JP2015097250A - Coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil device that is suitable for downsizing and improves reliability and manufacture efficiency.SOLUTION: A coil device 10 is changed from low pressure to high pressure in a winding shaft direction. The coil device 10 includes: a bobbin 20 including a rod-like core, a hollow cylinder accommodating the core and a plurality of flanges protruding from the hollow cylinder in an outer diameter direction; a secondary coil 40 which is wound separately around a plurality of secondary coil grooves which are formed on an outer peripheral surface of the hollow cylinder while being held between the flanges; a primary coil 30 which is wound separately around a plurality of primary coil grooves which are formed on the outer peripheral surface of the hollow cylinder while being held between the flanges between the secondary coil grooves; a low-pressure side terminal 50 provided in any flange and connected to the primary coil and the secondary coil; a primary high-pressure side terminal 60 which is provided in any flange and to which a primary high-pressure side end portion of the primary coil is connected; and a secondary high-pressure side terminal 70 which is provided in any flange and to which a secondary high-pressure side end portion of the secondary coil is connected.

Description

  The present invention relates to a high voltage generating coil device for lighting a discharge lamp used in, for example, an automotive headlamp, a liquid crystal projector, or an overhead projector.

  For example, a coil device shown in the following Patent Document 1 is known as a high voltage generating coil device used for, for example, a headlamp for an automobile. In such a coil device, a bobbin around which a secondary winding is wound is placed on a printed circuit board, and then a plurality of primary coil pieces molded into a U shape are placed on the printed board from above the bobbin. Form the winding.

  However, in the coil device according to the prior art, since the primary winding is formed by connecting a plurality of primary coil pieces with printed wiring, there are many joint portions by welding or soldering, and the reliability and manufacturing efficiency of the joint portion. There is a problem from the viewpoint. Moreover, since such a coil apparatus requires a printed circuit board, it also has a problem from the viewpoint of miniaturization.

JP-A-11-307373

  The present invention has been made in view of such a situation, and an object thereof is a high voltage generating coil device that changes from a low voltage to a high voltage along an axial direction, and is suitable for downsizing and has good reliability and manufacturing efficiency. Is to provide a simple coil device.

In order to achieve the above object, a coil device according to the present invention comprises:
A rod-shaped core,
A bobbin having a hollow cylindrical portion that accommodates the core, and a plurality of flanges protruding from the hollow cylindrical portion in the outer diameter direction;
A secondary winding that is sandwiched between the flanges and wound separately into a plurality of secondary winding grooves formed on the outer peripheral surface of the hollow cylindrical portion;
A primary winding wound around the flange portion between the secondary winding groove portions and divided into a plurality of primary winding groove portions formed on the outer peripheral surface of the hollow cylindrical portion;
A low voltage side terminal provided on any one of the flanges and connected to the primary winding and the secondary winding;
A primary high-voltage side terminal provided on any one of the flanges and connected to a primary high-voltage side end of the primary winding;
A secondary high voltage side terminal provided on any one of the flanges and connected to a secondary high voltage side end of the secondary winding.

  In the coil device according to the first aspect of the present invention, the primary winding and the secondary winding are wound around the groove portion for the primary winding and the groove portion for the secondary winding formed on the outer peripheral surface of the bobbin. Since the low voltage side terminal, the primary high voltage side terminal, and the secondary high voltage side terminal are provided, the coil device is configured by one bobbin that does not require a printed circuit board. Therefore, such a coil device is suitable for downsizing, and since the number of joints is small, the reliability is good and the manufacture is easy.

  An area where the secondary winding is not wound may exist at at least one end of the core. With this configuration, it becomes possible to improve the inductance (L value) of the coil device by improving the flow of magnetic flux at the core end, and to reduce the total number of turns in the secondary winding. become. By reducing the number of turns, the direct current resistance can be reduced, and the wire diameter of the wire can also be reduced.

  Compared with the number of winding layers of the secondary winding wound around the groove portion for the secondary winding located in the center portion in the longitudinal direction of the core, the second portion located at the end portion in the longitudinal direction of the core. The number of winding layers of the secondary winding wound around the groove for the secondary winding may be reduced. With this configuration, it is possible to improve the inductance (L value) of the coil device when the total number of turns is the same. Further, by improving the inductance, it is possible to reduce the total number of turns in the secondary winding if the inductance is the same. By reducing the number of turns, the direct current resistance can be reduced, and the wire diameter of the wire can also be reduced.

  Further, for example, the plurality of secondary winding groove portions include a secondary low-pressure side groove portion, and a radial thickness of the hollow cylindrical portion located on the high-pressure side from the secondary low-pressure side groove portion is the secondary low-pressure side groove portion. A thicker secondary high pressure side groove may be included.

  By changing the thickness of the hollow cylinder portion between the high pressure side and the low pressure side, it is possible to suitably ensure the voltage resistance of the coil device while reducing the size.

  For example, the number of layers of the secondary winding wound around the secondary low-voltage side groove may be larger than the number of layers of the secondary winding wound around the secondary high-voltage side groove. .

  By reducing the number of layers of the secondary high-pressure side groove portion where the thickness of the hollow cylindrical portion is large, the maximum outer diameter of the flange portion can be suppressed and the coil device can be downsized.

  Further, for example, the primary winding and the secondary winding may be constituted by a continuous wire from the primary high voltage side end to the secondary high voltage side end.

  By configuring the primary winding and the secondary winding with a continuous wire, the number of electrical joints included in the coil device can be reduced, and the DC resistance can be reduced. Further, since the primary winding and the secondary winding can be formed by a continuous winding process, such a coil device has a high manufacturing efficiency.

  The low-voltage side terminal may have a wire fixing portion fixed by fusing at a boundary portion between the primary winding and the secondary winding of the wire.

  The low-voltage side terminal having a wire fixing portion that is fixed to the boundary portion between the primary winding and the secondary winding by fusing can be easily and reliably attached.

