JP2018133456A - Coil device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a coil device which can be made compact, and yet has stable leakage characteristics.SOLUTION: A coil device has a bobbin 20, a first coil 31 composed of a tabular conductor, a second coil 32 composed of a tabular conductor and located separately from the first coil 31, and an intermediate coil 33 located between these first and second coils 31, 32. The bobbin 20 includes an intermediate bobbin 23, a first bobbin 21 and a second bobbin 22. The intermediate coil 33 is wound around an intermediate cylinder part 236 so as to adhere to a first intermediate flange 231 and a second intermediate flange 232, and a second cylinder part 226 is combined to the second end of the intermediate cylinder part 236, so that the second intermediate flange 232 abuts on the opposite side surface of the second coil 32 abutting on a second end flange 220.SELECTED DRAWING: Figure 4

Description

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

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

  As an example of a coil apparatus, the coil apparatus shown in the following patent document 1 is mentioned, for example. The coil device shown in Patent Document 1 includes a primary coil and a pair of secondary coils (bus bars) that sandwich the primary coil vertically. In this coil device, the primary side bobbin around which the primary coil is wound is sandwiched between the secondary side bobbins in which the secondary coil is insert-molded.

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

  In this coil device, since the arcuate side wall portion is formed on the secondary bobbin, the accommodating portion is provided inside the side wall portion, and the primary bobbin is accommodated in the accommodating portion, the secondary bobbin There is also a problem that it is difficult to reduce the outer diameter of the device.

JP 2013-89787 A

  The present invention has been made in view of such a situation, and an object of the present invention is to provide a coil device that can be reduced in size and has stable leakage characteristics.

In order to achieve the above object, a coil device according to the present invention comprises:
With bobbin,
A first coil portion made of a plate-like conductor;
A second coil part that is located separately from the first coil part and is made of a plate-like conductor;
A coil device having an intermediate coil portion located between the first coil portion and the second coil portion,
The bobbin is
An intermediate cylinder portion around which the intermediate coil portion is wound, and a first intermediate flange portion and a second intermediate flange portion formed on each of the first end and the second end in the axial direction of the intermediate cylinder portion; With bobbin,
A first bobbin having a first tubular portion combined with the first end, wherein a first end collar is formed on the first tubular portion;
A second bobbin having a second cylindrical portion combined with the second end, and a second end collar formed on the second cylindrical portion;
The intermediate coil portion is wound around the intermediate cylinder portion so as to contact (preferably closely contact) the first intermediate flange portion and the second intermediate flange portion,
The second tube portion is combined with the second end of the intermediate tube portion so that the second intermediate flange portion contacts the opposite surface of the second coil portion that contacts the second end flange portion.

  The bobbin in the present invention is configured by integrally combining a first bobbin, an intermediate bobbin, and a second bobbin. In addition, the second coil that does not house the intermediate bobbin inside the second bobbin, but is combined with the second cylindrical portion at the second end of the intermediate cylindrical portion and abuts (preferably closely contacts) the second end collar. The second intermediate flange is in contact (preferably in close contact) with the surface opposite to the portion.

  Since the intermediate coil portion is wound around the intermediate bobbin so as to be in contact with the second intermediate flange portion, the intermediate coil portion wound around the intermediate bobbin, and the second coil portion disposed on the second bobbin, Are spaced apart at a distance corresponding to the thickness of the second intermediate collar. When the intermediate bobbin is molded, the thickness of the second intermediate brim portion can be controlled and controlled relatively accurately.

  Also, if the second bobbin is arranged on the lower side in the direction of gravity, and the intermediate bobbin and the first bobbin are combined on the second bobbin, the first coil part is arranged on the first intermediate collar part, Due to the gravity of the first coil part, the lower surface of the first coil part comes into contact (preferably in close contact) with the upper surface of the first intermediate collar part. Further, the intermediate coil portion is wound around the intermediate bobbin so as to abut (preferably closely contact) the lower surface of the first intermediate flange portion.

  Therefore, the intermediate coil part wound around the intermediate bobbin and the first coil part arranged on the first bobbin can be arranged at a distance corresponding to the thickness of the first intermediate collar part. When the intermediate bobbin is molded, the thickness of the first intermediate collar can be controlled relatively accurately.

  After combining the first bobbin, the intermediate bobbin, and the second bobbin in this way, if these bobbins are fixed by a fixing means such as an adhesive, the first coil part, the intermediate coil part, and the second coil part The distance in the direction of the winding axis is kept constant corresponding to the thickness of each flange. Therefore, it is easy to enhance the coupling between these coil portions, and a coil device with stable leakage characteristics can be realized.

  Moreover, since there is no need to perform insert molding or the like, the height of the bobbin in the winding axis direction can be reduced. Furthermore, since the second bobbin is not housed in the second bobbin but is combined with the second end of the intermediate tube, the radial size of the second bobbin is reduced. be able to. The first bobbin is the same as the second bobbin.

  Furthermore, since the first coil portion and the second coil portion are configured by plate-like conductors, a large current can flow through the first coil portion and the second coil portion.

  The second coil portion may have a substantially ring plate shape. In addition, a positioning portion that contacts the inner peripheral side surface of the second coil portion may be formed at an intersection between the inner surface of the second end flange portion and the outer peripheral surface of the second cylindrical portion. By setting it as such a structure, it can prevent that the inner peripheral side surface of a 2nd coil part contact | abuts to a positioning part, and a 2nd coil part is displaced in a radial direction.

  Preferably, the positioning portion is formed on an outer peripheral side surface of the step portion, and the second intermediate flange portion contacts the step surface of the step portion. Preferably, the length of the stepped portion in the axial direction is equal to or less than the plate thickness of the second coil portion. By setting it as such a structure, a 2nd intermediate collar part adhere | attaches reliably on a 2nd coil part.

  Preferably, an intermediate notch portion that is notched at a predetermined depth is formed on the second end side of the inner peripheral side surface of the intermediate tube portion, and on the first end side of the second tube portion, An engagement convex portion that engages with the intermediate notch portion is formed, and the engagement convex portion is formed so that a gap is formed between a front end surface of the engagement convex portion and a bottom surface of the intermediate notch portion. Engages the intermediate notch. By setting it as such a structure, a 2nd intermediate collar part adhere | attaches reliably on a 2nd coil part.

