) FIG. 1 is an upper perspective view of a common mode choke coil according to a first embodiment of the disclosure. FIG. 2 is a lower perspective view of the common mode choke coil. FIG. 3 is an upper perspective view of the inside of the common mode choke coil. FIG. 4 is an exploded perspective view of the common mode choke coil. FIG. 5 is a plan view of the common mode choke coil.

(12) As illustrated in FIG. 1 to FIG. 5, a common mode choke coil 1 includes a case 2, a core 3 having a ring-like shape and housed in the case 2, and first and second coils 41 and 42 opposed to each other and wound on the core 3. The choke coil 1 further includes first to fourth ferrite beads 61 to 64 connected to the first and second coils 41 and 42.

(13) The case 2 includes a bottom plate 21 and a box-like cover 22 covering the bottom plate 21. The case 2 may be formed of plastic such as PPS or a ceramic material, for example. A core 3 is disposed on the bottom plate 21. The core 3 on the bottom plate 21 has the central axis C extending perpendicular to the bottom plate 21. The central axis C of the core 3 is the central axis of the inner hole of the core 3. The case 2 (the bottom plate 21 and the cover 22) has a rectangular shape when seen in a direction along the central axis C of the core 3. In this embodiment, the shape of the case 2 is square. The case 2 may have an oblong shape.

(14) Electrode terminals 51 to 54 are disposed on the bottom plate 21. The first electrode terminal 51 and the second electrode terminal 52 are located at two opposite corners of the rectangular bottom plate 21. The third electrode terminal 53 and the fourth electrode terminal 54 are located at two opposite corners of the rectangular bottom plate 21. The first and third electrode terminals 51 and 53 are opposed to each other. The second and fourth electrode terminals 52 and 54 are opposed to each other.

(15) The electrode terminals 51 to 54 are attached to the bottom surface of the bottom plate 21. The bottom plate 21 has holes 21a extending through the case 2 between the upper surface and the lower surface. The electrode terminals 51 to 54 overlap the holes 21a and are exposed to the inside of the case 2 through the holes 21a.

(16) As shown, for example, in Fi. 5, the shape of the core 3 (i.e., the shape of the inner circumferential surface and the outer circumferential surface of the core 3) is an elongated shape having a long axis L and a short axis S when viewed in the direction along the central axis C. The long axis L is an axis of symmetry extending in a direction along a major diameter or a direction along the long side through the central axis C. The short axis S is an axis of symmetry extending in a direction along a minor diameter or a direction along the short side through the central axis C. The core 3 has two opposed long sections 31 extending along the long axis L and two opposed short sections 32 extending along the short axis S. In this embodiment, the core 3 has an elliptical shape. The core 3 may have an oblong shape or an oval shape, but not a precise circular shape. The four corners of the oblong shape each may be right-angled or curved. The core may have a square shape. The four corners of the square may be right-angled or curved. The cross-sectional area of the core taken perpendicular to the circumferential direction of the core 3 is constant in the circumferential direction of the core 3. The cross-section of the core 3 has a quadrilateral shape. The four corners of the quadrilateral cross-section of the core 3 may be right-angled or curved (R surface).

(17) The core 3 may be a ceramic core formed of a ceramic material such as ferrite or a metal core. The core 3 has two surfaces on opposite sides in the direction along the central axis C. One of the surfaces faces the inner surface of the bottom plate 21. The other of the surfaces faces the inner surface of the cover 22. The core 3 is housed in the case 2 with the long axis L of the core 3 extending in a direction along one of the sides of the case 2 (the bottom plate 21).

(18) The first coil 41, which is wound on the core 3, is located between the first electrode terminal 51 and the second electrode terminal 52. One end of the first coil 41 is connected to the first electrode terminal 51. The other end of the first coil 41 is connected to the second electrode terminal 52.

(19) The second coil 42, which is wound on core 3, is located between the third electrode terminal 53 and the fourth electrode terminal 54. One end of the second coil 42 is connected to the third electrode terminal 53. The other end of the second coil 42 is connected to the fourth electrode terminal 54.