  Further, for example, the secondary high-voltage side terminal may be provided in a first flange portion that protrudes in the outer diameter direction from one end portion of the hollow cylinder portion among the plurality of flange portions.

  By providing the secondary high-voltage side terminal in the first flange portion disposed at one end, it is possible to easily form the secondary windings for the plurality of secondary winding groove portions.

  The plurality of flanges may include a connection flange that connects a part of the pair of flanges sandwiching one of the primary winding grooves, and the low-voltage side terminal includes the connection flange May be provided.

  By providing the low voltage side terminal in the connecting rod part, the space for installing the low voltage side terminal can be suppressed, and the coil device can be miniaturized.

  In addition, for example, at least a part of the plurality of flange portions is formed from the outer peripheral surface of the flange portion toward the inner diameter direction, and a cut portion that allows the secondary winding to pass therethrough, and the outer peripheral surface of the flange portion A primary winding passage formed above and allowing the primary winding to pass therethrough.

  The flange portion has a notch portion and a primary winding passage formed on the outer peripheral surface of the flange portion, thereby further reducing the size of the coil device while ensuring an insulation distance between the secondary winding and the primary winding. It is possible.

FIG. 1 is a perspective view of a coil device according to an embodiment of the present invention. FIG. 2 is a top view of the coil device shown in FIG. FIG. 3 is a side view of the coil device shown in FIG. 4A is a cross-sectional view taken along line IV-IV in FIG. FIG. 4B is a cross-sectional view showing a modification of FIG. 4A. FIG. 5 is an exploded perspective view of the coil device shown in FIG. FIG. 6 is a circuit diagram of the coil device shown in FIG. FIG. 7A is a perspective view of a coil device according to another embodiment of the present invention. FIG. 7B is a perspective view of the coil device shown in FIG. 7A viewed from different angles. FIG. 8 is a top view of the coil device shown in FIG. 7A. FIG. 9 is a side view of the coil device shown in FIG. 7A. FIG. 10 is a cross-sectional perspective view taken along line XX of FIG. 7B. FIG. 11 is an exploded perspective view of the coil device shown in FIG. 7A.

  Hereinafter, the present invention will be described based on embodiments shown in the drawings.

First Embodiment FIG. 1 is a perspective view of a coil device 10 as a transformer according to an embodiment of the present invention, and FIG. 6 is a circuit diagram of the coil device 10. As shown in FIG. 1, in the coil device 10, the primary winding 30 and the secondary winding 40 are formed along the Z-axis direction that is the winding axis direction. The coil device 10 is a coil device that changes from a low voltage to a high voltage along the winding axis direction.

  As shown in FIG. 6, the coil device 10 includes a low-voltage side terminal 50 that is electrically connected to low-voltage side ends of both the primary winding 30 and the secondary winding 40, and a high-voltage side end of the primary winding 30. The primary high-voltage side terminal 60 connected to the part and the secondary high-voltage side terminal 70 connected to the high-voltage side end of the secondary winding 40 are represented by a circuit having three phases (three terminals). The In such a coil device 10, a winding shaft (Z-axis) extends from the Z-axis negative direction end connected to the low-voltage side terminal 50 to the Z-axis positive direction end connected to the secondary high-voltage side terminal 70. ), The voltage of the secondary winding 40 changes from a low voltage to a high voltage, and a high voltage output can be obtained from the secondary high voltage side terminal 70. In the present embodiment, the winding axis direction is the Z-axis direction, and the directions perpendicular to the Z-axis direction and perpendicular to each other are the X-axis direction and the Y-axis direction.

  As shown in FIG. 1, the coil device 10 includes a bobbin 20, a primary winding 30, a secondary winding 40, a low-voltage side terminal 50, a primary high-voltage side terminal 60, and a secondary high-voltage side terminal 70. Have. Moreover, as shown in FIG. 4A which is a cross-sectional view and FIG. 5 which is an exploded perspective view, the coil device 10 includes a rod-shaped core 12 which is accommodated in a hollow cylinder portion 21 of a bobbin 20, and the hollow cylinder A cap 14 for preventing the core 12 from falling out of the hollow cylindrical portion 21 is provided at the opening of the portion 21. In FIG. 5, the primary winding 30 and the secondary winding 40 are not shown.

  The core 12 has an elliptical or oval cross section, and is disposed such that the longitudinal direction of the core 12 is the winding axis direction (Z-axis direction). Further, the long axis direction in the cross-sectional shape of the core 12 coincides with the Y axis direction, and the short axis direction coincides with the X axis direction.

  The core 12 is made of, for example, a magnetic material such as a ferrite magnetic material, a soft magnetic material such as permalloy, or a metal magnetic material formed by metal dusting. When the coil device 10 is used, for example, as a high voltage coil device mainly intended for in-vehicle use, a use environment of −40 to + 130 ° C. (a storage temperature of −40 to + 150 ° C.) is required. In order to maintain the electrical characteristics, a magnetic material having a Curie temperature of 200 ° C. or higher is preferable.

  In the coil device 10, the secondary winding 40 is not directly wound around the core 12, but the secondary winding is provided on the outer peripheral surface of the hollow cylindrical portion 21 that suitably insulates the core 12 and the secondary winding 40. A wire 40 is wound. Therefore, in the coil device 10, not only an insulating material such as Ni—Zn-based ferrite but also Mn—Zn-based ferrite, which is a conductive material having a high magnetic permeability and a high magnetic flux density, is suitably used as the core 12. Can be used.

  The bobbin 20 has a hollow cylindrical portion 21 that houses the core 12 and a plurality of flanges that protrude from the hollow cylindrical portion 21 in the outer diameter direction. The bobbin 20 is made of a material having excellent insulating properties, and is made of, for example, a synthetic resin such as PBT, PET, LCP, or PPS. However, a hydrolysis-resistant resin is often required. Alternatively, the bobbin 20 may be made of ceramic or the like. In order to suitably secure insulation between the core 12 and the primary winding 30 and the secondary winding 40, it is preferable not to form a through hole on the outer peripheral surface of the hollow cylindrical portion 21.

