CN108428539B

CN108428539B - Coil device

Info

Publication number: CN108428539B
Application number: CN201810133860.0A
Authority: CN
Inventors: 熊谷胜; 岩仓正明
Original assignee: TDK Corp
Current assignee: TDK Corp
Priority date: 2017-02-15
Filing date: 2018-02-09
Publication date: 2020-10-13
Anticipated expiration: 2038-02-09
Also published as: JP2018133456A; CN108428539A; JP6424910B2

Abstract

The invention provides a coil device which can be miniaturized and has stable leakage characteristics. The coil device has: a skeleton (20); a first coil part (31) composed of a plate-shaped conductor; a second coil part (32) which is located at a position different from the first coil part (31) and is composed of a plate-like conductor; and an intermediate coil part (33) positioned between the first coil part (31) and the second coil part (32). A skeleton (20) is provided with: middle skeleton (23), first skeleton (21), second skeleton (22). The intermediate coil part (33) is wound around the intermediate cylinder part (236) in close contact with the first intermediate flange part (231) and the second intermediate flange part (232), and the second cylinder part (226) is combined with the second end of the intermediate cylinder part (236) in such a manner that the second intermediate flange part (232) abuts against the surface of the second coil part (32) opposite to the second end flange part (220).

Description

Coil device

Technical Field

The present invention relates to a coil device that can be suitably used as a transformer such as a leakage transformer.

Background

Coil devices are used for various electric products for various purposes. For example, a coil device is used in a DC/DC converter that lowers a high voltage supplied from a high-voltage battery of an electric vehicle or a hybrid vehicle to a low voltage and supplies the low voltage to other electric devices, and is generally used as a transformer such as a leakage transformer.

As an example of the coil device, for example, a coil device shown in the following patent document 1 can be cited. The coil device disclosed in patent document 1 includes a primary coil and a pair of secondary coils (bus bars) sandwiching the primary coil. In this coil device, a secondary side bobbin insert-molded with a secondary coil sandwiches a primary side bobbin around which a primary coil is wound.

In the coil device configured as described above, the distance in the winding axis direction between the primary coil and the secondary coil is determined by the sum of the thickness of the flange portion of the primary-side bobbin and the insert molding thickness of the secondary-side bobbin. Therefore, it is difficult to set the distance in the winding direction between the primary coil and the secondary coil to a constant thickness, and it is difficult to stabilize the leakage characteristics.

In this coil device, in order to form an arc-shaped side wall portion on the secondary side bobbin, a housing portion is provided inside the side wall portion, and the primary side bobbin is housed in the housing portion, which causes a problem that the outer diameter of the secondary side bobbin becomes large, making miniaturization difficult, and the like.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2013-89787

Disclosure of Invention

The present invention has been made in view of such circumstances, and an object thereof is to provide a coil device which can be downsized and has stable leakage characteristics.

In order to achieve the above object, a coil device according to the present invention includes:

a framework;

a first coil portion formed of a plate-shaped conductor;

a second coil portion which is located at a position different from the first coil portion and is formed of a plate-like conductor;

a middle coil part located between the first coil part and the second coil part,

the skeleton is provided with:

an intermediate bobbin having an intermediate cylinder portion around which the intermediate coil portion is wound, the intermediate cylinder portion having first and second axial ends at which first and second intermediate flanges are formed, respectively;

a first frame having a first tube section combined with the first end, a first end flange section formed in the first tube section;

a second frame having a second tube portion combined with the second end, a second end flange portion formed on the second tube portion,

the intermediate coil portion is wound around the intermediate tube portion so as to be in contact with (preferably in close contact with) the first intermediate flange portion and the second intermediate flange portion,

the second tube portion is combined with a second end of the intermediate tube portion such that the second intermediate flange portion abuts against a surface of the second end flange portion opposite to the second coil portion.

The frame in the present invention is configured by integrally combining a first frame, an intermediate frame, and a second frame. In addition, instead of housing the intermediate bobbin inside the second bobbin, the second tube portion is combined with the second end of the intermediate tube portion, and the second intermediate flange portion is brought into contact with (preferably into close contact with) the opposite side surface of the second coil portion in contact with (preferably into close contact with) the second end flange portion.

In order that the intermediate coil portion is wound around the intermediate bobbin so as to be in contact with the second intermediate flange portion, the intermediate coil portion wound around the intermediate bobbin and the second coil portion disposed on the second bobbin are disposed apart by a distance corresponding to the thickness of the second intermediate flange portion. When the intermediate frame is molded, the thickness of the second intermediate flange portion can be relatively accurately controlled and the intermediate frame can be molded.

Further, if the second frame is disposed so as to be the lower side in the direction of gravity and the intermediate frame and the first frame are combined with each other, the first coil portion is disposed above the first intermediate flange portion, and the lower surface of the first coil portion is brought into contact with (preferably, brought into close contact with) the upper surface of the first intermediate flange portion by the weight of the first coil portion. The intermediate coil portion is wound around the intermediate frame so as to be in contact with (preferably in close contact with) the lower surface of the first intermediate flange portion.

Therefore, the intermediate coil portion wound around the intermediate bobbin and the first coil portion disposed on the first bobbin are disposed apart by a distance corresponding to the thickness of the first intermediate flange portion. When the intermediate frame is molded, the thickness of the first intermediate flange portion can be relatively accurately controlled and the molding can be performed.

By combining the first bobbin, the intermediate bobbin, and the second bobbin in this manner, if these bobbins are fixed by fixing means such as an adhesive, for example, the distances in the reel direction of the first coil portion, the intermediate coil portion, and the second coil portion are maintained constant in accordance with the thickness of each flange portion. Therefore, coupling between these coil portions can be easily improved, and a coil device having stable leakage characteristics can be realized.

Further, since it is not necessary to perform insert molding or the like, the height of the bobbin in the reel direction can be reduced. Further, since the intermediate frame is not housed inside the second frame but the second tube portion is combined with the second end of the intermediate tube portion, the size of the second frame in the radial direction can be reduced. The first skeleton is also the same as the second skeleton.

Further, since the first coil portion and the second coil portion are formed of a plate-like conductor, a large current can be made to flow through the first coil portion and the second coil portion.

The second coil portion may have a substantially annular plate shape. Further, a positioning portion that abuts against an inner peripheral side surface of the second coil portion may be formed at an intersection portion between an inner surface of the second end flange portion and an outer peripheral surface of the second cylindrical portion. With this configuration, the inner peripheral side surface of the second coil part abuts against the positioning part, and the second coil part can be prevented from being positionally displaced in the radial direction.