  Preferably, the engaging convex portion engages with the intermediate notch portion so that an inner peripheral side surface of the intermediate cylindrical portion and an outer peripheral side surface of the engaging convex portion face each other. By setting it as such a structure, the outer peripheral side surface of an engaging convex part functions as a positioning surface, and it can prevent that an intermediate | middle cylinder part is displaced in a radial direction.

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

  In addition, the first end of the intermediate cylinder portion is in contact with the first end of the intermediate cylindrical portion so that the first end flange is in contact (preferably in close contact) with the opposite surface of the first coil portion that is in contact with the first intermediate flange. One cylinder part may be combined.

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

FIG. 1A is a perspective view of a transformer as a coil device according to an embodiment of the present invention. 1B is a perspective view when the case and the bottom plate are removed from the transformer shown in FIG. 1A. 2 is an exploded perspective view of the transformer shown in FIG. 1A. FIG. 3 is a cross-sectional view of the main part of the transformer along the line III-III shown in FIG. 1A. FIG. 4 is a cross-sectional view of the main part of the bobbin along the line IV-IV shown in FIG. 1A. 5A is a perspective view of a bobbin in the transformer shown in FIG. 1A. FIG. 5B is an exploded perspective view of the bobbin shown in FIG. 5A. FIG. 5C is a cross-sectional view of a main part of the bobbin shown in FIG. 5A. 5D is a cross-sectional view of a main part of a modification of the bobbin shown in FIG. 5A. 5E is a detailed cross-sectional view of the bobbin shown in FIG. 5A. FIG. 5F is a perspective view when an insulating cover or the like is attached to the bobbin shown in FIG. 5A. 6A is a perspective view of a coil portion in the transformer shown in FIG. 1A. 6B is an exploded perspective view of the coil portion shown in FIG. 6A. 6C is a perspective view of a modification of the first coil portion and the second coil portion in the coil portion shown in FIG. 6A. FIG. 7 is a circuit diagram showing an equivalent circuit of the transformer shown in FIG. 1A.

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

  A transformer 10 as a coil device according to the present embodiment shown in FIG. 1A is a DC / DC that steps down a high voltage supplied from a high voltage battery of an electric vehicle or a hybrid vehicle to a low voltage and supplies it to other electric devices. Used for DC converters.

  As shown in FIG. 2, the transformer 10 includes a bobbin 20, magnetic cores 40 a and 40 b, a cover 50, a lead wire cover 60, a terminal 80, a case 90 that accommodates these, and a bottom plate 91. Have In the drawing, the X axis, the Y axis, and the Z axis are perpendicular to each other, and the Z axis corresponds to the height (thickness) of the transformer 10. In the present embodiment, the lower side of the transformer 10 in the Z-axis direction is the installation surface of the transformer. Further, the Y axis coincides with the longitudinal direction of the base portions 44a and 44b in the magnetic cores 40a and 40b. Further, the X axis is adapted to coincide with the longitudinal direction of the bobbin 20.

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

  Boss portions 92 are formed at the four corners of the bottom plate 91. For example, a bolt hole is formed in the boss portion 92. The case 90 itself is made of metal, but may be made of synthetic resin or the like. Note that the bottom plate 91 and the case 90 may be integrally formed by die-casting aluminum or the like. By making the entire case out of metal, heat dissipation is further enhanced.

  As shown in FIG. 3, the heat dissipation resin 100 is filled in the case 90. Although it does not specifically limit as resin for thermal radiation, For example, resin excellent in heat dissipation whose thermal conductivity is 0.5-5, Preferably it is 1-3 W / m * K is preferable. Examples of the resin excellent in heat dissipation include silicone resin, urethane resin, and epoxy resin, among which silicone resin and urethane resin are preferable. Moreover, in order to improve heat dissipation, the resin may be filled with a filler having high thermal conductivity.

  Moreover, it is preferable that the resin for thermal radiation of this embodiment has a Shore A hardness of 100 or less, preferably 60 or less. This is because even if the magnetic cores 40a and 40b and the bobbin 20 are deformed by heat, the deformation is absorbed and excessive stress is not generated in the magnetic cores 40a and 40b. An example of such a resin is a potting resin.

  As shown in FIGS. 3 and 4, the coil 30 attached to the bobbin 20 includes a first coil part 31, a second coil part 32, and these along the central axis (Z-axis direction) of the bobbin 20. And an intermediate coil portion 33 located between the first coil portion 31 and the second coil portion 32. That is, each coil part 31-33 is arrange | positioned along the said central axis so that the 3rd coil part 33 may be pinched | interposed by the 1st coil part 31 and the 2nd coil part 32. FIG.

  The intermediate coil portion 33 is composed of an intermediate wire 37, and the first coil portion 31 and the second coil portion 32 are made of conductive plate-like conductors (in this embodiment, bus bars) 38 and 39, respectively. It is configured. By constituting each coil part 31 and 32 with a bus bar, a large current can be passed through each coil part 31 and 32.

  In the present embodiment, the intermediate wire 37 constitutes a primary coil, and the bus bars 38 and 39 constitute secondary coils. That is, as shown in FIG. 7A, the intermediate coil portion 33 constituted by the intermediate wire 37 is the primary side, and the first coil portion 31 and the second coil portion 32 constituted by the bus bars 38 and 39 are the secondary side. As a result, a transformer is formed between the two.

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

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

  The lead portions 37a and 37b shown in FIG. 1A are both end portions of the intermediate wire 37 shown in FIGS. As shown in FIG. 1A, a terminal 80 made of, for example, a metal terminal is connected to each end of the lead portions 37a and 37b by soldering or the like, and both ends of the wire 37 are electrically connected to the terminal 80. is there.

  As shown in FIGS. 6A and 6B, the bus bars 38 and 39 are formed in a substantially ring plate shape (substantially C-shaped plate shape) having a substantially elliptical opening 383 and 393 in the center. The bus bars 38 and 39 are manufactured by punching a flat plate made of a conductive material such as a copper plate and then bending each part. The shape of the bus bars 38, 39 is not limited to a substantially ring plate shape (substantially C-shaped plate shape), and may be another shape such as an elliptical shape or a square shape. In the present embodiment, the bus bars 38 and 39 are each constituted by one turn, but may be constituted by a plurality of turns.