  As shown in FIG. 2 and FIG. 4A, the plurality of flanges included in the bobbin 20 include first flanges that protrude in the outer diameter direction from one end portion (Z-axis negative direction side end portion) of the hollow cylinder portion 21. 23a, the 11th collar part 23k which protrudes in an outer diameter direction from the other edge part (Z-axis positive direction side edge part) of the hollow cylinder part 21, and it arrange | positions between the 1st collar part 23a and the 11th collar part 23k. The second collar part 23b to the tenth collar part 23j are included. The plurality of flanges are arranged from the Z-axis negative direction end of the bobbin 20 toward the Z-axis positive direction end, the first flange 23a, the second flange 23b, the third flange 23c,. The parts 23k are arranged in this order.

  A plurality (seven in this embodiment) of secondary winding grooves are formed on the outer peripheral surface of the hollow cylindrical portion 21. As shown in FIG. 2, the plurality of secondary winding groove portions include a secondary winding groove portion 24a, a second flange portion 23b, and a third flange portion sandwiched between the first flange portion 23a and the second flange portion 23b. Secondary winding groove 24b sandwiched between 23c, secondary winding groove 24c sandwiched between third flange part 23c and fourth flange part 23d, and secondary sandwiched between fifth flange part 23e and sixth flange part 23f A winding groove 24d, a secondary winding groove 24e sandwiched between the seventh flange 23g and the eighth flange 23h, a secondary winding groove 24f sandwiched between the ninth flange 23i and the tenth flange 23j, And a secondary winding groove 24g sandwiched between the tenth flange 23j and the eleventh flange 23k. The first flange portion 23a to the eleventh flange portion 23k sandwich the respective secondary winding groove portions 24a to 24g in the winding axis direction.

  The secondary winding grooves 24a to 24g include secondary winding grooves 24f and 24g as secondary low voltage side grooves located on the low voltage side (Z-axis negative direction side), and secondary high voltage located on the high voltage side. Secondary winding groove portions 24a and 24b as side groove portions are included. As shown in FIG. 4A, the secondary winding groove portions 24a and 24b as the secondary high-voltage side groove portions are the first portions 21a of the hollow cylindrical portion 21 that constitute the groove bottom portions of the secondary winding groove portions 24a and 24b. And the radial thickness D1 of the second portion 21b is the diameter of the sixth portion 21f and the seventh portion 21g of the hollow cylindrical portion 21 constituting the groove bottom portions of the secondary winding groove portions 24a and 24b which are the secondary low-voltage side groove portions. It is larger than the direction thickness D2. Thereby, the insulation of the secondary winding 40 wound around the high voltage side secondary winding grooves 24a and 24b and the core 12 can be suitably secured. On the low pressure side, the volume of the secondary winding groove portions 24f and 24g can be increased by reducing the radial thickness of the hollow cylindrical portion 21, and the coil device 10 can be downsized.

  The third portion 21c and the fourth portion constituting the bottom portions of the secondary winding groove portions 24c to 24e disposed between the secondary winding groove portions 24a and 24b and the secondary winding groove portions 24f and 24g. For the same reason, the radial thickness of 21d and the fifth portion 21e is preferably smaller than the radial thickness D1 of the first portion 21a and the second portion 21b, and the radial direction of the sixth portion 21f and the seventh portion 21g. It is preferable to make it larger than the thickness D2.

  As shown in FIGS. 3 and 4A, on the outer peripheral surface of the hollow cylindrical portion 21, in addition to the secondary winding groove portions 24a to 24g described above, a plurality (three in this embodiment) of primary winding groove portions are provided. Is formed. The plurality of primary winding groove portions include a primary winding groove portion 25a and a secondary winding groove portion 24d sandwiched between the fourth flange portion 23d and the fifth flange portion 23e between the secondary winding groove portions 24c and 24d. 24e between the sixth flange portion 23f and the seventh flange portion 23g and the eighth winding portion 23h and the ninth flange portion 23i between the secondary winding groove portions 24e and 24f. Includes a primary winding groove 25c. The secondary winding groove portions 24c to 24f and the fourth flange portion 23d to the ninth flange portion 23i sandwich the primary winding groove portions 25a to 25c in the winding axis direction, respectively.

  As shown in FIG. 4A, the secondary winding 40 is wound around the outer peripheral surface of the hollow cylinder portion 21 of the bobbin 20 in seven secondary winding groove portions 24 c to 24 f. The number of turns, the number of rows (the number of overlaps in the winding axis direction), and the number of layers (the number of overlaps in the outer diameter direction) of the secondary winding 40 disposed in each of the secondary winding groove portions 24a to 24g are not particularly limited. The number of rows of the secondary windings 40 arranged in the groove portions 24c to 24f for the secondary windings is set to a predetermined value or less (for example, 6 columns or less in the present embodiment), so that the resistance of the wires constituting the secondary winding 40 is improved. This is preferable from the viewpoint of ensuring voltage reliability.

  Of the secondary winding groove portions 24a to 24g, the number of layers of the secondary winding 40 wound around the secondary winding groove portions 24f and 24g which are secondary low-voltage side groove portions (5 in this embodiment) is It is preferable that the number of layers of the secondary winding 40 wound around the secondary winding grooves 24a and 24b, which are secondary high-voltage side grooves, is larger than the number of layers (3 in this embodiment). As described above, since the radial thickness of the central cylindrical portion is small on the low-pressure side, the wire constituting the secondary winding 40 is within a range that does not protrude from the ninth flange portion 23i to the eleventh flange portion 23k in the outer diameter direction. The coil device 10 can be reduced in size by increasing the number of layers of the secondary winding 40.

