CN112786289A

CN112786289A - Coil device

Info

Publication number: CN112786289A
Application number: CN202011187298.3A
Authority: CN
Inventors: 堀川俊之; 岩仓正明; 熊谷胜; 佐佐木胜一
Original assignee: TDK Corp
Current assignee: TDK Corp
Priority date: 2019-11-05
Filing date: 2020-10-30
Publication date: 2021-05-11
Also published as: JP7347129B2; JP2021077679A

Abstract

The invention provides a coil device with good insulation between terminals and easy space saving. A coil device (10) is provided with: a bobbin (20) on which a first conductive wire (37) constituting the first coil part (35) and a second conductive wire (38) constituting the second coil part (36) are wound; a terminal base (80) to which a pair of first lead portions (37a, 37b) of the first lead wire (37) and a pair of second lead portions (38a, 38b) of the second lead wire (38) are drawn out. The terminal block (80) is formed by insert molding the fixing portions (64 alpha, 64 beta) for fixing the terminals (60 a-60 d). Each of the terminals (60 a-60 d) has: an external connection portion (69) protruding from the terminal block (80) in the X-axis direction; lead wire connection portions (68 alpha, 68 beta) are integrally formed to protrude from the terminal block (80) along the X axis and to be connected to the external connection portion (69) with lead portions (37a, 37b, 38a, 38b) interposed therebetween.

Description

Coil device

Technical Field

The present invention relates to a coil device suitable for use as, for example, a transformer.

Background

Patent document 1 discloses a coil device having a terminal block having a pair of lead portions from which lead wires are drawn out. However, the conventional coil device has the following problems: it is difficult to arrange a plurality of terminals close to each other in an insulated state, and it is difficult to save space in order to secure insulation.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2015-65431

Disclosure of Invention

Problems to be solved by the invention

The present invention has been made in view of such circumstances, and an object thereof is to provide a coil device which is excellent in insulation between terminals and which can easily save space.

Means for solving the problems

In order to achieve the above object, the present invention provides a coil device including: a spool on which the wire is wound; a conductive terminal connected to a lead portion of the lead wire; and an insulating terminal block to which the terminal is attached, wherein the terminal includes: a fixing portion fixed to the terminal base; an external connection portion formed integrally with the fixing portion at a front end position protruding from the terminal block along a first axis; and a wire connecting portion that protrudes from the terminal block at a position between the fixing portion and the external connecting portion along the first axis, is integrally molded with the external connecting portion, and is connected to the external connecting portion with the lead portion interposed therebetween.

In the coil device of the present invention, the fixing portion and the external connection portion of the terminal are arranged along the first axis, and the lead wire connection portion is formed therebetween. Therefore, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent, and the space can be saved. In addition, it contributes to miniaturization of the coil device.

Preferably, the fixing portion and the external connection portion are integrally connected to each other at a connection portion exposed from the terminal block, and the wire connection portion is integrally formed at the connection portion. With this configuration, even when a plurality of terminals are arranged in the terminal block, the insulation between the terminals is excellent, and space can be saved. In addition, it contributes to miniaturization of the coil device.

Preferably, the fixing portion and the connecting portion are formed continuously as a part of the base plate, and the lead connecting portion is formed by bending and folding back from a side edge of the connecting portion so as to be able to sandwich the lead portion.

More preferably, the external connection portion includes an insertion piece formed by bending at a predetermined angle from the connection portion.

With such a configuration, the terminal can be easily formed by press working or the like using a conductive plate material such as a metal plate. Further, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent, and the space can be saved. In addition, it contributes to miniaturization of the coil device.

Preferably, the insertion piece has an insertion edge portion that is insertable into the external substrate along a third axis parallel to a winding axis of the lead. With such a configuration, the connection of the terminal to the external substrate is extremely easy.

The coil device of the present invention may further include a cover member having a contact portion that can come into contact with a reverse insertion edge portion of the insertion piece on a side opposite to the insertion edge portion. With this configuration, the cover member receives a reaction force when the insertion piece is inserted into the receiving-side terminal of the external circuit, and the connection of the terminal to the external board is facilitated. In addition, excessive force is not applied to the terminal.

A notch may be formed at a bent intersection of the distal end portion of the coupling portion and the insertion piece. With this configuration, the insertion sheet can be effectively prevented from being strained or deformed, and the insertion sheet can be easily inserted into the receiving-side terminal of the external substrate.

The outer connecting portion and the wire connecting portion may be offset from each other on a second axis intersecting the first axis. With such a configuration, the lead portion of the lead wire and the lead wire connection portion can be easily connected by welding or fusion bonding.

The terminal block may be configured separately from the bobbin, and may be attached to a terminal block connection portion of the bobbin. With this configuration, when the specification of the terminal block is changed, the terminal block attached to the bobbin may be replaced with a terminal block corresponding to the specification, and it is not necessary to newly manufacture the entire bobbin from the beginning. Therefore, it is possible to flexibly cope with the specification change of the terminal block, and it is possible to provide a coil device having a high degree of freedom in design.

In addition, the bobbin and the terminal block may be separately molded, and materials suitable for each may be used for molding. For example, by forming the bobbin with a material having high thermal conductivity, a coil device having excellent thermal conductivity can be obtained. Further, by including a filler in the material constituting the bobbin, the bobbin having excellent strength can be obtained, and the strength of the coil device can be improved. Further, by molding the terminal block using a material having excellent moldability, dimensional accuracy can be improved even for a terminal block having a complicated shape, and it is possible to contribute to downsizing of the coil device.

Further, when the bobbin is molded, it is not necessary to use a mold in consideration of the specification of the terminal block, and a mold corresponding to the specification of the bobbin can be used. Therefore, the mold can be made simpler in structure and easier to manufacture than when the bobbin with the terminal block integrated therein is molded.

Further, the terminal block may be attached to the terminal block connecting portion of the bobbin from a direction substantially perpendicular to the winding axis of the bobbin. In this case, the height position of the terminal provided in the terminal holder with respect to the bobbin is easily positioned with high accuracy, and the positioning of the coil device to the external terminal connected to the terminal is easily performed.

Preferably, the terminal block connecting portion is formed with a bobbin groove for the lead portion to pass through, and the lead portion is drawn out through the bobbin groove between the terminal block and the terminal block connecting portion.

With this configuration, the insulation between the plurality of lead portions can be improved.

Preferably, the terminal block is provided with a guide groove for guiding the lead portion passing through the bobbin groove to the lead wire connection portion. With this configuration, the lead portion is easily guided to the lead wire connecting portion, and the lead portion is easily connected.