  A first terminal portion 381a is formed at one end of the bus bar 38, and a second terminal portion 381b is formed at the other end. In addition, a first terminal portion 391a is formed at one end of the bus bar 39, and a second terminal portion 391b is formed at the other end. As shown in FIG. 6A, the first terminal portion 381a of the bus bar 38 is connected to the second terminal portion 391a of the bus bar 39 so as to overlap in the Z-axis direction, and the second terminal portion 381b of the bus bar 38 is connected to the second terminal portion 381b of the bus bar 39. The two terminal portions 391b are connected so as to overlap in the Z-axis direction. Thereby, the bus bars 38 and 39 are connected, and overlap on the same axis so that the openings 383 and 393 communicate with each other. Moreover, as shown to Fig.7 (a), the 1st coil part 31 and the 2nd coil part 32 are connected in parallel.

  As shown in FIG. 5B, the first terminal block 24 and the second terminal block 25 are integrally formed on the upper surfaces of both ends in the X-axis direction of the first bobbin 21 (first end collar 210). Each terminal block 24, 25 has side wall portions 241, 251. The side wall parts 241 and 251 are formed so as to surround the peripheral edges of the terminal blocks 24 and 25 except for the side where the terminal parts 381a, 381b, 391a and 391b of the lead parts 37a and 37b and the bus bars 38 and 39 are drawn. . The first terminal block 24 is formed with a positioning surface 242 that contacts the plate-like raised portions 384a and 384b of the bus bar 38 and positions them.

  Each positioning surface 242 is guided to the first end side in a state where the first plate-like raised portions 384a and 394a rising in the Z-axis direction and the second plate-like raised portion lead portions 384b and 394b are close to each other. In the second terminal block 25, engagement protrusions 253 are formed on both outer end walls of the side wall 251 in the Y-axis direction. The function of the engaging protrusion 253 will be described later.

  The second terminal block 25 is formed with a pair of locking portions 252. As shown in FIG. 5F, the first lead portions 37a and 37b raised in the Z-axis direction by the lead rising portions 371a and 371b are wound around the pair of locking portions 252 from the inner side to the outer side in the Y-axis direction. , Guided outward in the X-axis direction.

  By locking the lead portions 37a and 37b to the pair of locking portions 252, the intermediate coil portion 33 constituted by the intermediate wire 37 positioned in the middle of the lead portions 37a and 37b shown in FIGS. 6A and 6B is not loosened. It is locked to prevent unwinding. In this state, the lead portions 37 a and 37 b can be pulled out in a direction away from the coil 30.

  As shown in FIG. 1B, a lead wire cover 60 is mounted on the terminal block 25 in the Z-axis direction so as to cover it. More specifically, holes 61 are formed in the side surfaces at both ends in the Y-axis direction of the drawing wire cover 60, and the holes 61 are engaged with engaging protrusions 253 formed in the terminal block 25. The lead wire cover 60 can be attached to the terminal block 25. Thereby, it is possible to prevent the lead portions 37 a and 37 b from protruding unnecessarily above the terminal block 25.

  As shown in FIG. 2, the magnetic cores 40 a and 40 b have the same shape in this embodiment, have an E-shaped cross section in the ZY cross section, and constitute a so-called E-type core. The mode of the magnetic cores 40a and 40b is not limited to the mode shown in FIG. 2, and the magnetic cores 40a and 40b are parallel to the XZ plane along the alternate long and short dash line (substantially central position in the Y-axis direction) A split core formed by cutting may be used. Alternatively, the magnetic core may be a split core formed by cutting the magnetic cores 40a and 40b in parallel to the YZ plane along a straight line (substantially central position in the X-axis direction) intersecting with the alternate long and short dash line in the figure.

  The magnetic core 40a disposed on the upper side in the Z-axis direction includes a base portion 44a extending in the Y-axis direction, a pair of side leg portions 48a projecting in the Z-axis direction from both ends in the Y-axis direction of the base portion 44a, and these Middle leg portion 46a protruding in the Z-axis direction from the center in the Y-axis direction. The magnetic core 40b disposed on the lower side in the Z-axis direction includes a base portion 44b extending in the Y-axis direction, a pair of side legs 48b protruding in the Z-axis direction from both ends in the Y-axis direction of the base portion 44b, Between these side leg parts 48b, it has the middle leg part 46b which protrudes in the Z-axis direction from the center of the Y-axis direction.

  The middle leg portion 46a is inserted into the core leg through hole 21a of the bobbin 20 from above in the Z-axis direction. Similarly, the middle leg portion 46b is inserted into the core leg through-hole 21a of the bobbin 20 from below in the Z-axis direction. It is comprised so that a front-end | tip may be contacted.

  Note that the middle leg 46b may be configured such that the tip of the middle leg 46b faces the tip of the middle leg 46a with a predetermined gap inside the core leg through hole 21a. Thus, by forming the gap, the leakage characteristics can be adjusted according to the width of the gap.

  The middle leg portion 46a and the middle leg portion 46b have a substantially elliptical column shape so as to coincide with the inner peripheral surface shape of the core leg through hole 21a. You may change according to the shape of the through-hole 21a for use. Moreover, the side leg parts 48a and 48b have an inner concave curved surface shape matched with the outer peripheral surface shape of the bobbin main body 21, and the outer surface has a plane parallel to the XZ plane. In the present embodiment, the materials of the cores 40a and 40b include soft magnetic materials such as metal and ferrite, but are not particularly limited.

  Covers 50 are disposed between the inner peripheral surfaces of the side legs 48a and 48b and the outer peripheral surfaces of the bobbins 20 (bobbins 21, 22, and 23). The cover main body 52 of the cover 50 has a shape that covers the outer periphery of the bobbin 20 located between the terminal blocks 24 and 25 in the bobbin 20. At both ends in the Z-axis direction of the cover main body 52, locking pieces 54 bent in a substantially vertical direction from the cover main body 52 toward the bobbin 20 are integrally formed. As shown in FIG. 3, the pair of locking pieces 54 formed on both sides of the cover main body 52 in the Z-axis direction includes the upper surface in the Z-axis direction of the first end collar 210 of the first bobbin 21, and the second It attaches so that the lower surface of the Z-axis direction of the 2nd end collar part 220 in a bobbin may be inserted | pinched.