  As shown in FIG. 2, the second collar part 23b to the tenth collar part 23j have a cut part 26b formed from the outer peripheral surface of the collar parts 23b to 23j toward the inner diameter direction. The secondary winding 40 is routed from one secondary winding groove 24a to 24f to another secondary winding groove 24b to 24g adjacent to the low voltage side by passing through the notch 26b. . Of the second collar part 23b to the tenth collar part 23j, the fourth collar part 23d and the fifth collar part 23e, the sixth collar part 23f and the seventh collar part 23g, and the eighth collar part 23h and the ninth collar part. 23i constitutes a pair of flange portions sandwiching the primary winding groove portion 25c, and connection flange portions 23α and 23β for connecting the pair of flange portions to each other are provided between the flange portions 23d to 23i. ing.

  Here, the primary winding groove portions 25a to 25c are sandwiched between the secondary winding groove portions 24c to 24e and the secondary winding groove portions 24d to 24f adjacent to the low voltage side thereof. For this reason, the primary winding 30 in these primary winding groove portions 25a to 25c and the secondary winding 40 passing through the cut portion 26b intersecting these groove portions 25a to 25c are close to each other. However, the cut portion 26b is formed in the connecting flange portion 23α that connects the adjacent flange portions, so that the primary winding 30 and the secondary winding 40 can cross three-dimensionally. And the insulation of the secondary winding 40 is suitably secured.

  The passage of the secondary winding 40 formed by the notches 26b formed in the flanges 23b, 23c, 23j and the connecting flange 23α is preferably formed obliquely with respect to the winding axis direction. Thus, the secondary winding 40 can be easily formed on the bobbin 20. In the example shown in FIG. 2, all the cut portions 26b are formed in the same direction and oblique to the winding axis direction.

  As shown in FIGS. 3 and 4A, the primary winding 30 is wound around the outer peripheral surface of the hollow cylindrical portion 21 of the bobbin 20 in three primary winding grooves 25a, 25b, and 25c. The number of turns of the primary winding 30 in each primary winding groove 25a to 25c is one, but is not particularly limited.

  As shown in FIG. 2, primary winding passages 27a and 27b through which the primary winding 30 passes are formed on the outer peripheral surfaces of the third flange portion 23c to the ninth flange portion 23i. Adjacent to the primary winding passages 27a and 27b, there are formed protrusions 28a and 28b protruding in the outer diameter direction from the outer peripheral surfaces of the third flange portion 23c to the ninth flange portion 23i, and the protrusion portions 28a and 28b. Prevents the primary winding 30 from deviating from the primary winding passages 27a, 27b.

  As described in detail in the manufacturing method, the primary winding 30 and the secondary winding 40 in the coil device 10 according to this embodiment are connected to the primary high-voltage side terminal 60 from the primary high-voltage side end 30a. It is constituted by a single continuous wire up to the secondary high-voltage side end 40a connected to the side terminal 70. Although it does not specifically limit as a wire which comprises the primary winding 30 and the secondary winding 40, For example, a covered wire like a three-layer insulated wire can be used.

  As shown in FIGS. 1 to 3, the low-voltage side terminal 50 is a connecting rod that connects a part of the pair of flange portions 23 h and 23 i sandwiching the primary winding groove portion 25 c arranged on the lowest voltage side at the outer peripheral portion. Provided in the section 23β. As shown in FIG. 5, the low-voltage side terminal 50 is inserted into a wire fixing portion 50a fixed to the boundary portion BD between the primary winding 30 and the secondary winding 40, and a slit formed in the connecting collar portion 23β. It has the insertion part 50b and the drawer | drawing-out part 50c for connecting to the exterior.

  The terminal 50 composed of the wire fixing portion 50a, the insertion portion 50b, and the lead portion 50c is integrally formed from a conductive plate material such as a metal plate, for example. The same applies to the terminals 60 and 70. Note that the connection flange 23β provided with the low voltage side terminal 50 and the connection flange 23α formed with the cut portion 26b may be formed continuously in the circumferential direction, but intermittently in the circumferential direction. It may be formed.

  The method for fixing the wire fixing portion 50a to the boundary portion BD is not particularly limited. For example, the wire fixing portion 50a can be fixed to the wire by fusing (heat caulking). According to fusing, since the insulation coating can be removed and the connection fixing operation can be performed simultaneously without cutting the wire and without removing the insulation coating of the wire in advance, the terminal fixing process can be simplified. .

  The primary high-voltage side terminal 60 is provided on the third flange 23 c of the bobbin 20. The primary high-voltage side terminal 60 includes a primary-side wire fixing portion 60a that is fixed to the primary high-voltage side end portion 30a of the primary winding 30, an insertion portion 60b that is inserted into a slit formed in the third flange portion 23c, and an external And a lead-out portion 60c for connecting to the. The primary side wire fixing part 60a and the primary high voltage side end part 30a can be joined by fusing or the like, similar to the wire fixing part 50a, but is not particularly limited.

  As shown in FIG. 1, the low-voltage side terminal 50 and the primary high-voltage side terminal 60 are connected to the upper portion of the bobbin (the Y-axis positive direction side portion) where the passage of the secondary winding 40 and the primary winding passage 27a are formed by the cut portion 26b. Thus, it is possible to realize a simple and wasteful wire routing by an automatic winding machine or the like.

  As shown in FIGS. 3 and 5, the secondary high-voltage side terminal 70 is provided in the first flange portion 23 a located at the Z-axis negative direction side end portion of the hollow cylinder portion 21. The secondary high voltage side terminal 70 includes a secondary side wire fixing portion 70a fixed to the secondary high voltage side end portion 40a of the secondary winding 40, and an insertion portion inserted into a slit formed in the first flange portion 23a. 70b and a lead-out portion 70c for connecting to the outside. The first flange portion 23a is formed with a cut portion 26a extending from the outer peripheral surface of the first flange portion 23a toward the inner diameter direction, and the secondary winding 40 is connected to the cut portion of the secondary side wire fixing portion 70a. 26a is passed around to the secondary winding groove 24a.