The terminal block connecting portion may have an engaging piece that engages with an engaging groove formed in the terminal block. By fitting the engaging piece into the engaging groove, the operation of joining the terminal block and the bobbin is facilitated, and the positioning of the terminal block to the bobbin is facilitated. In addition, the terminal block and the terminal block connecting portion can be firmly connected.

A support body may be attached to the terminal block or the terminal block connection portion, and the support body may hold and insulate the connection portion of the terminal from below. With such a structure, the terminal projecting from the terminal block in a long length can be supported stably.

Preferably, the fixing portion of the terminal is fixed to the terminal holder by insert molding. With this configuration, even when a plurality of terminals are arranged in the terminal block, the insulation between the terminals is excellent, and space saving is facilitated.

Drawings

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

Fig. 2A is an exploded perspective view of the coil device shown in fig. 1.

Fig. 2B is an enlarged perspective view of the terminal metal member shown in fig. 2A.

Fig. 3 is a perspective view of the bobbin with the terminal block shown in fig. 2A.

Fig. 4A is an exploded perspective view of the bobbin, the terminal block, and the support body shown in fig. 2A.

Fig. 4B is an exploded perspective view of the spool and insulating adapter shown in fig. 4A.

Fig. 4C is a perspective view of the bobbin shown in fig. 4B viewed from another angle.

FIG. 5 is an enlarged perspective view of the terminal block of the terminal fitting shown in FIG. 2A.

Fig. 6 is a perspective view of only the terminal block shown in fig. 5 viewed from another angle.

Fig. 7 is a perspective view of the first coil portion and the second coil portion of the coil device shown in fig. 1.

Detailed Description

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

The transformer 10 shown in fig. 1 as an example of the coil device of the present embodiment can be used for, for example, an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), an in-Vehicle charger for a commuter Vehicle (Vehicle), a power supply circuit for household or industrial Electric equipment, a power supply circuit for computer equipment, and the like. As shown in fig. 2A, the transformer 10 includes: bobbin 20, magnetic cores (split cores) 40a and 40b, and terminal block 80.

In the drawings, the X axis, the Y axis, and the Z axis are perpendicular to each other, and in the present embodiment, the X axis corresponds to the longitudinal direction of the bobbin 20, and the Y axis substantially coincides with the direction of the dividing line that divides the pair of divided

cores

42a, 42a or the pair of divided

cores

42b, 42 b. The direction of the parting line may also be along the X-axis. The Z-axis corresponds to the height (thickness) direction 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.

As shown in fig. 2A, the bobbin 20 has a bobbin main body 24 and a terminal block connection portion 22 formed on an upper portion of one end of the bobbin main body 24 in the X-axis direction. The bobbin 20 is made of plastic such as PPS, PET, PBT, or LCP, for example, but may be made of other insulating material. The bobbin 20 is preferably made of a material having heat resistance. These insulating members may be filled with a filler such as glass in order to improve strength and thermal conductivity.

As shown in fig. 2A, in the present embodiment, the

magnetic cores

40a, 40b may be separated into two divided

cores

42A, 42A and 42b, 42b each having the same shape. In the present embodiment, the

split cores

42a, 42b, and 42b are all the same shape, and have a cross-sectional E-shape in the Z-Y cross section, thereby constituting a so-called E-shaped core. The other pair of

split cores

42b, 42b arranged at the lower portion in the Z-axis direction also have an E-shaped cross section in the Z-Y cross section, and constitute a so-called E-shaped core.

Each of the split cores 42a disposed on the upper side in the Z-axis direction includes: a base portion 44a extending in the Y-axis direction; and a pair of middle leg portions 46a and side leg portions 48a projecting in the Z-axis direction from both ends of the base portion 44a in the Y-axis direction. Each of the split cores 42b disposed on the lower side in the Z-axis direction includes: a base portion 44b extending in the Y-axis direction; and a pair of leg portions 46b and a side leg portion 48b projecting in the Z-axis direction from both ends of the base portion 44b in the Y-axis direction.

The outer surfaces of the

base portions

44a and 44b are in contact with the inner surfaces of the terminal block protruding portions formed on the inner surfaces of the terminal block 80 connected to the upper portion of the one end of the bobbin body 24 (the center side in the X-axis direction of the bobbin 20) and the protruding pieces 29 formed on the upper portion of the other end of the bobbin body 24, thereby preventing the

magnetic cores

40a and 40b from being displaced in the X-axis direction or the Y-axis direction.

The pair of leg portions 46a is inserted into the core leg through hole 26 of the bobbin 20 from above in the Z-axis direction. Similarly, the pair of center leg portions 46b are inserted into the core leg through hole 26 of the bobbin 20 from below in the Z-axis direction, and the distal ends thereof are in contact with the distal ends of the center leg portions 46a or face each other with a predetermined gap in the through hole 26.

The separation convex portion 27 (see fig. 2A and 2B) is formed along the Z-axis direction at a position facing the X-axis direction on the inner peripheral surface of the winding tube portion 28 constituting the through hole 26. The separation protrusion 27 is interposed between the

middle leg portions

42a, 42a and between the middle leg portions 42b, and the

middle leg portions

42a, 42a or the

middle leg portions

42b, 42b are formed so as to face each other with a predetermined gap in the through hole 26 without contacting each other. The predetermined gap can be adjusted by the thickness of the separation projection 27 in the Y-axis direction.

The

intermediate leg portions

42a, 42a or the

intermediate leg portions

42b, 42b are formed in an elliptic cylindrical shape that is long in the X-axis direction so as to conform to the shape of the inner peripheral surface of the through hole 26 in a combined state, but the shape thereof is not particularly limited and may vary depending on the shape of the through hole 26. The

side legs

48a and 48b have an inner concave curved surface shape corresponding to the outer peripheral surface shape of the cover main body 52 of the cover 50, and the outer surfaces thereof have planes parallel to the X-Z plane. In the present embodiment, the material of each of the

split cores

42a and 42b is not particularly limited, but may be a soft magnetic material such as metal or ferrite.

The cover body 52 of the cover 50 has a shape covering the outer periphery of the bobbin body 24. Locking pieces 54 bent in a substantially vertical direction from the cover body 52 to the bobbin body 24 are integrally formed at both ends of the cover body 52 in the Z-axis direction.

The pair of locking pieces 54 formed on both sides of the cover main body 52 in the Z-axis direction have locking protruding pieces 540. A hole 540a is formed in a substantially central portion of the locking projection 540.