(20) The first coil 41 and the second coil 42 are opposed to each other in the short axis S direction of the core 3 having an elongated shape and are each wound on the core 3 in the long axis L direction of the elongated shape. In other words, the first coil 41 is wound on one of the long sections 31 of the core 3 and the second coil 42 is wound on the other of the long sections 31 of the core 3. The winding directions of the first coil 41 and the second coil 42 on the core 3 are opposite. The number of turns of the first coil 41 and the number of turns of the second coil 42 are the same. The first and second coils 41 and 42 are single-layer coils. The first and second coils 41 and 42 do not intersect with the long axis L of the core 3 when viewed in the direction along the central axis C of the core 3. This configuration provides an insulating space extending along the long axis L of the core 3 between the first coil 41 and the second coil 42. The first and second coils 41 and 42 are located further inside than the outermost end of the core 3 in the long axis L direction of the core 3 when viewed in the direction along the central axis C of the core 3. This configuration reduces the size of the common mode choke coil 1 in the long axis L direction.

(21) The first to fourth ferrite beads 61 to 64 are formed of a magnetic material, such as NiZn and MnZn. The ferrite beads 61 to 64 have a tubular shape and reside on the respective four corners of the case 2. The axes of the ferrite beads 61 to 64 are parallel to the central axis C of the core 3. The ferrite beads 61 to 64 are located radially outwardly from the core 3.

(22) The first ferrite bead 61 is located at a first end of the first coil 41 (adjacent to the first electrode terminal 51). The second ferrite bead 62 is located at a second end of the first coil 41 (adjacent to the second electrode terminal 52). The third ferrite bead 63 is located at a first end of the second coil 42 (adjacent to the third electrode terminal 53). The fourth ferrite bead 64 is located at a second end of the second coil 42 (adjacent to the fourth electrode terminal 54).

(23) The first coil 41 is composed of wire members connected to each other. The wire members are not printed wires, but rod-like members. The wire members may be rigid or flexible. The wire members have bent wire members 410 each bent in a substantially U-shape and straight wire members 411, 412, and 413 extending in a substantially straight line. The first coil 41 includes, in this order from the first end to the second end, the first straight wire member 411, the second straight wire member 412, pairs (five pairs in this embodiment) of the bent wire member 410 and the third straight wire member 413, and the first straight wire member 411. The first, second, and third straight wire members 411, 412, and 413 have different lengths.

(24) The wire members 410 to 413 each may be a polyamide imide copper wire including a copper wire and an insulating film covering the copper wire. The thickness of the insulating film may be 0.029 mm to 0.072 mm. The insulating film is coated with an insulating material such as polyolefin resin.

(25) The bent wire members 410 and the third straight wire members 413 are alternately connected. A first end of the third straight wire member 413 is connected to a first end of one of the bent wire members 410. A second end of the third straight wire member 413 is connected to a first end of another one of the bent wire members 410. This is repeated such that the bent wire members 410 and the third straight wire members 413 are wound on the core 3 in a helical manner. In other words, one pair of the bent wire member 410 and the third straight wire member 413 constitutes one unit providing one turn. In FIG. 5, the numbers indicated in the bent wire members 410 are the number of turn. The first coil 41 have five turns wound on the core 3.

(26) The first straight wire members 411 are disposed in the first and second ferrite beads 61 and 62. The first straight wire member 411 in the first ferrite bead 61 is connected to the first electrode terminal 51. The first straight wire member 411 in the second ferrite bead 62 is connected to the second electrode terminal 52.

(27) The second coil 42 is composed of wire members as the first coil 41. Specifically described, the second coil 42 includes, in this order from one side to the other end, a first straight wire member 421, a second straight wire member 422, pairs (five pairs in this embodiment) of a bent wire member 420 and a third straight wire member 423, and another first straight wire member 421. The bent wire members 420 and the third straight wire members 423 are alternately connected to be wounded on the core 3. The second coil 42 wound on the core 3 has five turns. The first straight wire members 421 are disposed in the third and fourth ferrite beads 63 and 64.