  Below, an example of the manufacturing method of the coil apparatus 10 is demonstrated using FIGS.

  As shown in FIG. 5, the method for manufacturing the coil device 10 according to the present embodiment includes a step of attaching terminals 50, 60, and 70 to the flange portions 23 a, 23 c, and 23 β of the bobbin 20, respectively. In addition, as shown in FIGS. 1 to 4A, the manufacturing method is performed by winding a wire around the secondary winding groove portions 24a to 24g and the primary winding groove portions 25a to 25c, so that the secondary winding 40 and the primary winding are wound. 30 is formed. Further, in this manufacturing method, as shown in FIGS. 2 and 3, the fixing portions 70a and 60a of the terminals 70 and 60 are respectively provided on the secondary high-voltage side end 40a and the primary high-voltage side end 30a which are both ends of the wire. And fixing the fixing portion 50a of the terminal 50 to the boundary portion BD between the primary winding 30 and the secondary winding 40. Furthermore, as shown in FIG. 5, this manufacturing method includes a step of housing the core 12 inside the hollow cylindrical portion 21 of the bobbin 20.

  In the step of attaching the terminals 50, 60, 70 to the bobbin 20, as shown in FIG. 5, the insertion portions 50b, 60b, 70b of the terminals 50, 60, 70 are inserted into the slits formed in the flange portions 23a, 23c, 23β. Insert. In the terminals 50, 60, and 70 shown in FIG. 5, the fixed portions 50a, 60a, and 70a and the lead-out portions 50c, 60c, and 70c are shown in a bent state. At least a part of these portions (particularly the drawer portion 70c) may not be bent so as not to interfere with the wire work.

  In the step of forming the windings 30 and 40, winding of the wire starts from the secondary winding groove 24a on which the high voltage side of the secondary winding 40 is disposed, and each secondary winding groove starts from the high voltage side toward the low voltage side. A secondary winding 40 is formed by winding a wire around 24a to 24g (see FIG. 4A). After the winding to the secondary winding groove 24g on the low voltage side is completed, the wires are routed to the primary winding groove 25c through the outer peripheral surfaces of the tenth flange 23j and the ninth flange 23i as shown in FIG. . Then, a primary winding 30 is formed by winding a wire around each primary winding groove 25c, 25b, 25a from the low voltage side to the high voltage side.

  In the step of fixing the fixing portions 50a, 60a, 70a of the terminals 50, 60, 70 to the wires, the portions corresponding to the boundary portion BD, the primary high-voltage side end portion 30a, and the secondary high-voltage side end portion 40a of the wire are sandwiched. The fixing is performed by bending the fixing portions 50a, 60a, and 70a while heating. In such a fusing process, the insulating coating of the wire in the portions corresponding to the boundary portion BD, the primary high-voltage side end portion 30a, and the secondary high-voltage side end portion 40a is removed by heating and pressurization. Therefore, conduction between the terminal 50 and the boundary portion BD, conduction between the terminal 60 and the primary high-voltage side end 30a, and conduction between the terminal 70 and the secondary high-voltage side end 40a are ensured. In addition, after the terminal is fixed, the wire is cut on both outer sides of the primary high-voltage side end 30a and the secondary high-voltage side end 40a. After the wire is cut, the lead-out portion 70c of the secondary high-voltage side terminal 70 is bent as necessary.

  In the step of housing the core 12, the coil device 10 shown in FIG. 1 is obtained by inserting the core 12 shown in FIG. 5 into the hollow cylindrical portion 21 of the bobbin 20 and then providing the cap 14 in the opening. In addition, the order of each process can be changed suitably, for example, the process of accommodating the core 12 may be performed before the process of forming the windings 30 and 40.

  The coil device 10 is installed in an installation part such as the inside of the case, and after the terminals 50, 60, 70 are wired, the coil device 10 is embedded in the resin by potting, or is not embedded in the resin and the windings 30, 40 are in the atmosphere. Used in an exposed state.

  The coil device 10 according to the above-described embodiment has good reliability, is suitable for downsizing, and is easy to manufacture. Further, as shown in FIG. 4A, by changing the thickness of the hollow cylindrical portion 21 between the high pressure side and the low pressure side, the voltage resistance of the coil device 10 can be suitably ensured while reducing the size.

  Moreover, since the coil apparatus 10 is comprised by one wire with which the primary winding 30 and the secondary winding 40 continue, direct current | flow resistance can be reduced and manufacture is easy. Further, as shown in FIG. 1, the secondary winding 40 is formed by forming the passage of the secondary winding 40 and the primary winding passages 27a and 27b by the cut portions 26b in the flange portions 23c to 23i on the bobbin upper side. The coil device 10 can be further downsized while ensuring the insulation distance of the primary winding 30.

  In the above-described embodiment, the primary winding 30 and the secondary winding 40 are configured by a single continuous wire. However, the primary winding 30 and the secondary winding 40 are separated from each other. Alternatively, it may be electrically connected via the low-voltage side terminal 50. Moreover, the fixing method of each terminal 50, 60, 70 and the primary winding 30 and the secondary winding 40 is not limited to fusing, and welding and other methods can also be adopted.

Second Embodiment FIG. 4B is a cross-sectional view of a coil device 10a as a transformer according to another embodiment of the present invention. Except for the following, it has the same configuration as the first embodiment and has the same functions and effects. Play. In the present embodiment, members common to the first embodiment are denoted by common member symbols, and description of the common members is omitted.

  In the present embodiment, as shown in FIG. 4B, the secondary winding is not applied to the secondary winding grooves 24a and 24g located at both ends of the core 12 in the Z-axis direction. With this configuration, it is possible to improve the inductance by improving the flow of magnetic flux at both ends of the core 12 in the Z-axis direction.