Preferably, the positioning portion is formed on an outer peripheral side surface of the stepped portion, and the second intermediate flange portion abuts against a stepped surface of the stepped portion. Preferably, the axial length of the step portion is equal to or less than the plate thickness of the second coil portion. With this configuration, the second intermediate flange portion is reliably brought into close contact with the second coil portion.

Preferably, an intermediate cutout cut out to a predetermined depth is formed on a second end side of an inner peripheral side surface of the intermediate tubular portion, and an engaging convex portion engaging with the intermediate cutout is formed on a first end side of the second tubular portion, the engaging convex portion engaging with the intermediate cutout so that a gap is formed between a front end surface of the engaging convex portion and a bottom surface of the intermediate cutout. With this configuration, the second intermediate flange portion is reliably brought into close contact with the second coil portion.

Preferably, the engaging convex portion is engaged with the intermediate cutout portion so that an inner peripheral side surface of the intermediate tube portion and an outer peripheral side surface of the engaging convex portion face each other. With this configuration, the outer peripheral side surface of the engaging convex portion functions as a positioning surface, and the intermediate cylinder portion can be prevented from being positionally displaced in the radial direction.

The first tube portion may be combined with the first end of the intermediate tube portion such that a space in which the first coil portion can be disposed is formed between the first end flange portion and the first intermediate flange portion.

Further, the first tube portion may be combined with the first end of the intermediate tube portion so that the first end flange portion abuts (preferably, is in close contact with) the opposite side surface of the first coil portion abutting on the first intermediate flange portion.

The first coil portion and the second coil portion constitute either a primary coil or a secondary coil, and the intermediate coil portion constitutes either the primary coil or the secondary coil.

Drawings

Fig. 1A is a perspective view of a transformer as a coil device according to an embodiment of the present invention;

FIG. 1B is a perspective view of the transformer shown in FIG. 1A with the housing and base plate removed;

FIG. 2 is an exploded perspective view of the transformer shown in FIG. 1A;

FIG. 3 is a sectional view of a principal part of the transformer taken along the line III-III shown in FIG. 1A;

FIG. 4 is a cross-sectional view of a main portion of the skeleton taken along line IV-IV shown in FIG. 1A;

FIG. 5A is a perspective view of the bobbin in the transformer shown in FIG. 1A;

FIG. 5B is an exploded perspective view of the armature shown in FIG. 5A;

FIG. 5C is a main portion sectional view of the bobbin shown in FIG. 5A;

FIG. 5D is a cross-sectional view of a principal part of a modification of the bobbin shown in FIG. 5A;

FIG. 5E is a detailed major portion cross-sectional view of the armature shown in FIG. 5A;

fig. 5F is a perspective view of the insulating cover or the like attached to the frame shown in fig. 5A;

FIG. 6A is a perspective view of a coil portion in the transformer shown in FIG. 1A;

FIG. 6B is an exploded perspective view of the coil part shown in FIG. 6A;

fig. 6C is a perspective view of a modified example of the first coil portion and the second coil portion in the coil portion shown in fig. 6A;

fig. 7 is a circuit diagram showing an equivalent circuit of the transformer shown in fig. 1A.

Description of the symbols

10 … transformer

20 … skeleton

21 … first skeleton

210 … first end flange portion

211 … cover clamping part

216 … first barrel part

217 … first engaging projection

218 … first engaging concave portion

219 … first positioning part

219a … first step

22 … second skeleton

220 … second end flange portion

226 … second canister portion

227 … second engaging protrusion

228 … second engaging concave part

229 … second detent

229a … second step portion

23 … intermediate skeleton

231 … first intermediate flange portion

231a … notch for locking first lead

232 … second intermediate flange portion

233 … third intermediate flange portion

233a … notch for locking second lead

233b … notch for winding wire plug

236 … middle cylinder part

237a … first intermediate cut-out portion

238a … first intermediate convex part

237b … second intermediate cutout portion

238b … second intermediate convex part

239 … middle positioning part

239a … intermediate step

24 … first terminal block

241 … first side wall part

242 … locating surface

25 … second terminal station

251 … second side wall part

252 … latch

253 … snap-fit projection

26 … skeleton foot

30 … coil part

31 … first coil part

32 … second coil part

33 … middle coil part

37 … middle winding

37a, 37b … lead part

371a, 371b … lead standing part

372 … intercoil connection

38. 39 … bus bar

381a, 381b, 391a, 391b … terminal part

383. 393 … opening part

384a, 384b, 394a, 394b … plate-shaped rising part

40a, 40b … magnetic core

44a, 44b … base

46a, 46b … middle foot

48a, 48b … side foot

50 … cover

52 … hood body portion

54 … stop sheet

56 … side foot guide sheet

58 … snap-fit portion

60 … leading-out winding cover

61 … snap-fit part

70 … stand

80 … terminal

90 … casing

91 … bottom plate

92 … sleeve part

100 … heat dissipating resin.

Detailed Description

The present invention will be described below based on embodiments shown in the drawings.

The transformer 10, which is the coil device according to the present embodiment shown in fig. 1A, is used to compress a high voltage supplied from a high-voltage battery of an electric vehicle or a hybrid vehicle into a low voltage and supply the low voltage to a DC/DC converter or the like of another electrical device.

As shown in fig. 2, the transformer 10 includes a bobbin 20,

magnetic cores

40a and 40b, a cover 50, a lead wire cover 60, a terminal 80, a case 90 that houses these components, and a bottom plate 91. In the drawings, the X, Y, and Z axes are perpendicular to each other, and the Z axis corresponds to the height (thickness) of the transformer 10. In the present embodiment, the lower part of the transformer 10 in the Z-axis direction serves as a transformer mounting surface. The Y axis coincides with the longitudinal direction of the bases 44a and 44b of the

magnetic cores

40a and 40 b. The X axis coincides with the longitudinal direction of the frame 20.

In the present embodiment, the bottom plate 91 is attached to the bottom opening of the housing 90 by caulking, bonding, or the like, and forms the housing 90 having an open top. The bottom plate 91 is preferably made of metal such as aluminum copper or iron having excellent heat dissipation properties, but may be made of PPS, PET, PBT or the like. Since the lower end surface of the magnetic core 40 in the Z-axis direction described below is in contact with the bottom plate 91, the bottom plate 91 is preferably made of a material having excellent heat dissipation properties. A cooling device such as a cooling pipe or a cooling fin may be attached to the lower side of the casing 90 via the bottom plate 91 or directly.

Sleeve (boss) portions 92 are formed at four corners of the bottom plate 91. The sleeve portion 92 is formed with, for example, a bolt hole. The housing 90 itself is made of metal, but may be made of synthetic resin or the like. Alternatively, the bottom plate 91 and the housing 90 may be integrally formed by die-casting aluminum or the like. The heat dissipation performance is further improved by forming the entire housing from metal.