(28) In the common mode choke coil 1 having the above-described configuration, the core 3 has an elongated shape. The first and second coils 41 and 42 each composed of the wire members are opposed to each other and wound on the core 3. The first and second coils 41 and 42 opposed to each other in the short axis S direction of the elongated shape are wound in the long axis L direction of the elongated shape.

(29) This allows the wire members of the first coil 41 located in the inner hole of the core 3 (portions of the bent wire member 410) and the wire members of the second coil 42 (portions of the bent wire member 420) to be arranged along the inner surface of the core 3 in the long axis L direction of the elongated shape. Thus, the wire members of the first coil 41 and the wire members of the second coil 42 are located close to each other in the short axis S direction of the elongated shape. In other words, the inner hole of the core 3 is able to be made smaller in the short axis S direction such that the wire members of the first coil 41 and the wire members of the second coil 42 come in contact with each other in the short axis S direction to reduce the dead space D in the inner hole of the core 3. Thus, the core 3 is able to expand toward the inner hole such that the dead space D in the inner hole of the core 3 is reduced. This increases the cross-sectional area of the core 3 in the radial direction (i.e., the cross-sectional area in a direction perpendicular to the central axis C of the core 3), leading to an increase in the L value.

(30) The L value is explained. The inductance L is expressed by the following (equation 1).
L=(μ.sub.0μT.sup.2Se)/Le  (equation 1)

(31) where

(32) L is inductance [H],

(33) μ.sub.0 is air magnetic permeability [H/m],

(34) μ is relative magnetic permeability (core) [-],

(35) T is the number of turns of each coil [-],

(36) Se is a cross-sectional area of the core (an area of the cross-section taken perpendicular to the central axis of the core) [m.sup.2], and

(37) Le is a magnetic path length [m].

(38) The core having an elongated shape is able to have a reduced inner surrounded area, allowing the cross-sectional area of the core to be larger by the reduced area. This improves the L value. In some cases, the core having an elongated shape has a longer magnetic path length Le than a circular core, which may be disadvantageous in improvement in the L value. However, the core having an elongated shape is advantageous in increasing the core cross-sectional area Se, which surpasses the disadvantage. Thus, the L value is improved.

(39) If the magnetic path length of the core having an elongated shape is shorter than that of a circular core, the L value is further improved. The conditions for this are explained.

(40) FIG. 6A illustrates a common mode choke coil including a circular core. As illustrated in FIG. 6A, a common mode choke coil 100 includes a circular core 101, a first coil 110, and a second coil 120, which are wound on the circular core 101. The dimensions are defined as indicated in FIG. 6A. The dimensions of the core and the magnetic path length of the core are expressed by following general formulas:
Φdcc=2/π(lz+TΦdw+Cp-p(T−1));
Φdci=Φdcc+Φdw+2Cc-p; and
Le2=π(Φdci+Wa)

(41) where

(42) Le2 is a magnetic path length of a core (a length of the core in the circumferential direction at the radial center of the width of the core) [mm],

(43) Φdw is a coil diameter [mm],

(44) Cc-p is a clearance between the inner surface of the core and the coil (a distance between the inner surface of the core and the wire member) [mm],

(45) Cp-p is a coil clearance (a distance between adjacent two of the wire members in an inner area of the core) [mm],

(46) Lz is the minimum distance between the first coil and the second coil in the inner area of the core [mm],

(47) Wa is a width of the core in a radial direction [mm],

(48) T is the number of turns of each coil [-],

(49) Φdci is an inner diameter of the core [mm], and

(50) Φdcc is a diameter between the centers of coils in the inner area of the core [mm].