The locking projection 540 is fixed to the step width portion 250 of the step portion 25 shown in fig. 4A. More specifically, when the locking projection 540 is fixed to the step width portion 250, the projection 250a formed on the step width portion 250 is fitted into the hole 540a of the locking projection 540. Thus, the pair of locking pieces 54 are attached so as to sandwich the upper and lower surfaces of the bobbin body 24 in the Z-axis direction, and are disposed on the step portion 25 formed on the upper surface of the bobbin body 24.

As shown in fig. 2A and 2B, 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. In the example shown in fig. 1, the side leg guide pieces 56 abut against the outer surfaces of the

base portions

44a, 44b on the outer sides in the X axis direction, but may abut against the outer surfaces of the

side leg portions

48a, 48b on the outer sides in the X axis direction. 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.

One of the side leg guide pieces 56 that is closer to the terminal block 80 in the X-axis direction is formed larger than the other side leg guide piece 56, and is disposed in the vicinity of one of the first lead portions 37a of the first lead wires 37 shown in fig. 7 when the cover 50 is attached to the bobbin 20 as shown in fig. 1. Therefore, the one side leg guide piece 56 close to the terminal block 80 functions to guide the one first lead portion 37a of the first lead wire 37 upward in the Z axis while securing the insulation distance (the spatial distance and the creeping distance) between the one first lead portion 37a and the

cores

40a and 40 b. The cover 50 is made of an insulating member such as plastic similar to the bobbin 20.

The first conductive wire 37 constituting the first coil portion 35 and the second conductive wire 38 constituting the second coil portion 36 shown in fig. 7 are wound around the bobbin main body 24.

As shown in fig. 3, 4A, and 4B, end

partition wall flanges

31 and 32 are integrally formed on both ends of the winding tube portion 28 of the bobbin 20 in the Z-axis direction so as to extend outward in the radial direction substantially in parallel with the X-Y plane. In the winding cylindrical portion 28 located between the end

partition wall flanges

31 and 32 in the Z-axis direction, the first coil portion 35 and the second coil portion 36 shown in fig. 7 are arranged at different positions in the Z-axis direction (the direction of the winding axis). A first lead wire 37 constituting one of the primary coil and the secondary coil is wound around the first coil portion 35, and a second lead wire 38 constituting the other of the primary coil and the secondary coil is wound around the second coil portion 36.

In the present embodiment, an insulating partition flange 30 substantially parallel to the X-Y plane is formed on the outer periphery of the winding tube 28 (see fig. 3) located between the first coil portion 35 and the second coil portion 36. A winding partition flange 33 (see fig. 3) for separating the winding portions of the first conductive wire 37 adjacent to each other along the winding axis (Z axis) from each other by each division region is formed in the first coil portion 35 shown in fig. 7.

In the present embodiment, similarly to the first coil portion 35, the second coil portion 36 shown in fig. 7 is also formed with winding partition wall flanges 34 (see fig. 3) for separating the winding portions of the second conductive wire 38 adjacent to each other along the winding axis (Z axis) into sections. As shown in fig. 4C, at least one

coupling groove

33a, 34a that couples the adjacent regions S1, S2 to each other or S1a, S2a to each other is formed at each of the winding

partition wall flanges

33 and 34, respectively.

As shown in fig. 4C, the

coupling grooves

33a, 34a are formed on the side of the winding

partition wall flanges

33, 34 opposite to the side in the X-axis direction on which the terminal block coupling portion 22 is disposed along the X-axis. These

connection grooves

33a and 34a are formed at a part of the

partition wall flanges

33 and 34 in the circumferential direction to a depth reaching the outer circumferential wall of the winding cylindrical portion 28.

As shown in fig. 4C, the first conductive wire 37 shown in fig. 7 is wound in the regions S1, S2 partitioned in the Z-axis direction by the

partition wall flanges

30, 33, 31, and the wound portions of the conductive wire can be separated from each other for each of the regions S1, S2. In the present embodiment, the width of the region along the Z axis in each of the regions S1 and S2 is set to a width that allows only one lead wire 37 to enter. However, in the present embodiment, the region width may be set to a width that allows two or more wires 37 to enter. In the present embodiment, the widths of the regions are preferably all the same, but may be slightly different.

In the second coil portion 36 shown in fig. 7, similarly to the first coil portion 35, the second conductive wire 38 shown in fig. 7 is wound in the regions S1a, S2a partitioned in the Z-axis direction by the

partition wall flanges

30, 34, 32 shown in fig. 4C, and the wound portions of the conductive wire can be separated from each other for each of the regions S1a, S2 a. In the present embodiment, the width of the region along the Z axis in each of the regions S1a and S2a is set to a width that allows only one lead wire 38 to enter. The width of the region may be made equal to the wire diameter of the lead 38.

The radial width of the partition wall flanges 30 to 34 shown in fig. 4C is set to a height at which one (1 or more layers) or more of the

conductive wires

37 or 38 can be inserted, but in the present embodiment, it is preferably set to a radial width at which 2 to 10 layers of the conductive wires can be wound. The radial widths of the partition wall flanges 30 to 34 are preferably all the same, but may be different.

As shown in fig. 4A, a terminal block 80 that is configured separately from the bobbin 20 is attached to the terminal block connection portion 22. The

first lead portions

37a and 37b of the first lead wire 37 and the

second lead portions

38a and 38b of the second lead wire 38 shown in fig. 7 are drawn out and fixed to the terminal block 80. The Y-axis width and the X-axis width of the terminal block connecting portion 22 are determined by the Y-axis width and the X-axis width of the bottom surface of the terminal block 80.

As shown in fig. 4A, a terminal block connecting portion 22 is provided on the front side of the bobbin 20 in the X-axis direction, and a projecting piece 29 is formed on the bobbin main body 24 on the side opposite to the terminal block connecting portion 22 in the X-axis direction. The projecting piece 29 has a surface substantially parallel to the YZ plane, and projects upward in the Z axis from the upper surface of the bobbin main body 24. The protruding piece restricts the movement of the magnetic core 40a shown in fig. 1 in the X-axis direction.

The terminal block connecting portion 22 integrally formed with the bobbin 20 includes: a base portion 22a extending in the Y axis direction, and an insulating wall 22b rising upward in the Z axis direction substantially perpendicular to the base portion 22 a. The insulating wall 22b is formed parallel to the Z-Y plane, and ensures insulation between the terminals (e.g., terminal metal fittings) 60a to 60d and the magnetic core 40a shown in fig. 2A. In addition, as shown in fig. 4A, the base portion 22a is formed parallel to the X-Y plane for mounting the terminal block 80.