As shown in fig. 3, the inside of the case 90 is filled with a heat dissipating resin 100. The heat dissipating resin is not particularly limited, but is preferably a resin having excellent heat dissipation properties, for example, having a thermal conductivity of 0.5 to 5, preferably 1 to 3W/m.K. Examples of the resin having excellent heat dissipation properties include silicone resins, polyurethane resins, and epoxy resins, and among them, silicone resins and polyurethane resins are preferable. In addition, in order to improve heat dissipation, a filler having high thermal conductivity may be filled in the resin.

The heat dissipating resin of the present embodiment preferably has a shore a hardness of 100 or less, and preferably 60 or less. This is because even if the

magnetic cores

40a and 40b or the frame 20 are deformed by heat, the deformation can be absorbed, and excessive stress does not occur in the

magnetic cores

40a and 40 b. As such a resin, a filling (Potting) resin is exemplified.

As shown in fig. 3 and 4, the coil 30 attached to the bobbin 20 includes a first coil portion 31, a second coil portion 32, and an intermediate coil portion 33 located between the first coil portion 31 and the second coil portion 32 along a central axis (Z-axis direction) of the bobbin 20. That is, the coil parts 31 to 33 are arranged along the central axis so that the 3 rd coil part 33 is sandwiched by the first coil part 31 and the second coil part 32.

The intermediate coil portion 33 is formed of an intermediate winding 37, and the first coil portion 31 and the second coil portion 32 are formed of conductive plate-like conductors (bus bars in the present embodiment) 38 and 39, respectively. By configuring the

respective coil portions

31 and 32 with the bus bars, a large current can be made to flow through the

respective coil portions

31 and 32.

In the present embodiment, the intermediate winding 37 constitutes a primary coil, and the bus bars 38 and 39 constitute a secondary coil. That is, as shown in fig. 7(a), the intermediate coil portion 33 formed of the intermediate winding 37 serves as a primary side, and the first coil portion 31 and the second coil portion 32 formed of the bus bars 38 and 39 serve as secondary sides, whereby a transformer is formed therebetween.

In the present embodiment, a high voltage acts on the primary coil as compared with the secondary coil, and a lower voltage acts on the secondary coil. The range of the voltage acting on the primary coil is, for example, 300 to 500V, and the range of the voltage acting on the secondary coil is 12 to 14V.

The intermediate winding 37 may be formed of a single wire or a twisted wire, and is preferably formed of a litz wire or the like. The outer diameter of the intermediate winding 37 is not particularly limited, but is preferably in the range of 1 to 3 mm. In addition, an insulating film is preferably formed on the intermediate winding 37.

Lead

portions

37a and 37b shown in fig. 1A are both ends of the intermediate winding 37 shown in fig. 3 and 4. As shown in fig. 1A, terminals 80 made of, for example, metal terminals are connected to the ends of the

lead portions

37a and 37b by soldering or the like, and both ends of the wire 37 are electrically connected to the terminals 80.

As shown in fig. 6A and 6B, the bus bars 38 and 39 are formed in a substantially annular plate shape (substantially C-shaped plate shape) having substantially

elliptical openings

383 and 393 at the center. The bus bars 38 and 39 are manufactured by punching a flat plate made of a conductive material such as a copper plate and then bending each part. The shape of the bus bars 38 and 39 is not limited to a substantially annular plate shape (substantially C-shaped plate shape), and may be other shapes such as an elliptical shape or a rectangular shape. In the present embodiment, each of the bus bars 38 and 39 may be formed of one turn or may be formed of a plurality of turns.

Bus bar 38 has first terminal portion 381a at one end and second terminal portion 381b at the other end. Further, bus bar 39 has a first terminal portion 391a at one end and a second terminal portion 391b at the other end. As shown in fig. 6A, first terminal portion 381a of bus bar 38 and second terminal portion 391a of bus bar 39 are connected so as to overlap each other in the Z-axis direction, and second terminal portion 381b of bus bar 38 and second terminal portion 391b of bus bar 39 are connected so as to overlap each other in the Z-axis direction. Thereby, the bus bars 38 and 39 are coupled to overlap coaxially with the

openings

383 and 393 in communication with each other. In addition, as shown in fig. 7(a), the first coil portion 31 and the second coil portion 32 are connected in parallel.

As shown in fig. 5B, the first terminal block 24 and the second terminal block 25 are integrally formed on the upper surfaces of both ends of the first frame 21 (the first end flange portion 210) in the X axis direction. Each

terminal block

24, 25 has a

side wall portion

241, 251.

Side wall portions

241 and 251 are formed so as to surround the peripheral edges of terminal blocks 24 and 25 except for the sides from which lead

portions

37a and 37b and

terminal portions

381a, 381b, 391a, and 391b of

bus bars

38 and 39 are drawn. The first terminal block 24 is provided with a positioning surface 242 that abuts against and positions the plate-like rising

portions

384a and 384b of the bus bar 38.

Each positioning surface 242 is guided to the first end side in a state where the first plate-like rising

portions

384a and 394a rising in the Z-axis direction and the second plate-like rising

portion lead portions

384b and 394b are close to each other. In the second terminal block 25, engaging protrusions 253 are formed on both outer end walls of the side wall portion 251 in the Y-axis direction. The function of the engaging protrusion 253 will be described later.

Further, a pair of locking portions 252 are formed on the second terminal block 25. As shown in fig. 5F, the

first lead portions

37a and 37b raised in the Z-axis direction by the lead-raising

portions

371a and 371b are wound around the pair of locking portions 252 from the inner side in the Y-axis direction to the outer side in the X-axis direction, and are guided to the outer side in the X-axis direction.

By locking the lead portions 37a and 37B to the pair of locking portions 252, the intermediate coil portion 33 formed of the intermediate winding 37 positioned in the middle of the lead portions 37a and 37B shown in fig. 6A and 6B is locked without looseness, and unwinding is prevented. In this state, the

lead portions

37a and 37b can be drawn out in a direction away from the coil 30.

As shown in fig. 1B, a lead wire cover 60 is attached to cover the terminal block 25 above in the Z-axis direction. More specifically, holes 61 are formed in the side surfaces of both ends of the drawn-out wire cover 60 in the Y-axis direction, and the drawn-out wire cover 60 can be attached to the terminal block 25 by engaging the holes 61 with the engaging projections 253 formed on the terminal block 25. This prevents the

lead portions

37a and 37b from being unnecessarily exposed above the terminal block 25.

As shown in fig. 2, the

magnetic cores

40a and 40b have the same shape in the present embodiment, and have an E-shaped cross section in the Z-Y cross section, thereby forming a so-called E-core. The form of the

magnetic cores

40a and 40b is not limited to the form shown in fig. 2, and the

magnetic cores

40a and 40b may be divided along the chain line (substantially the center position in the Y axis direction) in the drawing so as to be parallel to the XZ plane. Alternatively, the

magnetic cores

40a and 40b may be divided into segments parallel to the YZ plane along a straight line (substantially the center in the X axis direction) intersecting the dashed-dotted line in the figure.