  As shown in FIG. 2, side leg guide pieces 56 extending in the Z-axis direction are integrally formed on the outer surfaces of both ends in the X-axis direction of the cover body 52. The outer surface of the cover main body 52 located between the pair of side leg guide pieces 56 is in contact with the inner surfaces of the side legs 48a and 48b, and the movement of the side legs 48a and 48b in the X-axis direction causes the pair of side legs 48a and 48b to move. The guide piece 56 is limited. These covers 50 are made of an insulating member such as plastic or metal similar to the bobbin 20.

  As shown in FIG. 5F, the hook-shaped engagement portion 58 formed inside the upper locking piece 54 of the cover 50 is a hook-shaped cover engagement portion formed on the upper surface of the first bobbin 21. 211 is detachably fitted.

  As shown in FIG. 5B, the bobbin 20 in this embodiment is divided into three parts, a first bobbin 21, an intermediate bobbin 23, and a second bobbin 22, and these bobbins 21, 22, and 23 are integrated. It is comprised by combining.

  Each of these bobbins 21, 22, and 23 is made of plastic such as PPS, PET, PBT, LCP, and nylon, but may be made of other insulating members. However, in this embodiment, the bobbins 21, 22, and 23 are preferably made of a plastic having a high thermal conductivity of, for example, 1 W / m · K or more, and may be made of, for example, PPS or nylon.

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

  Further, the third intermediate flange 233 protrudes radially outward on the outer peripheral surface of the intermediate cylinder 236 located between the first intermediate flange 231 and the second intermediate flange 232 in the Z-axis direction. It is formed. In this embodiment, each collar part 231,232,233 is comprised so that the thickness of the Z-axis direction of each collar part 231,232,233 may become equal. The first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231.

  Due to the third intermediate flange 233 formed between the first intermediate flange 231 and the second intermediate flange 232, the gap between these flanges is in order from the top in the Z-axis direction as shown in FIG. 5C. Partitions S1 and S2 are formed. An intermediate wire 37 is wound around the sections S1 and S2. In addition, the number of the intermediate collar part 233 and division S1 and S2 is not specifically limited.

  As shown in FIG. 4, in the present embodiment, the intermediate coil portion 33 is configured by winding an intermediate wire 37 continuously in sections S <b> 1 and S <b> 2 by a plurality of turns such as 5 turns. In the present embodiment, the third intermediate flange 233 serves to partition the intermediate coil portion 33 wound around the first end side and the intermediate coil portion 33 wound around the second end side in the Z-axis direction. .

  As shown in FIG. 5C, the section width T3 along the Z-axis in the sections S1 and S2 around which the intermediate wire 37 constituting the intermediate coil portion 33 is wound allows one intermediate wire 37 to enter in the Z-axis direction. The width is preferably set. This is because α is easy to wind. However, the partition width T3 may be set to a width in which two or more intermediate wires 37 can enter in the Z-axis direction. In the present embodiment, the section widths T3 in the sections S1 and S2 are preferably all the same, but may be slightly different.

  Further, the radial length H1 of each of the flange portions 231 to 233 is set to a height at which one or more (one or more layers) of the intermediate wires 37 can enter. In the present embodiment, preferably 3 to 8 layers. The height is set so that the wire can be wound. The lengths H1 of the flanges 231 to 233 are preferably all the same, but may be different.

  In the present embodiment, the winding method of the intermediate wire 37 wound around the sections S1 and S2 is α winding. From the inter-coil connection portion 372 shown in FIG. 6B, the intermediate wires 37 are connected to the sections S1 and S2 shown in FIG. 5C. Winding 37 is started and winding is started, and the lead portions 37a and 37b shown in FIG. 5F are pulled out.

  Here, the α winding will be described. For example, in order to α-wind the intermediate wire 37 around the bobbin 20 shown in FIG. 5A, first, the inter-coil connection portion 372 of the intermediate wire 37 shown in FIG. 6B is inserted into the third intermediate flange portion 233 shown in FIG. 5B. Pass through the notch 233b.

  As shown in FIG. 4, the upper half of the intermediate wire 37 in the Z-axis direction is wound around the outer periphery of the intermediate bobbin 23 in multiple layers (five layers in the figure) inside the section S <b> 1. At the same time, the lower half of the intermediate wire 37 is wound around the outer periphery of the intermediate bobbin 20 in a plurality of layers in the direction opposite to the winding method in the section S1 (or in the same direction) inside the section S2. These operations may be performed using an automatic winding machine.

  As shown in FIG. 5E, on the first end side of the inner peripheral side surface of the intermediate cylinder part 236, a first intermediate notch part 237a cut out toward the second end with a predetermined depth is formed. On the second end side of the inner peripheral side surface of the intermediate cylinder part 236, a second intermediate notch part 237b that is notched toward the first end with a predetermined depth is formed. Each of the intermediate notches 237a and 237b is formed along the inner peripheral side surface of the winding tube 236.

  As shown in FIG. 5B, in the vicinity of both ends in the X-axis direction of each intermediate notch 237a, 237b, the first intermediate convex portion 238a and the depth of the notch in the Z-axis direction are smaller than the other portions. A second intermediate convex portion 238b is formed. In the example shown in FIG. 5B, the circumferential widths of the first intermediate convex portion 238a and the second intermediate convex portion 238b are different from each other, but may be equal.

  As shown in FIG. 5E, the length of the intermediate notch 237a in the Z-axis direction (the length from the upper surface of the intermediate positioning portion 239 described later) LC1a is preferably 1 of the length of the intermediate cylindrical portion 236 in the Z-axis direction. / 10 to 4/10, more preferably around 1/3. Further, the length in the Z-axis direction of the intermediate notch portion 237b (the length from the lower surface of the second intermediate flange portion 232) LC1a is 1/10 to 4/10 of the length in the Z-axis direction of the intermediate cylinder portion 236, and Preferably it is around 1/3.