In the base portion 22a, in order to guide the

lead portions

37a, 37b, 38a, and 38b of the

lead wires

37 and 38 shown in fig. 7 to the terminals 60a to 60d of the terminal block 80, as shown in fig. 4A, 4 bobbin-side notches (bobbin grooves) 23a to 23d are formed so as to be recessed in the X-axis direction intermittently along the Y-axis (intermittently in the Y-axis direction). Further, engaging pieces 22c having a smaller wall thickness in the Z-axis direction than the center are formed at both ends of the base portion 22a along the Y-axis. Each engaging piece 22c is inserted into and fitted into engaging

grooves

84b, 86b formed on the back side of the terminal block 80 shown in fig. 6 and below both ends in the Y-axis direction.

As shown in fig. 5, terminal block 80 includes a rod member 82 extending in the Y-axis direction, and end blocks 84 and 86 are respectively integrated with both ends of rod member 82 in the Y-axis direction. As shown in fig. 6, the engagement hooks 84a, 86a are formed at the lower portions of the end blocks 84, 86 in the Z-axis direction together with the

engagement grooves

84b, 86 b.

As shown in fig. 6, on the back surface of the lever member 82 in the X axis direction, guide notches 82a to 82d are formed so as to be intermittently recessed in the X axis direction along the Y axis direction. These guide notches 82a to 82d are formed so as to correspond to the positions of the bobbin-side notches (bobbin grooves) 23a to 23d shown in fig. 4A in the Y-axis direction, and face these notches. These guide notches 82a to 82d also communicate with upper surface side notches formed in the upper surface of the terminal block 80 in the Z-axis direction.

As shown in fig. 4B, slit grooves 23B1 parallel to a plane including the X axis and the Y axis are formed only in the bobbin groove 23B along the concave edge of the bobbin groove 23B. The flat upper surface portion 72 of the insulating adapter 70 is inserted into the slit groove 23b1, and the insulating adapter 70 is attached to the terminal block connecting portion 22. The insulating adapter 70 is attached to the terminal block connecting portion 22 of the bobbin 20 after the second wire 38 shown in fig. 7 is attached to the bobbin 20 shown in fig. 4B.

The guide notch 82B of the terminal block 80 shown in fig. 4A communicates with the guide groove 76 of the insulating adapter 70 shown in fig. 4B attached to the bobbin-side notch 23B in a state where the terminal block 80 is connected to the terminal block connecting portion 22, and passes through the first lead portion 37B at this portion.

As shown in fig. 4B, the insulating adapter 70 has: a curved plate-shaped side surface portion 71, a plate-shaped upper surface portion 72 formed on the upper portion of the side surface portion 71 in the Z-axis direction, and a plate-shaped bottom surface portion 73 formed on the lower portion of the side surface portion 71 in the Z-axis direction. A guide groove 76 extending in the Z-axis direction is formed in a part of the curved outer surface of the side surface portion 71. The other lead portion 37b of the first wire 37 shown in fig. 7 passes through the guide groove 76 in the Z-axis direction.

The insulating adapter 70 shown in fig. 4B is attached to the bobbin 20 before the terminal block 80 shown in fig. 4A is connected to the terminal block connecting portion 22. Before the insulating adapter 70 shown in fig. 4B is mounted on the terminal block connecting portion 22, the

lead portions

37a, 38B, and 38a shown in fig. 4A are inserted through the bobbin-

side notches

23a, 23c, and 23d, respectively. Only the lead portion 37b does not pass through the bobbin-side notch 23 b. After the insulating adapter 70 shown in fig. 4B is attached to the terminal block connecting portion 22, only the lead portion 37B passes through the guide groove 76 of the insulating adapter 70.

Then, by attaching the terminal block 80 to the terminal block connection portion 22, the

lead portions

37a, 38b, and 38a shown in fig. 4A are sandwiched between the

notches

23a, 23c, and 23d and the

notches

82a, 82c, and 82d, respectively. The lead portion 37b is sandwiched between the guide groove 76 of the insulating adapter 70 attached to the notch 23b and the notch 82b of the terminal block 80.

As shown in fig. 5, terminal attachment portions 83a to 83d are formed at intervals along the Y-axis direction in the vicinity of the Z-axis direction of the adjacent notches 82a to 82d formed in the lever member 82. The terminals 60a to 60d are attached to the terminal attachment portions 83a to 83 d. The

terminals

60a and 60b have the same shape, respectively, and the

terminals

60c and 60d have the same shape, respectively.

As shown in fig. 2B, each of the terminals 60a and 60B has a flat plate-like base plate 62 α. A fixing portion 64 α is formed as a part of the base plate 62 α at one end of the base plate 62 α in the X-axis direction, and a connecting portion 66 α is formed as a part of the base plate 62 α at the other end of the base plate 62 α. A lead connecting portion 68 α, which is a lead connecting portion formed by folding and projecting in the Y-axis direction, is formed at one side edge of the connecting portion 66 α close to the fixing portion 64 α, and is bent integrally with the connecting portion 66 α.

Further, an external connection portion 69, which is an insertion piece, is formed integrally with the other side edge of the connection portion 66 α apart from the fixing portion 64 α, offset from the lead connection portion 68 α in the X-axis direction, and bent at a predetermined angle from the plane of the connection portion 66 α. The external connection portion 69 as the insertion piece is also flat plate-shaped like the base plate 62 α, and in the present embodiment, is formed by bending so as to be substantially perpendicular to each other. The flat external connection portion 69 extends further in the X axis direction than the end portion of the base plate 62 α in the X axis direction, and has an insertion edge portion 69a at a lower end edge portion of the external connection portion 69 in the Z axis direction, which is insertable into a receiving-side terminal of an external circuit board not shown.

A reverse insertion edge 69b is preferably formed on the opposite side of the flat plate-shaped external connection portion 69 from the insertion edge 69a in the Z-axis direction, substantially in parallel with the insertion edge 63 a. The reverse insertion edge 69b can abut against a protruding (or recessed) abutment portion 102 formed on the rear surface of the terminal cover 100 as the insulating cover member shown in fig. 1.

As shown in fig. 2B, a notch 67 is formed at a bent intersection between the front end portion of the coupling portion 66 α in the X-axis direction and the reverse insertion edge portion 69B of the external connection portion 69 as an insertion piece. By providing the notch 67, the bending work of the external connection portion 69 as the insertion piece with respect to the base plate 62 α is facilitated, the angle thereof is easily maintained at a predetermined angle, and the insertion piece is not easily bent or the like and is easily inserted into the receiving-side metal fitting of the circuit board not shown.

As shown in fig. 3, the lead portions 37a and 37B are crimped to the lead connecting portion 68 α shown in fig. 2B, and connected by thermocompression bonding or the like. Alternatively, the connection may be made by other connection means than riveting. As another connection method, there can be exemplified: brazing, welding, resistance welding, ultrasonic welding, laser welding, rivet fixing, thermocompression bonding, thermofusion bonding, and the like.