Third Embodiment FIGS. 7A and 7B are perspective views of a coil device 110 as a transformer according to still another embodiment of the present invention, and have the same configuration as that of the first embodiment except for the following. Have the same effect. In the present embodiment, the members common to the first embodiment are denoted by the same reference numerals in the last two digits, and the description of the common members is partially omitted.

  As shown in FIGS. 7A and 7B, the coil device 110 includes a bobbin 120, a primary winding 130, a secondary winding 140, a low voltage side terminal 150, a primary high voltage side terminal 160, and a secondary high voltage side terminal. 170. Further, as shown in FIGS. 10 and 11, the coil device 110 has a rod-shaped core 112 that is accommodated in the hollow cylindrical portion 121 of the bobbin 120.

  A cap 114 is provided at an opening provided at one end of the hollow cylinder 121 so that the core 112 does not fall out of the hollow cylinder 121. Note that an end wall is formed integrally with the hollow cylinder 121 at the other end of the hollow cylinder 121 so that the core 112 does not fall out. Further, in FIG. 11, the primary winding 30 and the secondary winding 40 are not shown.

  As shown in FIG. 11, the cap 114 has a plate-shaped cap main body 114a, and attachment pieces 114c are integrally formed at both ends in the X-axis direction. An attachment hole 114d is formed at the corner between the attachment piece 114c and the main body 114a. Each mounting hole 114d can be engaged with an engaging convex portion 123jb of a mounting concave portion 123ja formed on an end surface of a flange portion 123j provided at one end portion of the bobbin 120 in the Z-axis direction. Therefore, an adhesive for attaching the cap 114 to the end of the bobbin 120 can be eliminated.

  The core 112 has the same configuration as the core 12 of the first embodiment. Further, in the coil device 110, similarly to the coil device 10, the secondary winding 140 is not directly wound around the core 112, but the hollow cylindrical portion 121 that suitably insulates the core 112 from the secondary winding 140. The secondary winding 140 is wound around the outer peripheral surface of the.

  The bobbin 120 has a hollow cylinder part 121 that houses the core 112 and a plurality of flange parts that protrude from the hollow cylinder part 121 in the outer diameter direction. The bobbin 120 is the same as the bobbin 20 and is made of a material having excellent insulating properties. As shown in FIGS. 8 and 9, the hollow cylindrical portion 121 is formed with a plurality of flange portions 123 a to 123 j protruding in the outer diameter direction in order from one end portion (Z-axis negative direction side end portion). is there.

  As shown in FIGS. 8 and 10, a plurality of flange portions 123 a to 123 j projecting in the outer diameter direction are formed on the outer peripheral surface of the hollow cylinder portion 121, and therefore, between these flange portions 123 a to 123 j. In addition, a groove for winding or passing the wire is formed. In the groove 124a formed between the flange 123a and the flange 123B, neither the primary winding nor the secondary winding is wound, and the wire end 140a of the secondary winding is connected to the flanges 124a and 124b. It only crosses through the cuts 126a, 126b that are formed. A wire serving as the secondary winding 140 on the high voltage side is wound in a plurality of turns in a groove 124b formed between the flange 123b and the flange 123c1.

  Furthermore, neither the wire that becomes the secondary winding 140 nor the wire that becomes the primary winding 130 is wound around the groove portion 125 formed between the flange portion 123c1 and the flange portion 123c2. A wire serving as the secondary winding 140 is wound in a plurality of turns in a groove 124c formed between the flange 123c2 and the flange 123d. A wire serving as the primary winding 130 is wound in only about one turn in a groove 125a formed between the flange 123d and the flange 123e.

  Furthermore, a wire serving as the secondary winding 140 is wound around the groove 124d formed between the flange 123e and the flange 123f by a plurality of turns. In a groove 125b formed between the flange 123f and the flange 123g, a wire serving as the primary winding 130 is wound with only about one turn. A wire serving as the secondary winding 140 is wound in a plurality of turns in a groove portion 124e formed between the flange portion 123g and the flange portion 123h. A wire serving as the primary winding 130 is wound in only about one turn in the groove 125c formed between the flange 123h and the flange 123i. A wire serving as the secondary winding 140 is wound around the groove 124f formed between the flange 123i and the flange 123j by a plurality of turns.

  That is, in this embodiment, five secondary winding groove portions 124b to 124f are formed along the Z-axis direction, and three primary winding groove portions 125a to 125c are formed therebetween. The secondary winding grooves 124b to 124f include a secondary winding groove 124f as a secondary low voltage side groove located on the low voltage side (Z-axis negative direction side) and a secondary high voltage side groove located on the high voltage side. As a secondary winding groove 124b. In the present embodiment, the thickness of the hollow cylinder 121 is constant along the Z-axis direction. Although the thickness of the hollow cylinder part 121 is not specifically limited, It is constant in the range of thickness D2-D1 of the hollow cylinder part 21 shown to FIG. 4A.

  As described above, in this embodiment, a plurality of (three in this embodiment) primary winding groove portions are provided on the outer peripheral surface of the hollow cylindrical portion 121 in addition to the above-described secondary winding groove portions 124a to 124f. 125a to 125c are formed. A secondary winding 140 is wound around the outer peripheral surface of the hollow cylindrical portion 121 in the bobbin 120 in five secondary winding groove portions 124b to 124f. The number of turns, the number of rows (the number of layers in the winding axis direction), and the number of layers (the number of layers in the outer diameter direction) of the secondary winding 140 arranged in each of the secondary winding grooves 124b to 124f are not particularly limited. It is preferable to configure as follows.

  That is, as shown in FIG. 10, the number of layers and the number of turns of the secondary winding 140 arranged in the secondary winding grooves 124b and 124f arranged at both ends in the Z-axis direction are the central part in the Z-axis direction. It is preferable that the number of layers and the number of turns of the secondary winding 140 disposed in each of the secondary winding groove portions 124c to 124e disposed in is smaller. It was confirmed that the inductance as the coil device can be improved by configuring in this way.