The magnetic core 40a disposed on the upper side in the Z-axis direction includes a base 44a extending in the Y-axis direction, a pair of side legs 48a protruding in the Z-axis direction from both ends of the base 44a in the Y-axis direction, and a middle leg 46a protruding in the Z-axis direction from the center in the Y-axis direction between the side legs 48 a. The magnetic core 40b disposed on the lower side in the Z-axis direction includes a base 44b extending in the Y-axis direction, a pair of side legs 48b protruding in the Z-axis direction from both ends of the base 44b in the Y-axis direction, and a middle leg 46b protruding in the Z-axis direction from the center in the Y-axis direction between the side legs 48 b.

The middle leg portion 46a is inserted into the core leg through hole 21a of the bobbin 20 from above in the Z-axis direction. Similarly, the center leg portion 46b is inserted into the core leg through hole 21a of the bobbin 20 from below in the Z-axis direction, and the tip ends thereof are configured to contact the tip end of the center leg portion 46a in the core leg through hole 21 a.

The tip of the center leg portion 46b may be disposed inside the core leg through hole 21a so as to face the tip of the center leg portion 46a with a predetermined gap therebetween. Thus, by forming the gap, the leakage characteristic can be adjusted according to the width of the gap.

The center leg portion 46a and the center leg portion 46b have a substantially elliptical columnar shape so as to conform to the shape of the inner peripheral surface of the core leg through hole 21a, but the shape thereof is not particularly limited and may be changed in accordance with the shape of the core leg through hole 21 a. The

side leg portions

48a, 48b have an inner concave curved surface shape conforming to the outer peripheral surface shape of the skeleton body 21, and the outer surfaces thereof have planes parallel to the X-Z plane. In the present embodiment, the material of each of the

cores

40a and 40b is a soft magnetic material such as metal or ferrite, but is not particularly limited.

Covers 50 are disposed between the inner peripheral surfaces of the

side leg portions

48a, 48b and the outer peripheral surfaces of the frames 20 (the

frames

21, 22, 23). The cover main body 52 of the cover 50 has a shape covering the outer periphery of the bobbin 20 between the terminal blocks 24 and 25 of the bobbin 20. Locking pieces 54 bent in a substantially vertical direction from the cover body 52 toward the bobbin 20 are integrally formed at both ends of the cover body 52 in the Z-axis direction. As shown in fig. 3, the pair of locking pieces 54 formed on both sides of the cover main body 52 in the Z-axis direction are attached so as to sandwich the upper surface of the first end flange portion 210 in the Z-axis direction in the first frame 21 and the lower surface of the second end flange portion 220 in the Z-axis direction in the second frame.

As shown in fig. 2, side leg guide pieces 56 extending in the Z-axis direction are integrally formed on outer surfaces of both ends of the cover main body 52 in the X-axis direction, respectively. The inner surfaces of the

side leg portions

48a, 48b contact the outer surface of the cover main body 52 positioned between the pair of side leg guide pieces 56, and the movement of the

side leg portions

48a, 48b in the X-axis direction is restricted by the pair of side leg guide pieces 56. These covers 50 are made of an insulating member such as plastic or metal similar to the frame 20.

As shown in fig. 5F, the hook-shaped engaging portion 58 formed on the inner side of the locking piece 54 on the upper side of the cover 50 is detachably fitted to the hook-shaped cover engaging portion 211 formed on the upper surface of the first bobbin 21.

As shown in fig. 5B, the frame 20 of the present embodiment is divided into three parts, i.e., a first frame 21, an intermediate frame 23, and a second frame 22, and these

frames

21, 22, and 23 are integrally combined.

These

skeletons

21, 22, and 23 are made of plastic such as PPS, PET, PBT, LCP, or nylon, for example, but may be made of other insulating members. However, in the present embodiment, the

skeletons

21, 22, and 23 are preferably made of plastic having a thermal conductivity of at least 1W/m · K, for example, and may be made of PPS, nylon, or the like, for example.

The intermediate frame 23 has an intermediate cylinder 236 around the outer periphery of which the intermediate coil portion 33 is wound. At each of a first end (in the present embodiment, an upper end in the Z-axis direction) and a second end (in the present embodiment, a lower end in the Z-axis direction) in the axial direction of the intermediate cylinder part 236, a first intermediate flange part 231 and a second intermediate flange part 232 are integrally formed substantially in parallel with the XY plane at a predetermined interval in the Z-axis direction so as to extend outward in the radial direction.

Further, a third intermediate flange portion 233 is formed so as to protrude radially outward on the outer peripheral surface of an intermediate cylindrical portion 236 located between the first intermediate flange portion 231 and the second intermediate flange portion 232 in the Z-axis direction. In the present embodiment, each of the

flanges

231, 232, and 233 is configured so that the thickness of each of the

flanges

231, 232, and 233 in the Z-axis direction is equal. The first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231.

As shown in fig. 5C, the third intermediate flange portion 233 formed between the first intermediate flange portion 231 and the second intermediate flange portion 232 has partitions S1 and S2 formed between these flange portions in this order from the upper side in the Z-axis direction. The intermediate winding 37 is wound around the sections S1 and S2. The number of the intermediate flange 233 and the sections S1 and S2 is not particularly limited.

As shown in fig. 4, in the present embodiment, the intermediate coil portion 33 is formed by winding the intermediate winding 37 in sections S1 and S2 in a plurality of turns such as five turns in succession. In the present embodiment, the third intermediate flange 233 functions to space the intermediate coil portion 33 wound on the first end side and the intermediate coil portion 33 wound on the second end side in the Z-axis direction.

As shown in fig. 5C, the section width T3 along the Z axis in the sections S1 and S2 in which the intermediate winding 37 constituting the intermediate coil unit 33 is wound is preferably set to a width that enters one intermediate winding 37 in the Z axis direction. This is because α -winding is easily performed. However, the section width T3 may be set to a width that extends into two or more intermediate windings 37 in the Z-axis direction. In the present embodiment, the division widths T3 of the respective divisions S1 and S2 are preferably all the same, but may be slightly different.

The radial length H1 of each of the flange portions 231 to 233 is set to a height that enters one or more (one or more) intermediate windings 37, and in the present embodiment, is preferably set to a height that enables winding of 3 to 8 layers of windings. The lengths H1 of the flange portions 231-233 are preferably all the same, but may be different.