  An intermediate positioning portion 239 that is in contact with the inner peripheral side surface of the first coil portion 31 is formed along the outer periphery of the intermediate cylindrical portion 236 at the intersection of the upper surface of the first intermediate flange portion 231 with the intermediate cylindrical portion 236. is there. The intermediate positioning portion 239 has an intermediate step portion 239a that rises substantially perpendicular to the upper surface of the first intermediate flange portion 231. With this configuration, when the first coil part 31 is disposed on the upper surface of the first intermediate flange part 231, the inner peripheral side surface of the first coil part 31 is the intermediate step part 239a (and the first step part to be described later). It is possible to prevent the first coil portion 31 from being displaced in the radial direction by contacting the portion 219a).

  As shown in FIG. 5B, a first lead locking notch 231a is formed on the second terminal block 25 side (X-axis negative direction side) of the first intermediate flange 231 and the third intermediate flange 233 is formed. A second lead locking notch 233a and a wire insertion notch 233b are formed on the second terminal block 25 side (X-axis negative direction side). The lead rising portions 371a and 371b of the lead portions 37a and 37b shown in FIG. 5F are locked in the lead locking notches 231a and 233a so that the lead rising portions 371a and 371b can be easily formed. 5B, when the intermediate wire 37 is wound around the outer periphery of the intermediate cylindrical portion 236 (α winding), the inter-coil connecting portion 372 shown in FIG. 6B is used. (Central portion of the intermediate wire 37 located approximately at the center between the lead portions 37a and 37b) is inserted therethrough.

  As shown in FIG. 5E, the first bobbin 21 has a first tube portion 216 that is combined with the first end of the intermediate tube portion 236. The first cylindrical portion 216 is integrally molded substantially parallel to the XY plane so that the first end collar portion 210 extends outward in the radial direction. A first engagement convex portion 217 that engages with the intermediate notch portion 237a is formed on the second end side of the inner peripheral side surface of the first tube portion 216. The 1st engagement convex part 217 is comprised by the engagement piece protruded to the 2nd end side.

  As shown in FIG. 5B, the first engagement convex portion 217 is formed along the outer periphery of the first tube portion 216. Near the both ends of the first engaging convex portion 217 in the X-axis direction, first concave portions 218 are formed so that the protruding width in the Z-axis direction toward the second end side is smaller than other portions. The first concave portion 218 engages with the first intermediate convex portion 238a, and portions other than the first concave portion 218 in the first engaging convex portion 217 are other than the first intermediate convex portion 238a in the intermediate notch 237a. Engage with the part. As a result, the first tube portion 216 is combined with the first end of the intermediate tube portion 236, and the first end shown in FIG. 5C is provided between the lower surface of the first end flange portion 210 and the upper surface of the first intermediate flange portion 231. A space A1 in which the coil part 31 can be arranged is formed. In the present embodiment, the distance (shortest distance) between the first coil portion 31 and the intermediate coil portion 33 is equal to the thickness of the first intermediate flange portion 231 that partitions them.

  As shown in FIG. 5E, a first positioning portion 219 that abuts on the inner peripheral side surface of the first coil portion 31 is provided at the intersection of the lower surface of the first end flange portion 210 with the first tube portion 216 in the first tube. It is formed along the outer periphery of the portion 216. The first positioning part 219 includes a first step part 219 a that falls substantially perpendicular to the lower surface of the first end collar part 210. With such a configuration, when the first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231, the inner peripheral side surface of the first coil portion 31 is the first step portion 219a (and the above-described intermediate step). Since the first coil portion 31 is in contact with the portion 239a), it is possible to prevent the first coil portion 31 from being displaced in the radial direction.

  In the present embodiment, the Z-axis direction length (height from the upper surface of the intermediate positioning part 239) LE1 of the first engagement convex part 217 is smaller than the Z-axis direction length LC1a of the intermediate notch part 237a. Therefore, when the first tube portion 216 is combined with the first end of the intermediate tube portion 236, the lower surface of the first positioning portion 219 comes into contact with the upper surface of the intermediate positioning portion 239, and the tip of the first engagement convex portion 217. A gap G1 is formed between the surface F1 and the bottom surface F3a of the intermediate notch 237a.

  As a result, the partition width T1 along the Z-axis in the space A1 is equal to the sum (LP1 + LP3) of the Z-axis direction length LP1 of the first step part 219a and the Z-axis direction length LP3 of the intermediate step part 239a. . In the present embodiment, the sum (LP1 + LP3), that is, the partition width T1 along the Z-axis in the space A1 is equal to or larger than the plate thickness TH1 of the first coil portion 31. Therefore, a gap LG10 may be formed between the upper surface of the first coil portion 31 and the lower surface of the first end collar portion 210.

  In addition, the length LP1 of the first step portion 219a and the length LP3 of the intermediate step portion 239a may be adjusted, and the value of the sum (LP1 + LP3) thereof may be changed as appropriate. For example, the sum LP1 + LP3 may be equal to or less than the plate thickness TH1 of the first coil portion 31. In this case, the lower surface of the first end collar portion 210 abuts on the upper surface of the first coil portion 31. That is, the first coil part 31 is sandwiched between the lower surface of the first end collar part 210 and the upper surface of the first intermediate collar part 231, and the partition width T <b> 1 is equal to the plate thickness TH <b> 1 of the first coil part 31. In that case, the gap LG10 between the upper surface of the first coil portion 31 and the lower surface of the first end collar portion 210 can be omitted.

  In the present embodiment, the length LE1 of the first engaging convex portion 217, the length LP1 of the first intermediate step portion 219a, the length LP3 of the intermediate step portion 239a, or the length LC1a of the first intermediate notch portion 237a is appropriately set. By adjusting, the gap G1 can be formed, and the partition width T1 along the Z-axis direction in the space A1 can be appropriately adjusted.

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

  As shown in FIG. 5B, the second bobbin 22 has a second cylinder portion 226 that is combined with the second end of the intermediate cylinder portion 236. The second cylindrical portion 226 is integrally formed so as to be substantially parallel to the XY plane so that the second end flange portion 220 extends outward in the radial direction.

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

  By forming the second positioning portion 229, the inner peripheral side surface of the second coil portion 32 comes into contact with the second step portion 229a when the second coil portion 32 is disposed on the upper surface of the second end flange portion 220. The second coil part 32 can be prevented from being displaced in the radial direction.