  Further, in the present embodiment, among the secondary winding groove portions 124c to 124e disposed in the center portion in the Z-axis direction, the secondary winding disposed in each of the high-voltage side secondary winding groove portions 124c and 124d. It is preferable to increase the number of columns of the wires 140 compared to the number of columns of the secondary winding groove 124e on the relatively low voltage side. The number of layers of the secondary winding 140 arranged in each of the high-voltage side secondary winding groove portions 124c and 124d may be relatively equal to the number of layers of the low-voltage side secondary winding groove portion 124e. .

  In the present embodiment, among the secondary winding groove portions 124c to 124e disposed in the center portion in the Z-axis direction, the secondary winding 140 disposed in each of the secondary winding groove portions 124d and 124e. By increasing the number of turns, the coupling coefficient between the primary winding 130 and the secondary winding 140 can be increased. This is because the secondary winding groove portions 124d and 124e are disposed between the primary winding groove portions 125a to 125c.

  Further, in the present embodiment, as shown in FIG. 10, it is preferable that both the primary winding 30 and the secondary winding 140 are not wound on both ends in the Z-axis direction of the core 112. . The lengths L1 and L2 in the Z-axis direction of these non-winding regions are preferably 1 to 12% (on one side) compared to the total length L0 of the core 112. That is, it is preferable that L1 / L0 is 0.01 to 0.12 or L2 / L0 is 0.01 to 0.12. In addition, the full length of the core 112 is comparable as the full length of the core 12 of 1st Embodiment.

  With this configuration, it becomes possible to improve the inductance (L value) of the coil device 110 by improving the flow of magnetic flux at both ends of the core 112, and to reduce the total number of turns in the secondary winding 140. It becomes possible to do. By reducing the number of turns, it is possible to reduce the direct current resistance, and it is also possible to reduce the wire diameter of the wire as compared with the first embodiment. Furthermore, in this embodiment, it becomes possible by further simplifying the structure of the coil device, contributing to improving the reliability of the coil device and improving the manufacturing efficiency.

  As shown in FIG. 8, between the pair of flanges 123d and 123e that pass the primary winding 130, between the pair of flanges 123f and 123g, and between the pair of flanges 123h and 123i, respectively. A connecting collar 123α is formed. Each connection flange 123α is formed with a notch 126b that connects adjacent secondary winding grooves. By providing each connection flange 123α between the primary winding 130 and the secondary winding 140, the insulation between the primary winding 30 and the secondary winding 40 is suitably ensured.

  Note that the cut portion 126b may be formed in a flange portion other than the connection flange portion 123α, and the passage of the secondary winding 40 formed by these cut portions 126b is formed obliquely with respect to the winding axis direction. It is preferable that the secondary winding 140 can be easily formed on the bobbin 120. In the example shown in FIG. 8, all of the cut portions 126b are formed obliquely with respect to the winding axis direction in the same direction.

  As shown in FIG. 8, the primary winding 130 is wound in three primary winding grooves 125a, 125b, and 125c. The number of turns (number of turns) of the primary winding 30 in each of the primary winding grooves 125a to 125c is about 1, but is not particularly limited. On the outer peripheral surfaces of the flange portions 123c2 to 123i, primary winding passages 127a and 127b through which the primary winding 130 passes are formed.

  Protrusions 128a and 128b are formed adjacent to the primary winding passages 127a and 127b so as to protrude in the outer diameter direction from the outer peripheral surfaces of the flanges 123c2 to 123i. The protrusions 128a and 128b are formed as primary windings. 130 is prevented from deviating from the primary winding passages 127a, 127b. In the present embodiment, the protrusions 128a and 128b are formed so as to protrude from the outer peripheral surfaces of the flanges 123c2 to 123i to the upper part in the Y-axis direction, and the primary windings passing through the primary winding passages 127a and 127b. The line 130 intersects the upper portion of the secondary winding 140 in the Y-axis direction in a three-dimensional manner without contacting the secondary winding 140.

  Note that a protrusion 128c is also formed on the flange 123j located at the end in the Z-axis direction, and the winding end of the secondary winding 140 wound around the secondary winding groove 124f is connected to the low-voltage side. Guidance is made toward the terminal 150a. Also in the coil device 110 according to the present embodiment, as in the first embodiment, the primary winding 130 and the secondary winding 140 are separated from the primary high-voltage side end portion 130 a connected to the primary high-voltage side terminal 160. It is composed of a single continuous wire up to the secondary high voltage side end portion 140a connected to the high voltage side terminal 170. Although it does not specifically limit as a wire which comprises the primary winding 130 and the secondary winding 140, For example, a covered wire like a three-layer insulated wire can be used.

  The low-voltage side terminal 150 is provided on a connection flange 123β that connects a part of the pair of flanges 123h and 123i sandwiching the primary winding groove 125c arranged on the lowest voltage side. As shown in FIG. 11, the low-voltage side terminal 150 includes a wire fixing portion 150 a that is fixed to the boundary portion BD between the primary winding 130 and the secondary winding 140 shown in FIG. 8, and a slit formed in the connection flange portion 123 β. And an extraction portion 150c for connecting to the outside. The terminal 150 including the wire fixing portion 150a, the insertion portion 150b, and the lead-out portion 150c is integrally formed from a conductive plate material such as a metal plate. The same applies to the terminals 160 and 170.

  A method for fixing the wire fixing portion 150a to the boundary portion BD is not particularly limited. For example, the wire fixing portion 150a can be fixed to the wire by laser welding or fusing (thermal caulking). According to laser welding and fusing, since the insulation coating can be removed and the connection fixing operation can be performed at the same time without cutting the wire and without removing the insulation coating of the wire in advance, the terminal fixing process is performed. It can be simplified.