In the present embodiment, the winding method of the intermediate wire 37 wound around the sections S1 and S2 is α -winding, and the intermediate wire 37 is passed through the inter-coil connection 372 shown in fig. 6B to the sections S1 and S2 shown in fig. 5C, is started to be wound, and is drawn out to the lead portions 37a and 37B shown in fig. 5F.

Here, α -winding will be explained. For example, when the intermediate winding 37 is wound around the bobbin 20 α shown in fig. 5A, first, the inter-coil connection portion 372 of the intermediate winding 37 shown in fig. 6B is passed through the winding insertion slit 233B of the third intermediate flange portion 233 shown in fig. 5B.

Then, as shown in fig. 4, the upper half portion of the intermediate winding wire 37 in the Z-axis direction is wound around the outer periphery of the intermediate bobbin 23 in multiple layers (5 layers in the drawing) inside the section S1. At the same time, the lower half of the intermediate winding wire 37 is wound in multiple layers around the outer periphery of the intermediate bobbin 20 in the section S2 in the direction opposite to the winding direction in the section S1 (or in the same direction). In addition, these operations may be performed using an automatic winder.

As shown in fig. 5E, a first intermediate cutout portion 237a cut out to a predetermined depth toward the second end is formed on the first end side of the inner peripheral side surface of the intermediate tube portion 236, and a second intermediate cutout portion 237b cut out to a predetermined depth toward the first end is formed on the second end side of the inner peripheral side surface of the intermediate tube portion 236. The

intermediate cutout portions

237a and 237b are formed along the inner peripheral side surface of the winding tube portion 236.

As shown in fig. 5B, a first intermediate convex portion 238a and a second intermediate convex portion 238B are formed near both ends of each of the intermediate cutout portions 237a and 237B in the X-axis direction so that the depth of the cutouts in the Z-axis direction is smaller than that of the other portions. In the example shown in fig. 5B, the first intermediate convex portion 238a and the second intermediate convex portion 238B have different circumferential widths, but may be equal.

As shown in fig. 5E, the length in the Z-axis direction of the intermediate cutout portions 237a (the length from the upper surface of the intermediate positioning portion 239 described below) LC1a is preferably 1/10 to 4/10, and more preferably about 1/3, of the length in the Z-axis direction of the intermediate cylindrical portion 236. The length LC1b of the intermediate notch 237b in the Z-axis direction (the length from the lower surface of the second intermediate flange 232) is preferably about 1/10 to 4/10 of the length of the intermediate cylindrical portion 236 in the Z-axis direction, more preferably about 1/3.

An intermediate positioning portion 239 that abuts against the inner peripheral side surface of the first coil portion 31 is formed along the outer periphery of the intermediate tube portion 236 at the intersection portion with the intermediate tube portion 236 on the upper surface of the first intermediate flange portion 231. The intermediate positioning portion 239 has an intermediate step portion 239a rising substantially perpendicularly to the upper surface of the first intermediate flange portion 231. With such a configuration, when the first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231, the inner peripheral side surface of the first coil portion 31 abuts against the intermediate step portion 239a (and the first step portion 219a described below), and the first coil portion 31 can be prevented from being displaced in the radial direction.

As shown in fig. 5B, a first lead wire locking notch 231a is formed on the second terminal base 25 side (X-axis negative direction side) of the first intermediate flange 231, and a second lead wire locking notch 233a and a wire insertion notch 233B are formed on the second terminal base 25 side (X-axis negative direction side) of the third intermediate flange 233. The

lead standing portions

371a and 371b of the

lead portions

37a and 37b shown in fig. 5F are locked to the

lead locking notches

231a and 233a, respectively, so that the

lead standing portions

371a and 371b are easily formed. As shown in fig. 4, the winding insertion slit 233B shown in fig. 5B is used to insert the inter-coil connecting portion 372 shown in fig. 6B (the central portion of the intermediate winding 37 located substantially at the center between the lead portions 37a and 37B) when the intermediate winding 37 is wound (wound a) around the outer periphery of the intermediate cylindrical portion 236.

As shown in fig. 5E, the first bobbin 21 has the first tubular portion 216 combined at the first end of the intermediate tubular portion 236. The first end flange portion 210 is integrally formed in the first cylindrical portion 216 substantially in parallel with the XY plane such that the first end flange portion 210 extends radially outward. A first engaging protrusion 217 that engages with the intermediate notch 237a is formed on a second end side of the inner peripheral side surface of the first cylindrical portion 216. The first engaging projection 217 is constituted by an engaging piece projecting toward the second end side.

As shown in fig. 5B, the first engaging projection 217 is formed along the outer periphery of the first tube portion 216. Near both ends of the first engaging protrusion 217 in the X axis direction, a first concave portion 218 is formed so that the protruding width in the Z axis direction on the second end side is smaller than that of the other portion. The first concave portion 218 engages with the first intermediate convex portion 238a, and the portion of the first engaging convex portion 217 other than the first concave portion 218 engages with the portion of the intermediate notch portion 237a other than the first intermediate convex portion 238 a. Thus, the first cylindrical portion 216 is combined with the first end of the intermediate cylindrical portion 236, and a space a1 in which the first coil portion 31 shown in fig. 5C can be arranged is formed between the lower surface of the first end flange portion 210 and the upper surface of the first intermediate flange portion 231. In the present embodiment, the distance (shortest distance) between the first coil portion 31 and the intermediate coil portion 33 is equal to the thickness of the first intermediate flange portion 231 that separates them.

As shown in fig. 5E, a first positioning portion 219 that abuts the inner peripheral side surface of the first coil portion 31 is formed along the outer periphery of the first tube portion 216 at the intersection portion of the lower surface of the first end flange portion 210 and the first tube portion 216. The first positioning portion 219 has a first stepped portion 219a that is lowered substantially perpendicularly with respect to the lower surface of the first end flange portion 210. With such a configuration, when the first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231, the inner peripheral side surface of the first coil portion 31 abuts against the first stepped portion 219a (and the intermediate stepped portion 239a described above), and therefore, the first coil portion 31 can be prevented from being displaced in the radial direction.

In the present embodiment, the Z-axis length (height from the upper surface of the intermediate positioning portion 239) LE1 of the first engaging protrusion 217 is smaller than the Z-axis length LC1a of the intermediate notch portion 237 a. Therefore, when the first tube part 216 is assembled to the first end of the intermediate tube part 236, the lower surface of the first positioning portion 219 abuts on the upper surface of the intermediate positioning portion 239, and a gap G1 is formed between the front end surface F1 of the first engaging projection 217 and the bottom surface F3a of the intermediate notch 237 a.