(51) FIG. 6B illustrates a common mode choke coil including a core having an elongated shape or an elongated core. As illustrated in FIG. 6B, a common mode choke coil 1 includes an elongated core 3, a first coil 41, and a second coil 42, which are wound on the elongated core 3. The dimensions are defined as indicated in FIG. 6B. The magnetic path length of the core is expressed by a general formula
Le1=2Lci+2Wci+πWa+2(π−4)Rin.
If Φdw<2Rin,Lci=(T−1)(Φdw+Cp-p)+2Rin,
if Φdw≥2Rin,Lci=TΦdw+(T+1)Cp-p,
if (lz+2Φdw+2Cc-p)<2Rin,Wci=2Rin, and
if (lz+2Φdw+2Cc-p)≥2Rin,Wci=lz+2(Φdw+Cc-p)

(52) where

(53) Le1 is a magnetic path length of a core (a length of the core in the circumferential direction at the radial center of the width of the core) [mm],

(54) Φdw is a coil diameter [mm],

(55) Cc-p is a clearance between the inner surface of the core and the coil (a distance between the inner surface of the core and the surface of the coil member) [mm],

(56) Cp-p is a coil clearance (a distance between the surfaces of adjacent two of the wire members in the inner area of the core) [mm],

(57) Lz is the minimum distance between the surface of the first coil and the surface of the second coil in the inner area of the core[mm],

(58) Wa is a width of the core in the radial direction [mm],

(59) T is the number of turns of each coil [-],

(60) Rin is a radius of curvature of four inner corners of the core [mm],

(61) Lci is an inner diameter of the inner area of the core in a long axis direction [mm], and

(62) Wci is an inner diameter of the inner area of the core in a short axis direction [mm].

(63) The circular core (FIG. 6A) and the elongated core (6B) have the same values for Φdw, Cc-p, Cp-p, lz, Wa, and T.

(64) The L value is further improved when the magnetic path length Le 1 of the elongated core is shorter than the magnetic path length Le2 of the circular core. In other words, when ΔLe=Le2−Le1 is calculated to be ΔLe>0, the L value is further improved.

(65) More specifically described, when Φdw<2Rin and (lz+2Φdw+2Cc-p)≥2Rin,
(Φdw+2Cc-p)>2Rin  Expression (1).

(66) When Φdw≥2Rin and (lz+2Φdw+2Cc-p)≥2Rin,
(4−π)Φdw+4Cp-p<(2π−4)Cc-p+2(4−π)Rin)  Expression (2).

(67) As described above, the magnetic path length of the elongated core is shorter than that of the circular core when at least one of the two relation Expressions (1) and (2) is satisfied. Thus, the L value is further improved.

(68) In the common mode choke coil 1 having the above-described configuration, if the core 3 has a square shape, the first and second coils 41 and 42 are opposed to each other in a direction along a first side of the square and are wound in a direction along a second side of the square. Thus, the wire members of the first coil 41 and the wire members of the second coil 42 in the inner hole of the core 3 are arranged along the inner surface of the core 3 in the direction along the second side of the square. This allows the wire members of the first coil 41 and the wire members of the second coil 42 to be close to each other in the direction along the first side of the square. Thus, the core 3 is able to expand toward the inner hole such that the dead space D in the inner hole of the core 3 is reduced, increasing the cross-sectional area of the core 3 in the radial direction. This increase the L value.

(69) In the common mode choke coil 1 having the above-described configuration, the case 2 has a rectangular shape and the core 3 has an elongated shape. The core 3 is housed in the case 2 with the long axis extending in the direction along one side of the case 2. With this configuration, the core 3 is able to radially outwardly expand such that the dead space D between the outer surface of the core 3 and the inner surface of the case 2 is reduced while a space for the wire members of the first coil 41 and the second coil 42 is provided between the outer surface of the core 3 and the inner surface of the case 2. Thus, the cross-sectional area of the core 3 is increased in the radial direction, leading to an increase in the L value. The core 3 having a square shape is able to have the same advantage when the core 3 is housed in the case 2 with one side of the core 3 extending in the direction along one side of the case 2.