  The primary high-voltage side terminal 160 is provided on a connecting collar 123β formed between the collar 123c1 and the collar 123c2 in the bobbin 120. The primary high-voltage side terminal 160 includes a primary-side wire fixing portion 160a that is fixed to the primary high-voltage side end portion 130a of the primary winding 130, an insertion portion 160b that is inserted into a slit formed in the connection flange portion 123β, and the outside. A lead-out portion 160c for connection. The primary side wire fixing portion 160a and the primary high voltage side end portion 130a can be joined by laser welding, fusing, or the like, similarly to the wire fixing portion 150a, but is not particularly limited.

  As shown in FIG. 8, the low-voltage side terminal 150 and the primary high-voltage side terminal 160 are connected to the upper portion of the bobbin (the Y-axis positive direction side portion) where the passage of the secondary winding 140 and the primary winding passage 127a are formed by the cut portion 126b. Thus, it is possible to realize a simple and wasteful wire routing by an automatic winding machine or the like.

  As shown in FIG. 11, the secondary high-voltage side terminal 170 is provided on the flange portion 123 a located at the Z-axis negative direction side end portion of the hollow cylinder portion 121. The secondary high-voltage side terminal 170 includes a secondary-side wire fixing portion 170a that is fixed to the secondary high-voltage side end portion 140a of the secondary winding 140, and an insertion portion 170b that is inserted into a slit formed in the flange portion 123a. And a lead-out portion 170c for connecting to the outside. As shown in FIG. 7B, the flange portion 123a is formed with a notch 126a that extends from the outer peripheral surface of the flange portion 123a toward the inner diameter direction, and the flange portion 123b has an inner diameter direction from the outer peripheral surface of the flange portion 123b. A notch 126b is formed toward the end. The secondary winding 140 is routed from the secondary wire fixing portion 170a to the secondary winding groove portion 124b through the cut portions 126a and 126b.

The manufacturing method, usage method, other modifications, and other effects of the coil device 110 are the same as those of the manufacturing method of the first embodiment, and the description thereof is omitted.

DESCRIPTION OF SYMBOLS 10,110 ... Coil apparatus 12, 112 ... Core 14, 114 ... Cap 20, 120 ... Bobbin 21, 121 ... Hollow cylinder part 30, 130 ... Primary winding 40, 140 ... Secondary winding 23a-23k, 123a-123j ... Huts 26a, 26b, 126a, 126b ... Cutouts 27a, 27b, 127a, 127b ... Primary winding passages 23α, 23β, 123α, 123β ... Connection flanges 24a to 24g, 124a to 124g ... Grooves for secondary winding 25a-25c, 125a-125c ... Primary winding groove 30a, 130a ... Primary high voltage side end 40a, 140a ... Secondary high voltage side end BD ... Boundary part 50, 150 ... Low voltage side terminal 50a, 150a ... Wire fixing part 60, 160 ... Primary high voltage side terminal 70, 170 ... Secondary high voltage side terminal

Claims (10)

A rod-shaped core,
A bobbin having a hollow cylindrical portion that accommodates the core, and a plurality of flanges protruding from the hollow cylindrical portion in the outer diameter direction;
A secondary winding that is sandwiched between the flanges and wound separately into a plurality of secondary winding grooves formed on the outer peripheral surface of the hollow cylindrical portion;
A primary winding wound around the flange portion between the secondary winding groove portions and divided into a plurality of primary winding groove portions formed on the outer peripheral surface of the hollow cylindrical portion;
A low voltage side terminal provided on any one of the flanges and connected to the primary winding and the secondary winding;
A primary high-voltage side terminal provided on any one of the flanges and connected to a primary high-voltage side end of the primary winding;
A coil device comprising: a secondary high-voltage side terminal provided at any one of the flanges and to which a secondary high-voltage side end of the secondary winding is connected. The coil device according to claim 1,
A coil device in which at least one end of the core in the longitudinal direction has a region where the secondary winding is not wound. The coil device according to claim 1 or 2,
The plurality of secondary winding groove portions include a secondary low-pressure side groove portion, and a secondary that is positioned on the high-pressure side from the secondary low-pressure side groove portion and has a radial thickness greater than that of the secondary low-pressure side groove portion. A coil device comprising a high-pressure side groove. The coil device according to claim 3,
The coil device characterized in that the number of layers of the secondary winding wound around the secondary low-voltage side groove is greater than the number of layers of the secondary winding wound around the secondary high-voltage side groove. . The coil device according to any one of claims 1 to 4,
The said primary winding and the said secondary winding are comprised by the wire which continues from the said primary high voltage | pressure side edge part to the said secondary high voltage | pressure side edge part, The coil apparatus characterized by the above-mentioned. The coil device according to claim 5,
The low-voltage side terminal has a wire fixing portion fixed by fusing to a boundary portion between the primary winding and the secondary winding of the wire. The coil device according to any one of claims 1 to 6,
The secondary high-voltage side terminal is provided in a first flange portion that protrudes in the outer diameter direction from one end portion of the hollow cylinder portion among the plurality of flange portions. The coil device according to any one of claims 1 to 7,
The plurality of flange portions include a connection flange portion that connects a part of the pair of flange portions sandwiching any one of the primary winding groove portions,
The coil device, wherein the low-voltage side terminal is provided in the connection flange. The coil device according to any one of claims 1 to 8,
At least a part of the plurality of flange portions is formed on the outer peripheral surface of the flange portion and a cut portion that is formed from the outer peripheral surface of the flange portion toward the inner diameter direction and allows the secondary winding to pass therethrough. And a primary winding passage through which the primary winding passes. The coil device according to any one of claims 1 to 9,
Compared with the number of winding layers of the secondary winding wound around the groove portion for the secondary winding located in the center portion in the longitudinal direction of the core, the second portion located at the end portion in the longitudinal direction of the core. A coil device characterized in that the number of winding layers of the secondary winding wound around the groove portion for the secondary winding is small.

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