As shown in fig. 2B, each of the

terminals

60c and 60d has a flat plate-like base plate 62 β. A fixing portion 64 β is formed as a part of the base plate 62 β at one end of the base plate 62 β in the X-axis direction, and a connecting portion 66 β is formed as a part of the base plate 62 β at the other end of the base plate 62 β. A lead connection portion 68 β, which is a lead connection portion formed by folding and projecting in the Y axis direction, is formed by folding integrally with the connection portion 66 β at one side edge of the connection portion 66 β close to the fixing portion 64 β.

An external connection portion 69, which is an insertion piece, is formed integrally with the lead connection portion 68 β so as to be displaced in the X-axis direction and bent at a predetermined angle from the plane of the connection portion 66 β, at the same side edge of the connection portion 66 β that is distant from the fixing portion 64 β. The external connection portion 69 as an insertion piece is also flat in shape like the base plate 62 β, and in the present embodiment, is formed by bending so as to be substantially perpendicular to each other. The flat plate-shaped external connection portion 69 extends further in the X-axis direction than the end portion of the base plate 62 β in the X-axis direction, and has an insertion edge portion 69a at a lower edge portion of the external connection portion 69 in the Z-axis direction, which is capable of being inserted into a receiving-side terminal of an external circuit board not shown.

As shown in fig. 2B, a notch 67 is formed at a bent intersection between the front end portion of the coupling portion 66 β in the X-axis direction and the reverse insertion edge portion 69B of the external connection portion 69 as an insertion piece. By providing the notch 67, the bending work of the external connection portion 69 as the insertion piece with respect to the base plate 62 β is facilitated, the angle thereof is easily maintained at a predetermined angle, and the insertion piece is not easily bent or the like, and is easily inserted into the receiving-side metal fitting of the circuit board not shown.

As shown in fig. 3, the lead portions 38B and 38a are connected to the lead connecting portion 68 β shown in fig. 2B by the same connection method as the lead connecting portion 68 α. In the present embodiment, the external connection portions 69 of the

terminals

60a and 60b and the external connection portions 69 of the

terminals

60c and 60d have the same size and shape, but may be different from each other.

In the present embodiment, the lead connecting portions 68 α of the

terminals

60a and 60b and the lead connecting portions 68 β of the

terminals

60c and 60d have slightly different shapes. This is because the

lead portions

37a, 37b, 38a, 38b connected to these lead connecting portions 68 α and 68 β are different in thickness and the like.

In the present embodiment, the base plates 62 α of the

terminals

60a and 60b and the base plates 62 β of the

terminals

60c and 60d have slightly different shapes. The bending direction of the external connection piece 69 with respect to the base plate 62 α of the

terminals

60a, 60b and the bending direction of the external connection piece 69 with respect to the base plate 62 β of the

terminals

60c, 60d are opposite to each other. This is because, for example, as shown in fig. 3, the intervals in the Y axis direction of the external connection portions 69 of the terminals 60a to 60d are substantially uniform, and insulation and the like between the

lead portions

37a, 37b, 38a, and 38b connected to the terminals 60a to 60d are easily ensured.

As shown in fig. 4A and 7, in the present embodiment, one first lead portion 37a of the pair of

first lead portions

37a and 37b of the first lead wire 37 is drawn out to the vicinity of the first end portion in the Y-axis direction on the side of the terminal block 80, and stands up toward the first end terminal 60 a.

The first lead portion 37a is drawn out from a region S1 shown in fig. 3 (a position on the outer periphery of the winding tube portion 28 farthest from the terminal block 80 along the Z axis) to the vicinity of the first end portion in the Y axis direction on the side of the terminal block 80. One end of the first lead portion 37a is connected to the first end-side terminal 60 a.

In addition, the other first lead portion 37b of the pair of

first lead portions

37a and 37b stands up toward the first inner terminal 60b located between the first end-side terminal 60a and the second end-side terminal 60d of the terminal block 80. The first lead portion 37b rises from the region S2 shown in fig. 3 in a direction parallel to the winding axis in the vicinity of the center of the first lead portion 37a in the Y-axis direction of the terminal block 80. One end of the first lead portion 37b is connected to the first inner terminal 60 b.

One second lead portion 38a of the pair of

second lead portions

38a and 38b of the second lead wire 38 is drawn out to the vicinity of the second end portion in the Y-axis direction on the other side of the terminal block 80, and is connected to the second end-side terminal 60d in the vicinity of the second end portion. The second lead portion 38a stands from a region S1a shown in fig. 3.

In addition, the other second lead portion 38b of the pair of

second lead portions

38a and 38b stands up toward the second inner terminal 60c located between the first inner terminal 60b and the second end terminal 60d of the terminal block 80. The second lead portion 38b is drawn out from a region S2a (a position closest to the terminal block 80 along the Z axis in the outer periphery of the winding tube portion 28) shown in fig. 3, and is connected to the second inner terminal 60 c.

In the present embodiment, the second lead wire 38 shown in fig. 7 is subjected to α -winding in the winding tube portion 28 shown in fig. 4C by the coupling groove 34a formed on the other X-axis side of the winding partition flange 34 shown in fig. 4C. Further, the first lead wire 37 shown in fig. 7 is subjected to α -winding in the winding cylindrical portion 28 by the coupling groove 33a formed on the other X-axis side of the winding partition wall flange 33 shown in fig. 4C. The winding method of the first and second

conductive wires

37 and 38 is not limited to the α -winding, and may be a normal winding.

In manufacturing the transformer 10, first, the following are prepared: the bobbin 20, the first lead wire 37, the second lead wire 38, the cover 50, the magnetic cores (split cores) 40a and 40b, and the terminal block 80 formed separately from the bobbin 20. Insert molding (or bonding) in the terminal block 80: a first end terminal 60a, a first inner terminal 60b, a second end terminal 60c, and a second inner terminal 60 d.

In the present embodiment, the fixing portions 64 α and 64 β of the terminals 60a to 60d shown in fig. 2B are embedded and fixed in the resin constituting the terminal block 80 by insert molding at the positions of the

terminal mounting portions

83a, 83B, 83c, and 83d of the terminal block 80 shown in fig. 5, respectively. The terminals 60a to 60d are formed so that portions other than the fixing portions 64 α and 64 β are exposed from the outer surface of the terminal block 80 in the X axis direction and protrude in the X axis direction.