As a result, the partition width T1 along the Z axis in the space a1 is equal to the sum (LP1+ LP3) of the Z-axis direction length LP1 of the first stepped portion 219a and the Z-axis direction length LP3 of the intermediate stepped portion 239 a. In the present embodiment, the sum (LP1+ LP3), i.e., the section width T1 along the Z axis in the space a1, is equal to or greater than the plate thickness TH1 of the first coil portion 31. Therefore, a gap LG10 may be formed between the upper surface of the first coil portion 31 and the lower surface of the first end flange portion 210.

Further, the length LP1 of the first stepped portion 219a and the length LP3 of the intermediate stepped portion 239a may be adjusted, and the value of the sum (LP1+ LP3) may be appropriately changed. For example, LP1+ LP3 may be equal to or less than the plate thickness TH1 of the first coil portion 31. In this case, the lower surface of the first end flange portion 210 abuts against the upper surface of the first coil portion 31. That is, the first coil portion 31 is sandwiched between the lower surface of the first end flange portion 210 and the upper surface of the first intermediate flange portion 231, and the section width T1 is equal to the plate thickness TH1 of the first coil portion 31. In this case, the gap LG10 between the upper surface of the first coil portion 31 and the lower surface of the first end flange portion 210 can be omitted.

In the present embodiment, the gap G1 can be formed and the partition width T1 in the space a1 along the Z-axis direction can be appropriately adjusted by appropriately adjusting the length LE1 of the first engaging convex portion 217, the length LP1 of the first intermediate step portion 219a, the length LP3 of the intermediate step portion 239a, or the length LC1a of the first intermediate notch portion 237 a.

In the present embodiment, when the first engaging convex portion 217 is engaged with the first intermediate notch portion 237a, the inner peripheral side surface of the intermediate tube portion 236 and the outer peripheral side surface of the first engaging convex portion 217 face each other, and the outer peripheral side surface of the first engaging convex portion 217 abuts against the first end side of the inner peripheral side surface of the intermediate tube portion 236. Therefore, the outer peripheral side surface of the first engaging projection 217 functions as a positioning surface, and the intermediate tube 236 can be prevented from being displaced in the radial direction. Further, a slight gap may be formed between the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the first convex engagement portion 217 in manufacturing.

As shown in fig. 5B, second frame 22 has a second tubular portion 226 that merges with a second end of intermediate tubular portion 236. The second tube portion 226 is integrally formed with the second end flange portion 220 substantially in parallel with the XY plane so as to extend radially outward.

As shown in fig. 5E, a second positioning portion 229 that abuts against the inner peripheral side surface of the second coil portion 32 is formed along the outer periphery of the second tube portion 226 at the intersection portion with the second tube portion 226 on the upper surface of the second end flange portion 220. The second positioning portion 229 has a second stepped portion 229a that stands substantially perpendicular to the upper surface of the second end flange portion 220. In the present embodiment, the height LP2 of the second step portion 229a is equal to or smaller than the plate thickness TH2 of the second coil portion 32.

By forming the second positioning portion 229, when the second coil portion 32 is disposed on the upper surface of the second end flange portion 220, the inner peripheral side surface of the second coil portion 32 abuts against the second stepped portion 229a, and therefore, the second coil portion 32 can be prevented from being displaced in the radial direction.

An engaging convex portion 227 that engages with the intermediate notch portion 237b is formed on a first end side of the inner peripheral side surface of the second tube portion 226. The engaging projection 227 is formed of an engaging piece projecting toward the first end side, and is formed along the outer periphery of the second tube portion 226 as shown in fig. 5B. The second concave portions 228 are formed near both ends of the engaging convex portion 227 in the X axis direction so as to have a smaller protruding width in the Z axis direction on the first end side than the other portions.

The second intermediate convex portion 238b is engaged with the second concave portion 228, and the portion of the engaging convex portion 227 other than the second concave portion 228 is engaged with the portion of the intermediate notch portion 237b other than the second intermediate convex portion 238 b. As a result, the second end of the intermediate tube portion 236 is coupled to the second tube portion 226, and as shown in fig. 5E, a space a2 in which the second coil portion 32 can be disposed is formed between the upper surface of the second end flange portion 220 and the lower surface of the second intermediate flange portion 232.

In the present embodiment, the length (height from the upper surface of second positioning portion 229) LE2 of engaging projection 227 is the same as or smaller than the length LC1b of intermediate notch portion 237 b. Therefore, when the intermediate tube portion 236 is combined with the second tube portion 226, the lower surface of the second intermediate flange portion 232 abuts against the upper surface of the second positioning portion 229, and a gap G2 is formed between the front end surface F2 of the engaging projection 227 and the bottom surface F3b of the intermediate notch portion 237 b. As a result, the partition width T2 along the Z axis in the space a2 is equal to the length LP2 of the second stepped portion 229 b.

In the present embodiment, the second positioning portions 229 are formed such that the length LP2 of the second stepped portion 229a is equal to or less than the plate thickness TH2 of the second coil portion 32. Therefore, the lower surface of the second intermediate flange portion 232 also comes into contact with (closely contacts) the upper surface of the second coil portion 32, and the weight of the first coil portion 31 is transmitted to the second coil portion 32 via the second intermediate flange portion 232.

That is, at least at the time of assembly, a force corresponding to the own weight of the first coil portion 31 is applied to the second coil portion 32, and is tightly sandwiched between the second intermediate flange portion 232 and the second end flange portion 220. In addition to the weight of the first coil part 31, the weights of the first bobbin 21, the intermediate bobbin 23, and the intermediate coil part 33 are transmitted to the second coil part 32 through the second intermediate flange 232.

As described above, in the present embodiment, since the lower surface of the second intermediate flange portion 232 is in close contact with the upper surface of the second coil portion 31, the distance (shortest distance) between the second coil portion 32 and the intermediate coil portion 33 is equal to the thickness of the second intermediate flange portion 232 that separates them.

In the present embodiment, a gap G2 is formed by the length LE2 of the engaging convex portion 227, the length LP2 of the second intermediate step portion 229a, and the length LC1b of the second intermediate notch portion 237b, and the lower surface of the second intermediate flange portion 232 is in close contact with the upper surface of the second coil portion 32.

In the present embodiment, when the engaging convex portion 227 is engaged with the second intermediate notch portion 237b, the inner peripheral side surface of the intermediate tube portion 236 and the outer peripheral side surface of the engaging convex portion 227 face each other, and the outer peripheral side surface of the engaging convex portion 227 abuts against the second end side of the inner peripheral side surface of the intermediate tube portion 236. Therefore, the outer peripheral side surface of the engaging projection 227 functions as a positioning surface, and the intermediate tube portion 236 can be prevented from being displaced in the radial direction. Further, a slight gap may be formed between the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the engaging convex portion 227 in manufacturing.