  On the first end side of the inner peripheral side surface of the second cylindrical portion 226, an engaging convex portion 227 that engages with the intermediate notch portion 237b is formed. The engaging convex portion 227 is formed of an engaging piece protruding to the first end side, and is formed along the outer periphery of the second cylindrical portion 226 as shown in FIG. 5B. In the vicinity of both ends of the engagement convex portion 227 in the X-axis direction, second concave portions 228 are formed so that the protruding width in the Z-axis direction toward the first end side is smaller than the other portions.

  The second concave portion 228 engages with the second intermediate convex portion 238b, and a portion other than the second concave portion 228 in the engaging convex portion 227 is a portion other than the second intermediate convex portion 238b in the intermediate notch portion 237b. Engage with. Thereby, the second end of the intermediate cylinder 236 is combined with the second cylinder 226, and the gap between the upper surface of the second end flange 220 and the lower surface of the second intermediate flange 232 is as shown in FIG. 5E. A space A2 in which the second coil portion 32 can be disposed is formed.

  In the present embodiment, the length (the height from the upper surface of the second positioning portion 229) LE2 of the engaging convex portion 227 is equal to or smaller than the length LC1b of the intermediate notch portion 237b. Therefore, when the intermediate cylinder part 236 is combined with the second cylinder part 226, the lower surface of the second intermediate flange part 232 comes into contact with the upper surface of the second positioning part 229, and the front end surface F2 of the engagement convex part 227, A gap G2 is formed between the bottom surface F3b of the intermediate notch 237b. As a result, the section width T2 along the Z axis in the space A2 is equal to the length LP2 of the second step portion 229a.

  In the present embodiment, the second positioning portion 229 is formed such that the length LP2 of the second step portion 229a is equal to or less than the plate thickness TH2 of the second coil portion 32. Therefore, the lower surface of the second intermediate flange 232 also abuts (adheres) to the upper surface of the second coil portion 32, and the weight of the first coil portion 31 is reduced by the second coil portion via the second intermediate flange 232. 32.

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

  As described above, in this embodiment, the lower surface of the second intermediate flange portion 232 and the upper surface of the second coil portion 31 are in close contact with each other, and therefore the distance (shortest distance) between the second coil portion 32 and the intermediate coil portion 33. Is equal to the thickness of the second intermediate flange 232 that partitions them.

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

  In the present embodiment, when the engaging convex portion 227 is engaged with the second intermediate notch portion 237b, the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the engaging convex portion 227 are opposed to each other and engaged. The outer peripheral side surface of the convex portion 227 contacts the second end side of the inner peripheral side surface of the intermediate cylinder portion 236. Therefore, the outer peripheral side surface of the engaging convex portion 227 functions as a positioning surface, and the intermediate cylinder portion 236 can be prevented from being displaced in the radial direction. Note that a slight gap may be formed between the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the engaging convex portion 227 in manufacturing.

  As shown in FIG. 5B, bobbin leg portions 26 are integrally formed on both ends in the X-axis direction of the second end flange 220, respectively. Each bobbin leg portion 26 is formed so as to protrude downward in the Z-axis direction from both ends of the second end flange 220 in the X-axis direction. As shown in FIG. 5C, each pedestal 70 is accommodated in each bobbin leg portion 26. In the example shown in FIG. 5C, the height of each pedestal 70 in the Z-axis direction is such that when each pedestal 70 is accommodated in each bobbin leg 26, the bottom surface of each pedestal 70 is below each bobbin leg 26 below the Z-axis. It is set to a height that protrudes. However, the height of each pedestal 70 in the Z-axis direction is not limited to this, and may be adjusted as appropriate.

  The transformer 10 according to the present embodiment is manufactured by assembling the members shown in FIG. Hereinafter, an example of a method for manufacturing the transformer 10 will be described with reference to FIG. In manufacturing the transformer 10, first, the bobbin 20 is prepared.

  The bobbin 20 in this embodiment is divided into three parts, a first bobbin 21, an intermediate bobbin 23, and a second bobbin 22, and is configured by combining these bobbins 21, 22, and 23 integrally. . An intermediate wire 37 shown in FIG. 6B is wound around the outer periphery of the intermediate bobbin 23 by α winding to form an intermediate coil portion 33. The intermediate coil portion 33 is preferably formed before the first bobbin 21, the intermediate bobbin 23, and the second bobbin 22 are assembled, but may be formed after the assembly.

  As shown in FIG. 5E, when the first coil portion 31 and the second coil portion 32 are assembled to the bobbin 20, it is preferable that the bobbins 21, 22, 23 are assembled at the same time.

  That is, the first coil portion 31 is disposed on the upper surface of the first intermediate flange portion 231 of the intermediate bobbin 23, and the first engagement convex portion 217 of the first tube portion 216 is formed on the first intermediate notch portion 237a of the intermediate tube portion 236. Engage and combine the first tube portion 216 with the first end of the intermediate tube portion 216.

  At the same time, or before and after that, the second coil portion 32 is disposed on the upper surface of the second end flange portion 220 of the second bobbin 22, and the second engagement convex portion 227 of the second tube portion 226 is placed on the intermediate tube portion 236. The second intermediate notch 237b is engaged, and the second end of the intermediate cylinder 236 is combined with the second cylinder 226.

  As described above, the first bobbin 21, the second bobbin 22, and the intermediate bobbin 23 are integrally combined to form the bobbin 20, and the bobbins 21, 22, and 23 are fixed with an adhesive or the like.

  Next, the lead portions 37a and 37b are drawn upward from the winding shaft from the intermediate coil portion 33 shown in FIG. 6B, and the lead portions 37a and 37b are locked to the first locking portions 252 as shown in FIG. 5F. Pull out in a direction away from the bobbin 20.

  Further, as shown in FIG. 6B, plate-like upright portions 384a and 384b and terminal portions 381a and 381b are formed on the bus bar 38 constituting the first coil portion 31. Further, plate-like upright portions 394a and 394b and terminal portions 391a and 391b are formed on the bus bar 39 constituting the second coil portion 32. In addition, the height of the plate-like upright portions 384a, 384b, 394a, 394b in the Z-axis direction is adjusted so that the terminal portions 381a, 381b and the terminal portions 391a, 391b are overlapped and connected in the Z-axis direction.