Next, the first coil portion 35 and the second coil portion 36 shown in fig. 7 are formed on the outer periphery of the bobbin 20 shown in fig. 4B. The first coil portion 35 and the second coil portion 36 shown in fig. 7 may be formed by using an automatic winding machine. The

wires

37 and 38 may be formed of a single wire or a stranded wire, and preferably, they are formed of an insulation-coated wire. The second conductor 38 may be the same as the first conductor 37, but may also be different. In the present embodiment, the outer diameter of the first lead 37 is larger than the outer diameter of the second lead 38, and for example, it is preferable that the outer diameter is larger than the outer diameter of the first lead 38

As shown in fig. 4A, one first lead portion 37a passes through the bobbin-side notch 23a, and the

second lead portions

38a, 38b pass through the bobbin-

side notches

23d, 23c, respectively. The other lead portion 37B does not pass through the bobbin-side notch 23B directly, and after the insulating adapter 70 shown in fig. 4B is attached to the notch 23B, it passes through the guide groove 76 of the adapter 70 along the Z-axis.

Next, the engaging pieces 22c shown in fig. 4A are inserted into the engaging

grooves

84b, 86b formed by the engaging hooks 84A, 86a of the terminal block 80 shown in fig. 6 from the X-axis direction, and the terminal block 80 is mounted on the terminal block connecting portion 22. An adhesive may also be used as needed.

Next, as shown in fig. 3, the lead portions 37a to 37d are connected to the lead connecting portions 68 α and 68 β of the terminals 60a to 60d, respectively. Then, a pair of covers 50 shown in fig. 2A is attached to the spool 20. Then, the center leg portions 46a of the pair of

split cores

42a, 42a separated in the X-axis direction and the center leg portions 46b of the pair of

split cores

42b, 42b separated in the X-axis direction are inserted from both sides of the core leg through holes 26 in the X-axis direction.

Next, as necessary, the upper portion in the Z-axis direction of the terminal block 80 attached to the bobbin 20 is covered with a terminal cover (cover member) 100 shown in fig. 1. If necessary, the lower portion of the transformer 10 (the portion below the terminals 60a to 60d) is housed in a case (not shown) having an open upper end, and a casting resin is injected into the case. The casting resin includes soft silicone resin, urethane resin, epoxy resin, and the like after injection, and the longitudinal elastic modulus of the casting resin is preferably 0.1 to 100 MPa.

The heat sink 110 shown in fig. 1 has a function of transferring heat transferred from the inside of the transformer 10 to the upper portion of the magnetic core 40a to, for example, a potting resin, and is made of aluminum, copper, or the like having excellent heat transfer properties. The heat sink 110 is not necessarily provided, but is preferably provided from the viewpoint of improving heat dissipation.

In the transformer 10 of the present embodiment, the terminal block 80 is configured separately from the bobbin 20 and is attached to the bobbin 20. Therefore, when the specification of the terminal block 80 is changed, the terminal block 80 attached to the bobbin 20 may be replaced with a terminal block corresponding to the specification, and it is not necessary to newly manufacture the entire bobbin 20 from the beginning. Therefore, it is possible to flexibly cope with the specification change of the terminal block 80, and it is possible to provide the transformer 10 having a high degree of freedom in design.

The bobbin 20 and the terminal block 80 can be molded separately, and can be molded from materials suitable for each. For example, by forming the bobbin 20 from a material having high thermal conductivity, the transformer 10 having excellent thermal conductivity can be obtained. Further, by including a filler in the material constituting the bobbin 20, the bobbin 20 having excellent strength can be obtained, and the strength of the transformer 10 can be improved. Further, by molding the terminal block 80 with a material having excellent moldability, even in the case of the terminal block 80 having a complicated shape, it is possible to improve the dimensional accuracy, and to contribute to downsizing of the transformer 10.

In addition, when the bobbin 20 is molded, it is not necessary to use a mold in consideration of the specification of the terminal block 80, and a mold corresponding to the specification of the bobbin 20 can be used. Therefore, compared to the case of molding the bobbin with the terminal holder 80 integrated, the structure of the mold can be simplified, and the manufacturing can be facilitated.

In the present embodiment, the bobbin 20 has a terminal block connecting portion 22 connectable to the terminal block 80. With this structure, the terminal block 80 can be easily attached to the bobbin 20 via the terminal block connecting portion 22.

In the present embodiment, as shown in fig. 4A, the terminal block connecting portion 22 is formed only on the X-axis side of the bobbin 20, and therefore, the terminal block 80 shown in fig. 6 is also disposed only on the X-axis side of the bobbin 20. Therefore, the size can be reduced compared to a conventional transformer in which the terminal blocks 80 are formed on both sides of the X axis of the bobbin 20.

In the present embodiment, the terminal block 80 is disposed on the X-axis side of the bobbin 20 and has a long shape in the Y-axis direction. That is, both ends of the terminal block 80 in the Y-axis direction protrude toward a dead space (corner portion of a rectangular space into which an ellipse is inscribed) located outside the elliptical bobbin main body 24. In this way, by disposing the terminal block 80 so as to effectively utilize the dead space of the transformer 10, it is possible to contribute to downsizing of the transformer 10.

In the present embodiment, the terminal block 80 can be attached to the terminal block connection portion 22 of the bobbin 20 from a direction (X-axis direction) substantially perpendicular to the winding axis (Z-axis) of the bobbin 20. Therefore, the height positions of the lead connecting portions 68 α and the external connecting portions 69 of the terminals 60a to 60d provided on the terminal block 80 are easily positioned with respect to the bobbin 20 with high accuracy, and the

lead portions

37a, 37b, 38a, and 38b are easily connected. In addition, the terminals 60a to 60d of the transformer 10 can be easily positioned with respect to the external terminals connected to the external connection portion 69.

Further, as shown in fig. 3, since the lead connecting portions 68 α and 68 β of the terminals 60a to 60d horizontally protrude from the terminal block 80 to the outside of the X axis at substantially equal intervals in the Y axis direction, the terminals 60a to 60d and the

lead portions

37a, 37b, 38a, and 38b can be easily connected. Further, the external connection portions 69 of the terminals 60a to 60d are disposed to protrude further outward in the X axis direction at substantially equal intervals in the Y axis direction than the lead connection portions 68 α and 68 β.

In the present embodiment, one first lead portion 37a of the first lead wire 37 shown in fig. 7 is drawn out to the vicinity of one end portion in the Y-axis direction of the terminal block 80 shown in fig. 3, and one second lead portion 38a of the second lead wire 38 is drawn out to the vicinity of the other end portion of the terminal block 80. The other first lead portion 37B of the first lead wire 37 and the other second lead portion 38B of the second lead wire 38 are drawn out from the center of the terminal block 80 in the Y-axis direction so as to be located on opposite sides to each other, and are insulated from each other by the insulating adapter 70 shown in fig. 4B. That is, in the present embodiment, the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are disposed outside and inside the insulating adapter 70 and insulated.