As shown in fig. 5B, the frame leg portions 26 are integrally formed at both ends of the second end flange portion 220 in the X-axis direction, respectively. Each of the frame legs 26 is formed to protrude downward in the Z-axis direction from both ends of the second end flange portion 220 in the X-axis direction. As shown in fig. 5C, each frame leg 26 houses a respective pedestal 70. In the example shown in fig. 5C, the height of each of the pedestals 70 in the Z-axis direction is set to a height at which the bottom surface of each of the pedestals 70 protrudes downward in the Z-axis direction from each of the frame legs 26 when each of the pedestals 70 is accommodated in each of the frame legs 26. However, the height of each pedestal 70 in the Z-axis direction is not limited thereto, and may be adjusted as appropriate.

The transformer 10 according to the present embodiment is manufactured by assembling the respective members shown in fig. 2. An example of a method for manufacturing the transformer 10 will be described below with reference to fig. 2 and the like. In manufacturing the transformer 10, the bobbin 20 is first prepared.

The frame 20 in the present embodiment is configured by being divided into three parts, i.e., a first frame 21, an intermediate frame 23, and a second frame 22, and by integrally combining these

frames

21, 22, and 23. An intermediate coil 37 shown in fig. 6B is wound around the outer periphery of the intermediate bobbin 23 by α -winding, thereby forming an intermediate coil portion 33. The intermediate coil part 33 is preferably formed before the first bobbin 21, the intermediate bobbin 23, and the second bobbin 22 are assembled, but may be formed after the assembly.

As shown in fig. 5E, when the first coil portion 31 and the second coil portion 32 are assembled to the bobbin 20, they are preferably assembled simultaneously with the

respective bobbins

21, 22, and 23.

That is, the first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231 of the intermediate frame 23, the first engagement convex portion 217 of the first cylindrical portion 216 is engaged with the first intermediate notch portion 237a of the intermediate cylindrical portion 236, and the first cylindrical portion 216 is combined with the first end of the intermediate cylindrical portion 216.

At the same time or before and after this, the second coil part 32 is disposed on the upper surface of the second end flange part 220 of the second frame 22, the second engaging convex part 227 of the second tube part 226 is engaged with the second middle notch part 237b of the middle tube part 236, and the second end of the middle tube part 236 is combined with the second tube part 226.

As described above, the first frame 21, the second frame 22, and the intermediate frame 23 are integrally combined to form the frame 20, and the

frames

21, 22, and 23 are fixed by an adhesive or the like.

Next, the lead portions 37a and 37B are drawn upward from the middle coil portion 33 shown in fig. 6B toward the winding axis, and as shown in fig. 5F, the lead portions 37a and 37B are locked to the first locking portions 252 and drawn in a direction away from the bobbin 20.

Further, as shown in fig. 6B, plate-shaped rising portions 384a, 384B and terminal portions 381a, 381B are formed on the bus bar 38 constituting the first coil portion 31. Further, plate-shaped rising

portions

394a and 394b and

terminal portions

391a and 391b are formed on bus bar 39 constituting second coil portion 32. In addition, the heights of the plate-like rising

portions

384a, 384b, 394a, 394b in the Z-axis direction are adjusted so that the

terminal portions

381a, 381b and the

terminal portions

391a, 391b overlap and are connected in the Z-axis direction.

Preferably, these plate-like rising

portions

384a, 384b, 394a, 394b and

terminal portions

381a, 381b, 391a, 391b are formed in advance on the bus bars 38 and 39, respectively. In this case, as shown in fig. 5D, it is preferable that the intermediate winding wire 37 be wound around the intermediate bobbin 23 before the first bobbin 21, the second bobbin 22, and the intermediate bobbin 23 are integrally combined together with the bus bars 38 and 39. After the first bobbin 21, the second bobbin 22, and the intermediate bobbin 23 are integrally combined together with the bus bars 38 and 39, the winding of the intermediate winding wire 37 is difficult due to the plate-shaped rising

portions

394a and 394 b.

As shown in fig. 2, after the bobbin 20 is formed, the covers 50 are attached to both sides of the bobbin 20 in the Y-axis direction, and then the

magnetic cores

40a and 40b are attached from the up-down direction in the Z-axis direction. That is, the front ends of the

center legs

46a, 46b and the front ends of the

side legs

48a, 48b of the

magnetic cores

40a, 40b are joined to each other.

Next, the base 70 shown in fig. 5D is housed inside the frame leg 26. Further, the base 70 may be attached to the frame leg 26 in advance. Thereafter, bottom plate 91 shown in fig. 2 is bonded to the bottom opening of case 90, the above-described assembly is housed in case 90 whose upper portion is open, and the interior of case 90 is filled with a heat dissipating resin. Through the steps described above, the transformer 10 according to the present embodiment can be manufactured.

As shown in fig. 5B, the bobbin 20 in the present embodiment is configured by integrally combining a first bobbin 21, an intermediate bobbin 23, and a second bobbin 22. Further, the second tube portion 226 is combined with the second end (lower end in the Z-axis direction) of the intermediate tube portion 236, instead of accommodating the intermediate frame 23 inside the second frame 22. As a result, as shown in fig. 5E, the second intermediate flange portion 232 is in close contact with the surface of the second coil portion 32 opposite to the surface in close contact with the second end flange portion 220.

As shown in fig. 4, in order for the intermediate coil portion 33 to be wound around the intermediate bobbin 23 so as to be in contact with the second intermediate flange portion 232, the intermediate coil portion 33 wound around the intermediate bobbin 23 and the second coil portion 32 disposed on the second bobbin 22 are disposed apart by a distance corresponding to the thickness of the second intermediate flange portion 232. When the intermediate frame 23 is molded, the thickness of the second intermediate flange portion 232 can be relatively accurately controlled and the molding can be performed.

Further, when the second bobbin 22 is disposed so as to be positioned on the lower side in the gravity direction (Z-axis direction) and the intermediate bobbin 23 and the first bobbin 21 are combined therewith, the first coil portion 31 is disposed above the first intermediate flange portion 231, and the lower surface of the first coil portion 31 is brought into close contact with the upper surface of the first intermediate flange portion 231 by the weight of the first coil portion 31. The intermediate coil portion 33 is wound around the intermediate bobbin 23 so as to be in contact with (preferably in close contact with) the lower surface of the first intermediate flange 231.

Therefore, the intermediate coil portion 33 wound around the intermediate bobbin 23 and the first coil portion 31 disposed at the first bobbin 21 can be disposed apart by a distance corresponding to the thickness of the first intermediate flange portion 231. When the intermediate frame 23 is molded, the thickness of the first intermediate flange 231 can be relatively accurately controlled and the molding can be performed.

