Filter component assembly kit, filter component, and method for manufacturing the filter component

Patent metadata

Field	Value
Publication number	US-10504642-B2
Application number	US-201815861099-A
Country	US
Kind code	B2
Filing date	Jan 3, 2018
Priority date	Feb 23, 2017
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

A filter component assembly kit includes a bobbin that is configured with first and second members and a core that is in a quadrangular frame shape. When the first member is assembled with the second member, a through hole is formed in the bobbin. The through hole extends in a first direction. The core is configured with first and second extension bars. The first and second extension bars extend in parallel in the first direction. When the first extension bar is disposed in the through hole of the bobbin, rotation of the core around the first extension bar is prevented. First allowance of the first extension bar in a second direction, which is perpendicular to the first direction, in the through hole is larger than second allowance of the first extension bar in a third direction, which is perpendicular to the first and second directions, in the through hole.

First claim

What is claimed is:

1. A filter component assembly kit comprising:
a bobbin including a first member connected to a second member so that a through hole is formed in a center of the bobbin, the through hole extending in a first direction; and
a core that is in a quadrangular frame shape, the core being configured with first, second, third, and fourth extension bars, the first and second extension bars extending in parallel in the first direction, the third and fourth extension bars extending in parallel in a second direction, the second direction being perpendicular to the first direction,
wherein when the first extension bar is disposed in the through hole of the bobbin, rotation of the core around the first extension bar is prevented,
a first allowance of the first extension bar in the second direction in the through hole is larger than a second allowance of the first extension bar in a third direction in the through hole, the third direction being perpendicular to the first and second directions,
a cross section of the first extension bar is quadrangular, and a cross section of a boundary of the through hole is quadrangular,
a width of the first extension bar in the third direction is larger than an inner dimension of the boundary of the through hole in the second direction, and
an inner dimension of the boundary of the through hole in the third direction is larger than a width of the first extension bar in the second direction.

2. The filter component assembly kit according to claim 1 ,
wherein the first member has an outer projection at at least one edge of the first member in the first direction, and the outer projection outwardly projects from the first member,
wherein when the first member is assembled with the second member and when the first extension bar is disposed in the through hole, the first member is located between the first and second extension bars in the second direction, and
a distance between an inner surface of the second extension bar and a middle outer surface of the first member located between the edges is longer than a distance between the inner surface of the second extension bar and a tip of the outer projection.

3. The filter component assembly kit according to claim 1 ,
wherein a circumscribed circle of the cross section of the first extension bar exceeds from the cross section of the boundary of the through hole, the cross section of the first extension bar extending in the second and third directions, the cross section of the boundary of the through hole extending in the second and third directions.

4. The filter component assembly kit according to claim 1 ,
wherein the first and second members of the bobbin have first and second recesses, respectively, and the first and second recesses configure the through hole when the first member is assembled with the second member, and
when the first extension bar is disposed in the first recess without assembling the first member with the second member, the core is rotatable around the first extension bar with respect to the first member.

5. The filter component assembly kit according to claim 4 ,
wherein the first member has a rotation prevention member at a position that is offset from the first recess, and
the rotation prevention member prevents rotation of the core around the first extension bar when the first extension bar is disposed in the through hole.

6. The filter component assembly kit according to claim 4 ,
wherein the first member has a first recess projection projecting toward the second member and an opposite first recess inner wall, the first recess projection partially configures the first recess, and the opposite first recess inner wall is opposed to the first recess projection while sandwiching the first recess therebetween,
the second member has a second recess projection projecting toward the first member and an opposite second recess inner wall, the second recess projection partially configures the second recess, and the opposite second recess inner wall is opposed to the second recess projection while sandwiching the second recess therebetween,
when the first member is assembled with the second member and when the first extension bar is disposed in the through hole, the first and second recess projections engage with the opposite second and first recess inner walls of the second and first recesses, respectively, so as to prevent the core from rotating around the first extension bar by abutting the first extension bar against the first and second recess projections.

7. The filter component assembly kit according to claim 1 ,
wherein an assemble direction of the first and second members corresponds to the second direction,
wherein when the first member is assembled with the second member and when the first extension bar is disposed in the through hole, the first member is located between the first and second extension bars in the second direction,
a combined length of the first member and the through hole in the second direction is D, and a length between an inner edge of the second extension bar and an outer edge of the first extension bar in the second direction is L, and
L<D.

8. The filter component assembly kit according to claim 1 ,
wherein the bobbin has first and second side surfaces that extend in the second and third directions,
one of the first and second side surfaces has an engagement recess, and
one of the third and fourth extension bars engages the engagement recess when the first member is assembled with the second member and when the first extension bar is disposed in the through hole.

9. The filter component assembly kit according to claim 8 ,
wherein an assemble direction of the first and second members is perpendicular to the second direction,
the engagement recess is formed by first and second engagement recesses which are formed in the first and second members, respectively, when the first member is assembled with the second member.

10. A filter component comprising:
a bobbin including a first member connected to a second member so that a through hole is formed in a center of the bobbin, the through hole extending in a first direction;
a wire wound around the bobbin; and
a core that is in a quadrangular frame shape, the core being configured with first, second, third, and fourth extension bars, the first and second extension bars extending in parallel in the first direction, the third and fourth extension bars extending in parallel in a second direction, the second direction being perpendicular to the first direction,
wherein the first extension bar is disposed in the through hole of the bobbin so that rotation of the core around the first extension bar is prevented,
a first allowance of the first extension bar in the second direction in the through hole is larger than a second allowance of the first extension bar in a third direction in the through hole, the third direction being perpendicular to the first and second directions,
a cross section of the first extension bar is quadrangular, and a cross section of a boundary of the through hole is quadrangular,
a width of the first extension bar in the third direction is larger than an inner dimension of the boundary of the through hole in the second direction, and
an inner dimension of the boundary of the through hole in the third direction is larger than a width of the first extension bar in the second direction.

11. The filter component according to claim 10 ,
wherein the first extension bar is fixed to the boundary of the through hole.

12. The filter component according to claim 10 ,
wherein a circumscribed circle of a cross section, which extends in the secon

Assignees

• Sumida Corp

Inventors

• Sasaki Naoki
• Chen Jiayu

Classifications

• H01F41/098

  Mandrels; Formers · CPC title

• H01F27/325

  Coil bobbins (formers for coils in general H01F5/02) · CPC title

• H01F37/00

  Fixed inductances not covered by group H01F17/00 · CPC title

• H01F27/306

  Fastening or mounting coils or windings on core, casing or other support · CPC title

• H01F27/266 Primary

  Fastening or mounting the core on casing or support (on coil H01F27/30) · CPC title