With this configuration, the first lead portion 37a can be raised up toward the terminal 60a near the one end of the terminal block 80 in a state where the first lead portion 37a is drawn out to a sufficient distance near the one end of the terminal block 80, and the first lead portion 37a is less likely to be loosened or bent when raised up. Therefore, the first lead portion 37a can rise up compactly toward the terminal 60a near the one end of the terminal block 80, and the transformer 10 can be downsized. The same effect can be obtained also in the second lead portion 38 a.

Further, by insulating the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 with the insulating adapter 70, it is possible to prevent occurrence of short-circuit failure between the

lead portions

37b, 38 b. In addition, a sufficient space distance can be secured between the first lead portion 37b and the second lead portion 38b, and insulation between the first lead portion 37b and the second lead portion 38b can be improved.

The other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are disposed outside and inside the insulating adapter 70 (side surface portion 71). By adopting such a structure, the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are isolated by the insulating adapter 70, and insulation between the first lead portion 37b and the second lead portion 38b can be effectively achieved.

In the present embodiment, the first lead portion 37a is locked to the extended flange portion 331, so that the first lead portion 37a can be effectively prevented from being displaced and can be easily raised when the first lead portion 37a is raised to the terminal block connecting portion 22.

In the present embodiment, the first and second

lead wires

37 and 38 are wound in the winding cylindrical portion 28 by α -winding. With this configuration, the transformer 10 can be made thin, and the leakage characteristics of the transformer 10 can be easily adjusted.

In the transformer 10 of the present embodiment, as shown in fig. 2B, the fixing portions 64 α and 64 β of the terminals 60a to 60d and the external connection portion 69 are arranged along the X axis, and the lead wire connection portions 68 α and 68 β are formed therebetween. Therefore, as shown in fig. 3, even when a plurality of terminals 60a to 60d are arranged in the terminal block 80, the insulation between the adjacent terminals 60a to 60d is excellent, and space saving can be achieved. In addition, the miniaturization of the transformer 10 shown in fig. 1 is also facilitated.

In the present embodiment, the external connection portion 69 of each of the terminals 60a to 60d has an insertion piece formed by bending at a predetermined angle (90 degrees) from the connection portions 66 α and 66 β that are part of the base plates 62 α and 62 β. The external connection portion 69 as each insertion piece has an insertion edge portion 69a that can be inserted into an external circuit board (not shown) along the Z axis.

With such a configuration, the terminals 60a to 60d can be easily formed by press working or the like using a conductive plate material such as a metal plate. Even if a plurality of terminals 60a to 60d are arranged on the terminal block 80, the insulation between the terminals 60a to 60d is excellent and the space can be saved. In addition, miniaturization of the transformer 10 is also facilitated.

Further, the terminals 60a to 60d are extremely easily connected to an external circuit board.

As shown in fig. 1, the transformer 10 has the terminal cover 100 in which the contact portion 102 that can contact the opposite insertion edge portion 69b of the insertion piece on the opposite side to the insertion edge portion 69a is formed, and the terminal cover 100 receives a reaction force when each external connection portion 69 as the insertion piece is inserted into a receiving side terminal (not shown) of the external circuit board, whereby the terminals 60a to 60d can be more easily connected to the external circuit board. And excessive force is not applied to the terminals 60a to 60 d.

As shown in fig. 2B, in each of the terminals 60a to 60d, notches 67 are formed at bent intersection portions between the distal end portions of the coupling portions 66 α and 66 β and the external connection portion 69. With such a configuration, the external connection portion 69 as an insertion piece can be effectively prevented from being strained or deformed, and the external connection portion 69 can be easily inserted into the receiving-side terminal of the external circuit board.

In the present embodiment, the external connection portion 69 and the lead connection portion 68 α or 68 β may be shifted from each other along the Y axis in each of the terminals 60a to 60 d. With such a configuration, the

lead portion

37a, 37b, 38a, or 38b of the lead wire can be easily connected to the lead connection portion 68 α or 68 β by soldering, welding, or the like.

In the present embodiment, as shown in fig. 4A, the terminal block connecting portion 22 is formed with bobbin-side notches 23a to 23d through which the

lead portions

37a, 37b, 38a, and 38b pass, respectively. The

lead portions

37a, 37b, 38a, and 38b are drawn out through the bobbin-side notches 23a to 23d between the terminal block 80 and the terminal block connecting portion 22, respectively. With this configuration, the insulation between the

lead portions

37a, 37b, 38a, and 38b can be improved.

The terminal block 80 is formed with guide grooves 82a to 82d for guiding the

lead portions

37a, 37b, 38a, and 38b passing through the spool-side notches 23a to 23d to the lead connecting portions 68 α and 68 β. With this configuration, the

lead portions

37a, 37b, 38a, and 38b are easily guided to the lead connecting portions 68 α and 68 β, respectively, and the

lead portions

37a, 37b, 38a, and 38b are easily connected.

In the present embodiment, as shown in fig. 4A, the terminal block connecting portion 22 has engaging pieces 22c on both sides in the Y axis direction, which engage with engaging

grooves

84b and 86b formed in the terminal block 80 shown in fig. 6. By fitting the engaging pieces 22c into the engaging

grooves

84b, 86b, the operation of joining the terminal block 80 and the bobbin 20 is facilitated, and the positioning of the terminal block 80 with respect to the bobbin 20 is facilitated. In addition, the terminal block 80 can be firmly connected to the terminal block connection portion 22.

In the present embodiment, as shown in fig. 4A, an insulating support body 90 that holds and insulates the connection portions 62 α and 62 β and the lead connection portions 68 α and 68 β of the terminals 90a to 90d from below in the Z-axis direction may be attached to the terminal block 80 or the terminal block connection portion 22. With such a configuration, the terminals 60a to 60d projecting from the terminal block 80 in a long direction can be supported stably.

Further, the mounting recess 92 may be formed along the Y axis on the bottom surface of the support body 90 in the Z axis direction. The upper end of the case for receiving, for example, casting resin is attached to the attachment recess 92. In this case, the external terminals 69 of the terminals 60a to 60d held by the terminal block 80 and the support body 90 protrude outward in the X-axis direction from the upper end of the housing in the upper portion of the housing.