  In the bus bars 38 and 39, these plate-like upright portions 384a, 384b, 394a and 394b and the terminal portions 381a, 381b, 391a and 391b are preferably molded in advance. In this case, as shown in FIG. 5D, the intermediate wire 37 is wound around the intermediate bobbin 23 before the first bobbin 21, the second bobbin 22, and the intermediate bobbin 23 are integrally combined with the bus bars 38 and 39. It is preferable to keep it. After the first bobbin 21, the second bobbin 22, and the intermediate bobbin 23 are integrally combined together with the bus bars 38 and 39, it is difficult to wind the intermediate wire 37 because of the plate-like upright portions 394a and 394b.

  As shown in FIG. 2, after the bobbin 20 is formed, the covers 50 are attached to both sides of the bobbin 20 in the Y-axis direction, and then the magnetic cores 40a and 40b are attached from the vertical direction in the Z-axis direction. That is, the tips of the middle legs 46a and 46b and the tips of the side legs 48a and 48b are joined together.

  Next, the base 70 shown in FIG. 5D is accommodated in the bobbin leg portion 26. A pedestal 70 may be attached to the bobbin leg 26 in advance. After that, the bottom plate 91 shown in FIG. 2 is bonded to the bottom opening of the case 90, and the assembly is housed in the case 90 having an open top, and the inside of the case 90 is filled with a heat radiation resin. Through the steps as described above, the transformer 10 according to the present embodiment can be manufactured.

  As shown in FIG. 5B, the bobbin 20 in the present embodiment is configured by integrally combining a first bobbin 21, an intermediate bobbin 23, and a second bobbin 22. In addition, the intermediate bobbin 23 is not housed in the second bobbin 22, but the second cylindrical portion 226 is combined with the second end (lower end in the Z-axis direction) of the intermediate cylindrical portion 236. As a result, as shown in FIG. 5E, the second intermediate flange 232 is in close contact with the opposite surface of the second coil portion 32 that is in close contact with the second end flange 220.

  As shown in FIG. 4, the intermediate coil portion 33 is wound around the intermediate bobbin 23 so as to be in contact with the second intermediate flange portion 232, so that the intermediate coil portion 33 wound around the intermediate bobbin 23, The second coil part 32 arranged on the two bobbins 22 is arranged at a distance corresponding to the thickness of the second intermediate collar part 232. When the intermediate bobbin 23 is molded, the thickness of the second intermediate flange 232 can be controlled with relatively high accuracy.

  Further, if the second bobbin 22 is arranged so as to be below the gravitational direction (Z-axis direction), and the intermediate bobbin 23 and the first bobbin 21 are combined on the second bobbin 22, The first coil portion 31 is disposed on the first coil portion 31, and the lower surface of the first coil portion 31 is in close contact with the upper surface of the first intermediate flange portion 231 due to the gravity of the first coil portion 31. Further, the intermediate coil portion 33 is wound around the intermediate bobbin 23 so as to be in contact (preferably in close contact) with the lower surface of the first intermediate flange portion 231.

  Therefore, the intermediate coil part 33 wound around the intermediate bobbin 23 and the first coil part 31 arranged on the first bobbin 21 are arranged at a distance corresponding to the thickness of the first intermediate collar part 231. be able to. When the intermediate bobbin 23 is molded, the thickness of the first intermediate flange 231 can be controlled relatively accurately.

  After the first bobbin 21, the intermediate bobbin 23, and the second bobbin 22 are combined in this way, the first coil part 31 and the intermediate coil part 33 can be obtained by fixing these bobbins with a fixing means such as an adhesive. The distance in the winding axis direction between the first coil portion 32 and the second coil portion 32 is kept constant corresponding to the thickness of each of the flange portions 231 and 232. Therefore, it is easy to increase the coupling between the coil portions 31, 33, 32, and it is possible to realize the transformer 10 that is a coil device with stable leakage characteristics.

  Moreover, in this embodiment, since it is not necessary to perform insert molding etc., the height of the bobbin 20 in the winding axis direction can be reduced. Further, since the intermediate bobbin 23 is not housed in the second bobbin 22, the second cylinder part 226 is combined with the second end (the lower end in the Z-axis direction) of the intermediate cylinder part 236. The size of the two bobbins 22 in the radial direction can be reduced. The first bobbin 21 is the same as the second bobbin 22.

  Furthermore, in this embodiment, as shown in FIG. 4, the first coil portion 31 and the second coil portion 32 are constituted by bus bars 38 and 39 that are plate-like conductors, and therefore the first coil portion. A large current can flow through 31 and the second coil section 32.

  In the present embodiment, as shown in FIG. 5E, the second coil portion 32 is provided at the intersection of the inner surface (upper surface in the Z-axis direction) of the second end flange portion 220 and the outer peripheral surface of the second cylindrical portion 226. The 2nd positioning part 229 contact | abutted to the inner peripheral side surface of this is formed. With such a configuration, it is possible to prevent the inner peripheral side surface of the second coil portion 32 from coming into contact with the positioning portion 229 and the second coil portion 32 from being displaced in the radial direction.

  Moreover, the positioning portion 229 is formed on the outer peripheral side surface of the step portion 229a, and the second intermediate flange 232 abuts on the step surface (upper surface in the Z-axis direction) of the step portion 229a. The length LP2 in the Z-axis direction of the step portion 229a is equal to or less than the plate thickness TH2 of the second coil portion 32. By adopting such a configuration, the second intermediate flange 232 reliably adheres to the surface of the bus bar 39 constituting the second coil portion 32.

  A second intermediate notch portion 237b that is notched at a predetermined depth is formed on the second end (lower end in the Z-axis direction) side of the inner peripheral side surface of the intermediate tube portion 236. On the first end (upper end in the Z-axis direction) side, a second engaging convex part 227 that engages with the second intermediate notch 237b is formed, and the second engaging convex part 227 has a distal end in the Z-axis direction. The engaging protrusion 227 engages with the intermediate notch 237b so that a gap G2 is formed between the surface F2 and the bottom surface F3b of the second intermediate notch 237b. With such a configuration, the lower surface of the second intermediate flange 232 is securely adhered to the upper surface of the bus bar 39 of the second coil portion 32.

  Furthermore, the engaging convex part 227 engages with the intermediate notch part 237b so that the inner peripheral side surface of the intermediate cylindrical part 236 and the outer peripheral side surface of the engaging convex part 227 face each other. By adopting such a configuration, the outer peripheral side surface of the engaging convex portion 227 functions as a positioning surface, and it is possible to prevent the intermediate cylinder portion 236 from being displaced in the radial direction.