After the first bobbin 21, the intermediate bobbin 23, and the second bobbin 22 are combined in this way, if these bobbins are fixed by a fixing method such as an adhesive, the distances in the reel direction of the first coil portion 31, the intermediate coil portion 33, and the second coil portion 32 are maintained constant in accordance with the thickness of the

flange portions

231, 232, respectively. Therefore, coupling between these

coil portions

31, 33, and 32 can be easily improved, and a transformer 10, which is a coil device having stable leakage characteristics, can be realized.

In addition, in the present embodiment, since it is not necessary to perform insert molding or the like, the height of the bobbin 20 in the reel direction can be reduced. Further, the intermediate frame 23 is not housed inside the second frame 22, but the second tube portion 226 is combined with the second end (lower end in the Z-axis direction) of the intermediate tube portion 236, so that the size of the second frame 22 in the radial direction can be reduced. The first bobbin 21 is also the same as the second bobbin 22.

In the present embodiment, as shown in fig. 4, the first coil portion 31 and the second coil portion 32 are formed of the plate-like bus bars 38 and 39 of the conductor, and a large current can be made to flow through the first coil portion 31 and the second coil portion 32.

In the present embodiment, as shown in fig. 5E, a second positioning portion 229 that abuts against the inner circumferential side surface of the second coil portion 32 is formed at the intersection between the inner surface (upper surface in the Z-axis direction) of the second end flange portion 220 and the outer circumferential surface of the second tube portion 226. With such a configuration, the inner circumferential side surface of the second coil part 32 abuts against the positioning part 229, and the second coil part 32 can be prevented from being displaced in the radial direction.

The positioning portion 229 is formed on the outer peripheral side surface of the stepped portion 229a, and the second intermediate flange portion 232 abuts against the stepped surface (the Z-axis direction upper surface) of the stepped portion 229 a. The Z-axis length LP2 of the stepped portion 229a is equal to or less than the plate thickness TH2 of the second coil portion 32. With such a configuration, the second intermediate flange portion 232 is reliably brought into close contact with the surface of the bus bar 39 constituting the second coil portion 32.

A second intermediate cutout portion 237b cut out to a predetermined depth is formed on the second end (lower end in the Z-axis direction) side of the inner peripheral side surface of the intermediate tube portion 236, a second engaging convex portion 227 engaged with the second intermediate cutout portion 237b is formed on the first end (upper end in the Z-axis direction) side of the second tube portion 226, and the engaging convex portion 227 is engaged with the intermediate cutout portion 237b such that a gap G2 is formed between the Z-axis direction front end surface F2 of the second engaging convex portion 227 and the bottom surface F3b of the second intermediate cutout portion 237 b. With this configuration, the lower surface of the second intermediate flange 232 is reliably brought into close contact with the upper surface of the bus bar 39 of the second coil part 32.

Further, the engaging convex portion 227 is engaged with the intermediate notch portion 237b so that the inner peripheral side surface of the intermediate tube portion 236 and the outer peripheral side surface of the engaging convex portion 227 face each other. With this configuration, the outer peripheral side surface of the engaging projection 227 functions as a positioning surface, and the intermediate tube 236 can be prevented from being displaced in the radial direction.

The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

For example, as shown in fig. 6C, the second terminal portion 381b of the bus bar 38 may be connected to the first terminal portion 391a of the bus bar 39, and the bus bars 38 and 39 may be connected to each other in a predetermined winding direction. In this case, as shown in fig. 7(b), the first coil portion 31 and the second coil portion 32, which are respectively constituted by the bus bars 38 and 39 on the secondary side, are connected in series.

In fig. 5E, the formation of the second positioning portions 229 may be omitted. Either one of the first positioning portion 219 and the intermediate positioning portion 239 may be omitted. In this case, for example, the function of the intermediate positioning portion 239 can be supplemented by setting the length of the first stepped portion 219A of the first positioning portion 219 in the Z-axis direction to LP1+ LP 3. Alternatively, the length of the intermediate step portion 239a of the intermediate positioning portion 239 in the Z-axis direction may be LP1+ LP3, and in this case, the function of the first positioning portion 219 may be substantially supplemented.

The relationship between the primary coil and the secondary coil may be reversed. That is, the bus bars 38 and 39 may constitute a primary coil, and the intermediate winding 37 may constitute a secondary coil.

Claims

1. A coil device is characterized in that,

comprising:

a framework;

a first coil portion formed of a plate-like conductor;

a second coil portion located at a position different from the first coil portion, formed of a plate-like conductor, and formed separately from the first coil portion; and

the skeleton is provided with:

an intermediate bobbin having an intermediate cylinder portion around which the intermediate coil portion is wound, the intermediate cylinder portion having a first intermediate flange portion and a second intermediate flange portion formed at a first end and a second end thereof in an axial direction, respectively;

a first frame having a first tube section combined with the first end, a first end flange section formed in the first tube section; and

the intermediate coil portion is wound around the intermediate tube portion so as to be in contact with the first intermediate flange portion and the second intermediate flange portion,

the first tube section is combined with a first end of the intermediate tube section so that the first coil section abuts the first intermediate flange section by the weight of the first coil section,

the second tube portion is combined with a second end of the intermediate tube portion so that the second intermediate flange portion abuts on a surface of the second coil portion opposite to the second end flange portion by the weight of the second coil portion.

2. The coil device according to claim 1,

the second coil part has a C-shaped plate shape,

a positioning portion that abuts against an inner peripheral side surface of the second coil portion is formed at an intersection portion between an inner surface of the second end flange portion and an outer peripheral surface of the second cylindrical portion.

3. The coil device according to claim 2,

the positioning part is formed on the outer peripheral side surface of the stepped part,

the second intermediate flange portion abuts against a step surface of the step portion,

the axial length of the step portion is equal to or less than the thickness of the second coil portion.

4. A coil device according to any one of claims 1 to 3,

an intermediate cut-out portion cut out to a predetermined depth is formed on a second end side of the inner peripheral side surface of the intermediate tube portion,

an engaging convex portion that engages with the intermediate cutout portion is formed on a first end side of the second tube portion,

the engaging convex portion is engaged with the intermediate notch portion so that a gap is formed between a front end surface of the engaging convex portion and a bottom surface of the intermediate notch portion.

5. The coil device according to claim 4,

the engaging convex portion is engaged with the intermediate notch portion such that an inner peripheral side surface of the intermediate cylinder portion and an outer peripheral side surface of the engaging convex portion face each other.

6. The coil device according to claim 1 or 2,

the first tube portion is combined with a first end of the intermediate tube portion so that a space in which the first coil portion can be arranged is formed between the first end flange portion and the first intermediate flange portion.

7. The coil device according to claim 6,

the first tube portion is combined with a first end of the intermediate tube portion so that the first end flange portion abuts against a surface of the first intermediate flange portion opposite to the first coil portion.

8. The coil device according to claim 1 or 2,