In the present embodiment, as shown in fig. 5, the fixing portions 64 α and 64 β of the terminals 60a to 60d shown in fig. 2B are fixed to the terminal mounting portions 83a to 83d of the terminal block 80 by insert molding. With such a configuration, even when the plurality of terminals 60a to 60d are arranged in the terminal block 80, the insulation between the adjacent terminals 60a to 60d is excellent, and space saving is facilitated.

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

In the above embodiments, the application example of the present invention to the transformer has been described, but the present invention can be applied not only to the transformer but also to other coil devices.

In the above embodiments, the magnetic core is configured by a combination of the E core and the E core as the split cores, but the magnetic core may be assembled by a combination of the E core and the I core.

Further, the first coil portion 35 and the second coil portion 36 may be arranged along the winding axis of the bobbin 20 in the reverse direction to the above-described embodiment, and the

first lead portions

37a and 37b and the

second lead portions

38a and 38b may be arranged in the reverse direction.

In the above embodiment, the X axis as the first axis, the Y axis as the second axis, and the Z axis as the third axis are substantially perpendicular to each other, but the angle of these axes is not limited to 90 degrees, and may be other angles.

In the present embodiment, the terminal fittings 60a to 60d may be fixed to the terminal block 80 by a method other than insert molding. In the above-described embodiment, the terminal block 80 is formed separately from the bobbin 20, and the terminal block 80 is attached to the terminal block attachment portion 22 of the bobbin 20 from the X-axis direction, but the terminal block 80 may be attached to the terminal block attachment portion 22 of the bobbin 20 from the upper portion in the Z-axis direction. Alternatively, the terminal block 20 may be integrally formed with the bobbin 20.

In the present embodiment, the 4 terminals 60a to 60d are attached to the single terminal block 80, but for example, the pair of

terminals

60a and 60b may be attached to one terminal block, the other pair of

terminals

60c and 60d may be attached to the other terminal block, and these terminal blocks may be attached to both ends of the bobbin 20 in the X-axis direction. The inner structure of the bobbin may be a double-tube structure, and the second coil portion 36 may be arranged so as to be insulated from the outside of the first coil portion 35, or may be arranged in reverse thereto, for example.

Description of the reference numerals

10 … … transformer

20 … … spool

22 … … terminal base connecting part

22a … … base body portion

22b … … insulating wall

22c … … engaging piece

22d … … clamping groove

23 a-23 d … … side notch of bobbin (bobbin groove)

23b1 … … slit groove

24 … … spool body

25 … … step part

250 … … step width part

250a … … projection

26 … … through hole for core pin

27 … … separation convex part

28 … … winding drum part

29 … … protruding piece

30 … … insulating partition flange

31. 32 … … end bulkhead flange

33. 34 … … wrap around partition flange

331 … … extended flange part

33a, 34a … … connecting groove

35 … … first coil part

36 … … second coil part

37 … … first conductor

37a, 37b … … first lead part

38 … … second conductor

38a, 38b … … second lead portion

40a, 40b … … magnetic core

42a, 42b … … split core

44a, 44b … … base body portion

46a, 46b … … middle foot

48a, 48b … … side foot

50 … … cover

52 … … cover body

54 … … stop sheet

540 … … stop projection

540a … … hole

56 … … side foot guiding sheet

60 a-60 d … … terminal

62 alpha, 62 beta … … base plate

64 alpha, 64 beta … … fixing part

66 alpha, 66 beta … … connecting part

67 … … notch

68 α, 68 β … … lead connection (wire connection)

69 … … external connection

69a … … insertion edge

69b … … reverse insertion edge

70 … … insulating adapter

71 … … side surface part

72 … … upper surface part

73 … … bottom surface

76 … … guide groove

80 … … terminal base

82 … … Bar Member

82a, 82b, 82c, 82d … … guide notches (guide grooves)

83 a-83 d … … terminal mounting part

84. 86 … … end block

84a, 86a … … snap hook

84b, 86b … … clamping groove

88 … … snap tab

90 … … support

92 … … mounting recess

100 … … terminal cover (cover component)

102 … … abutment

110 … … heat sink.

Claims

1. A coil device having: a spool on which the wire is wound; a terminal connected to a lead portion of the lead wire; and a terminal block to which the terminal is mounted,

the coil device is characterized in that:

the terminal has:

a fixing part fixed to the terminal block;

an external connection portion formed integrally with the fixing portion at a front end position protruding from the terminal block along a first axis; and

and a wire connecting portion that protrudes from the terminal block at a position between the fixing portion and the external connecting portion along the first axis, is integrally molded with the external connecting portion, and is connected to the external connecting portion with the lead portion interposed therebetween.

2. The coil device according to claim 1, wherein:

the fixing portion and the external connection portion are integrally connected to each other at a connection portion exposed from the terminal block, and the wire connection portion is integrally formed at the connection portion.

3. The coil device according to claim 2, wherein:

the fixing portion and the coupling portion are continuously formed as a part of the base plate,

the lead wire connecting portion is formed by bending back from a side edge of the connecting portion so as to sandwich the lead portion.

4. A coil device according to claim 2 or 3, wherein:

the external connection portion has an insertion piece formed by bending at a predetermined angle from the connection portion.

5. The coil device according to claim 4, wherein:

the insertion piece has an insertion edge portion that is insertable into an external substrate along a third axis parallel to a winding axis of the lead.

6. The coil device according to claim 5, wherein:

the cover member is provided with a contact portion capable of contacting with a reverse insertion edge portion of the insertion piece on the opposite side of the insertion edge portion.

7. The coil device according to claim 4, wherein:

a notch is formed at a bent intersection of the distal end of the coupling portion and the insertion piece.

8. A coil device according to any one of claims 1 to 3, wherein:

the outer connecting portion and the wire connecting portion are offset from each other on a second axis intersecting the first axis.

9. A coil device according to any one of claims 1 to 3, wherein:

the terminal block is formed separately from the bobbin and is attached to a terminal block connecting portion of the bobbin.

10. The coil device according to claim 9, wherein:

a bobbin groove for passing the lead part is formed in the terminal block connecting part,

the lead part is drawn out through the bobbin groove between the terminal block and the terminal block connection part.

11. The coil device according to claim 10, wherein:

the terminal block is provided with a guide groove for guiding the lead portion passing through the bobbin groove to the lead wire connection portion.

12. The coil device according to claim 9, wherein:

the terminal block connecting portion has an engaging piece that engages with an engaging groove formed in the terminal block.

13. The coil device according to claim 9, wherein:

a support member is attached to the terminal block or the terminal block connection portion, and the support member holds and insulates the connection portion of the terminal from below.

14. A coil device according to any one of claims 1 to 3, wherein: the fixing portion of the terminal is fixed to the terminal block by insert molding.