(70) In the common mode choke coil 1 having the above-described configuration, the bent wire members 410 and 420 and the third straight wire members 413 and 423 that are alternately connected are wound on the core 3 and the straight wire member 411 is disposed in each of the ferrite beads 61 to 64. This configuration allows the bent wire members 410 and 420 to be positioned only around the core 3, requiring only one kind of the bent wire members 410 and 420. In contrast, if the bent wire members are wound on both of the core and the ferrite beads, more kinds of the bent wire members are required.

Second Embodiment

(71) FIG. 7 is a plan view illustrating a common mode choke coil according to a second embodiment of the disclosure. The second embodiment differs from the first embodiment in the shape of the case. This difference is explained below. In the second embodiment, the same reference numeral is assigned to the same component as that in the first embodiment without duplicated explanation.

(72) As illustrated in FIG. 7, a case 2A has an oblong shape when viewed in the direction along the central axis C of the core 3. The core 3 has an elongated shape (an elliptical shape in this embodiment) when viewed in the direction along the central axis C of the core 3. The core 3 is housed in the case 2A with the long axis L extending in the long axis direction of the case 2A. In FIG. 7, the coils and the ferrite beads are not illustrated.

(73) Since the core 3 is housed in the case 2A with the long axis L of the core 3 extending in the long axis direction of the case 2A, the core 3 is able to be housed in the case 2A with a higher filling factor of the core 3 to the case 2A.

Example

(74) Next, Table 1 indicates a comparison between an example including a common mode choke coil having an elliptical core and a comparative example including a known common mode choke coil having a circular core.

(75) TABLE-US-00001 TABLE 1 Elliptical Core Circular Core L value [μH] 194 183 Rdc [mΩ] 1.49 1.49 Core Magnetic Path Length [mm] 40.6 39.1 Core Cross-sectional Area [mm.sup.2] 25.1 22.8

(76) In the elliptical core and the circular core, the diameter of the coil is 1.8 mm and the number of turns of the coil is five. The outer dimension of the case is 20 mm×20 mm×11.5 mm. The inner dimension is 19 mm×19 mm×10.5 mm. The material of the core is MnZn (μ′=10000). The ferrite beads are placed on the respective four corners. The R dimension of the four inner corners of the elliptical core is 3 mm

(77) Each of the first and second coils is a single-layer coil. The cross-sectional area of the core taken perpendicular to the circumferential direction of the core is constant in the circumferential direction of the core. The cross-sectional shape of the core is quadrilateral. The first coil and the second coil are separate from each other by an insulating distance. The height of the core in the direction along the central axis is constant in the circumferential direction of the core. There is a space between adjacent wire members. The diameter of the coil (the wire member) is constant. The L value is calculated by the (equation 1) above.

(78) As can be seen from Table 1, the L value is higher in the elliptical core than in the circular core. The L value of the elliptical core is higher than that of the circular core by 6.1%. This results from that the cross-sectional area of the elliptical core is larger than that of the circular core by 14%, although the magnetic path length of the elliptical core is longer than that of the circular core by 9%. The L value is increased, because the L value improvement effect due to the increase in the cross-sectional area surpasses the L value reduction effect due to the increase in the magnetic path length.

(79) The present disclosure is not limited to the above-described embodiments and may be modified without departing from the scope of the disclosure. For example, features of the first and second embodiments may be used in various combinations.

(80) In the above-described embodiments, the number of ferrite beads is four but may be three or less or five or more. The ferrite beads are located radially outwardly from the core but may be located radially inwardly from the core. The case has a rectangular shape but may have a circular shape, for example.

(81) The ferrite beads may be eliminated in a configuration including a core having an elongated shape and a rectangular case, in which wire members are opposed in the short axis direction of the elongated shape. In such a case, the cross-sectional area of the short sections of the core is able to be made large to increase the cross-sectional area of the magnetic material.