  The present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention.

  For example, as shown in FIG. 6C, the second terminal portion 381b of the bus bar 38 may be connected to the first terminal portion 391a of the bus bar 39, and the bus bars 38, 39 may be connected so as to be continuous in a predetermined winding direction. In this case, as shown in FIG.7 (b), the 1st coil part 31 and the 2nd coil part 32 which are each comprised by the bus bar 38 and 39 on the secondary side are connected in series.

  In addition, in FIG. 5E, the formation of the second positioning portion 229 may be omitted. Further, any one of the first positioning part 219 and the intermediate positioning part 239 may be omitted. In this case, for example, the function of the intermediate positioning portion 239 can be complemented by setting the length in the Z-axis direction of the first step portion 219a of the first positioning portion 219 to LP1 + LP3. Alternatively, the length in the Z-axis direction of the intermediate stepped portion 239a of the intermediate positioning portion 239 may be LP1 + LP3. In this case, the function of the first positioning portion 219 can be substantially supplemented.

  Further, the relationship between the primary coil and the secondary coil described above may be reversed. That is, the bus bars 38 and 39 may constitute a primary coil, and the intermediate wire 37 may constitute a secondary coil.

DESCRIPTION OF SYMBOLS 10 ... Transformer 20 ... Bobbin 21 ... 1st bobbin 210 ... 1st end collar 211 ... Cover engaging part 216 ... 1st cylinder part 217 ... 1st engaging convex part 218 ... 1st engaging concave part 219 ... 1st Positioning part 219a ... 1st step part 22 ... 2nd bobbin 220 ... 2nd end collar part 226 ... 2nd cylinder part 227 ... 2nd engagement convex part 228 ... 2nd engagement recessed part 229 ... 2nd positioning part 229a ... Second step portion 23 ... Intermediate bobbin 231 ... First intermediate flange portion 231a ... First lead locking notch 232 ... Second intermediate flange portion 233 ... Third intermediate flange portion 233a ... Second lead locking notch 233b ... Wire Insertion notch 236 ... intermediate cylinder part 237a ... first intermediate notch part 238a ... first intermediate convex part 237b ... second intermediate notch part 238b ... second intermediate convex part 239 ... intermediate positioning part 239a ... intermediate step part 24 ... 1st terminal block 241 ... first side wall 242 ... positioning surface 25 ... second terminal block 251 ... second side wall 252 ... locking portion 253 ... engaging projection 26 ... bobbin leg 30 ... coil 31 ... first coil 32 ... 2nd coil part 33 ... Intermediate coil part 37 ... Intermediate wire 37a, 37b ... Lead part 371a, 371b ... Lead rising part 372 ... Inter-coil connection part 38, 39 ... Bus bar 381a, 381b, 391a, 391b ... Terminal part 383, 393 ... Openings 384a, 384b, 394a, 394b ... Plate-like uprights 40a, 40b ... Magnetic cores 44a, 44b ... Base parts 46a, 46b ... Middle legs 48a, 48b ... Side legs 50 ... Covers 52 ... Cover body parts 54 ... locking piece 56 ... side leg guide piece 58 ... engaging part 60 ... lead wire cover 61 ... engaging part 70 ... pedestal 80 ... terminal 90 ... Scan 91 ... bottom plate 92 ... boss 100 ... heat radiating resin

Claims (8)

With bobbin,
A first coil portion made of a plate-like conductor;
A second coil part that is located separately from the first coil part and is made of a plate-like conductor;
A coil device having an intermediate coil portion located between the first coil portion and the second coil portion,
The bobbin is
An intermediate cylinder portion around which the intermediate coil portion is wound, and a first intermediate flange portion and a second intermediate flange portion formed on each of the first end and the second end in the axial direction of the intermediate cylinder portion; With bobbin,
A first bobbin having a first tubular portion combined with the first end, wherein a first end collar is formed on the first tubular portion;
A second bobbin having a second cylindrical portion combined with the second end, and a second end collar formed on the second cylindrical portion;
The intermediate coil portion is wound around the intermediate cylinder portion so as to contact the first intermediate flange portion and the second intermediate flange portion,
A coil device in which the second tube portion is combined with the second end of the intermediate tube portion such that the second intermediate flange portion contacts the opposite surface of the second coil portion that contacts the second end flange portion. . The second coil portion has a substantially ring plate shape,
2. The coil according to claim 1, wherein a positioning portion that abuts against an inner peripheral side surface of the second coil portion is formed at an intersection between the inner surface of the second end flange portion and the outer peripheral surface of the second cylindrical portion. apparatus. The positioning part is formed on the outer peripheral side surface of the step part,
The second intermediate flange comes into contact with the stepped surface of the stepped portion;
The coil device according to claim 2, wherein a length of the stepped portion in the axial direction is equal to or less than a plate thickness of the second coil portion. On the second end side of the inner peripheral side surface of the intermediate tube portion, an intermediate notch portion that is notched at a predetermined depth is formed,
On the first end side of the second cylindrical part, an engaging convex part that engages with the intermediate notch part is formed,
The engagement convex part engages with the intermediate notch part so that a gap is formed between a front end surface of the engagement convex part and a bottom surface of the intermediate notch part. The coil apparatus as described.   5. The coil device according to claim 4, wherein the engaging convex portion engages with the intermediate notch portion such that an inner peripheral side surface of the intermediate cylindrical portion and an outer peripheral side surface of the engaging convex portion face each other.   The first tube portion is combined with the first end of the intermediate tube portion so that a space in which the first coil portion can be disposed is formed between the first end flange portion and the first intermediate flange portion. The coil device according to any one of claims 1 to 5.   The said 1st cylinder part is combined with the 1st end of the said intermediate | middle cylinder part so that the said 1st end collar part may contact | abut on the opposite side surface of the said 1st coil part which contact | abuts the said 1st intermediate collar part. 6. The coil device according to 6.   The first coil part and the second coil part constitute either one of a primary coil or a secondary coil, and the intermediate coil part constitutes either the primary coil or the secondary coil. The coil device according to any one of claims 1 to 7, wherein

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