JP2021170674A - Coil device - Google Patents

Abstract

To provide a coil device which can stabilize the inductance while reducing the resistance in a wiring line, and which is also excellent in heat dissipation.SOLUTION: A lead base 22 of a coil device 10 comprises: a first base portion 22a on which both ends of a first wire 37, namely a pair of first lead parts 37a, 37b, are disposed such that they are insulated from each other; and a second base portion 22b which is adjacent to the first base portion, and on which both ends of a second wire 38, namely a pair of second lead parts 38a, 38b, are disposed such that they are insulated from each other as well as from the first lead part. The first base portion and the second base portion are provided with a pair of first lead grooves 22a1, 22a2 and a pair of second lead grooves 22b1, 22b2, respectively. The first lead grooves and the second lead grooves have first axial-direction groove portions continuing therefrom. Raised parts 37c, 37d of the first lead part and raised parts 38c, 38d of the second lead part pass through the first axial-direction groove portions.SELECTED DRAWING: Figure 2

Description

The present invention relates to a coil device having excellent heat dissipation, which is used as, for example, a reactor, an inductor, or a transformer.

As a coil device used for applications such as a reactor, for example, the device shown in Patent Document 1 is known. In a conventional coil device, it is common that a plurality of terminals are mounted on both sides along a first axis substantially perpendicular to the bobbin shaft core. With such a structure, it is easy to route the lead portion of the wire wound around the outer circumference of the bobbin.

Japanese Unexamined Patent Publication No. 2014-36194

However, if there are multiple terminals on both sides of the bobbin, it is necessary to wire from both sides of the bobbin to the circuit board, etc., which increases the resistance for wiring and makes the inductance unstable. It was found that there were challenges. In addition, there is an increasing demand for improving heat dissipation by moving the coil device, which requires heat dissipation, to one side instead of the center of the circuit board.

The present invention has been made in view of such an actual situation, and an object of the present invention is to provide a coil device capable of lowering the resistance of wiring, stabilizing the inductance, and having excellent heat dissipation. be.

In order to achieve the above object, the coil device according to the present invention
The first wire wound around the bobbin and
A second wire that is insulated from the first wire and wound around the outer circumference of the bobbin,
A coil device having a lead pedestal provided at one end along a first axis substantially perpendicular to the bobbin shaft core.
The lead pedestal is
A first pedestal portion in which a pair of first reed portions at both ends of the first wire are arranged so as to be insulated from each other, and a first pedestal portion.
Adjacent to the first pedestal portion, a pair of second lead portions at both ends of the second wire are insulated from each other and the first lead portion is also insulated from the second pedestal portion. Have.

In the coil device according to the present invention, the pair of first lead portions of the first wire and the pair of second leads of the second wire are provided not from both sides of the bobbin but from the lead pedestal provided at one end of the bobbin. I try to pull out the part. Therefore, it becomes easy to move the coil device, which requires heat dissipation, to one side instead of the center of the circuit board, the heat dissipation structure is simplified, and the heat dissipation characteristics are improved. Further, even if the coil device is moved to the end of the circuit board or the circuit element group, the first lead portion and the second lead portion can be pulled out from the lead pedestal at one end, and is used for wiring. The resistance does not increase and the inductance stabilizes. Further, a coil device having low resistance and low loss can be realized at low cost.

Preferably, the first pedestal portion is formed with a pair of first reed grooves through which the pair of the first reed portions pass.
A pair of second lead grooves through which the pair of the second lead portions pass is formed in the second pedestal portion.
The 1-lead groove and the 2nd lead groove are separated by an insulating wall provided on the lead pedestal.

With such a configuration, good insulation between the first lead portion and the second lead portion is ensured, and it becomes easy to arrange the lead pedestal at one end of the bobbin.

Preferably, the first wire and the second wire are wound around the bobbin along the shaft core in order from the vicinity of the lead pedestal. The second pedestal portion may be arranged outside the first pedestal portion along the first axis. Alternatively, the first pedestal portion may be arranged so as to be surrounded by the second pedestal portion.

With such a configuration, good insulation between the first lead portion and the second lead portion is ensured, and it becomes easy to arrange the lead pedestal at one end of the bobbin.

Preferably, a lead guide cover is attached to the outer circumference of the bobbin where the lead pedestal is located, and a pair of first lead portions of the first wire on the way from the outer circumference of the bobbin to the lead pedestal. And the pair of second lead portions of the second wire on the way from the outer circumference of the bobbin to the lead pedestal are insulated.

With such a configuration, good insulation between the first lead portion and the second lead portion is ensured, and it becomes easy to arrange the lead pedestal at one end of the bobbin.

Preferably, the lead guide cover has a second lead intermediate groove that guides the pair of second lead portions of the second wire from the outer circumference of the bobbin toward the lead pedestal in directions away from each other. It is equipped.

With this configuration, the second lead portion of the second wire wound around the outer circumference of the bobbin on the side far from the lead pedestal is insulated from the first lead portion of the first wire of the second wire. It becomes easy to guide to the lead pedestal while preventing unwinding. Therefore, the inductance can be stabilized. Further, the reduction in resistance and the reduction in loss of the coil device can be further improved.

A pair of the second lead portions are separated from each other in the axial direction to insulate the outer circumference of the bobbin on which the lead pedestal is located, and intersect with each other when viewed from the axial direction to form the lead guide cover. A collar portion that guides the user may be provided.

With this configuration, the second lead portion of the second wire wound around the outer circumference of the bobbin on the side far from the lead pedestal is insulated from the first lead portion of the first wire of the second wire. It becomes easy to guide to the lead pedestal while preventing unwinding. Therefore, the inductance can be stabilized. Further, the reduction in resistance and the reduction in loss of the coil device can be further improved.

Since the first wire is wound around the outer circumference of the bobbin on the side close to the lead pedestal, the first lead portion of the first wire is different from the second lead portion of the second wire when viewed from the axis. The first wire can be easily guided to the lead pedestal while preventing the first wire from unwinding without overlapping with each other.

The lead guide cover may be provided with a guide inclined wall that guides the pair of the second lead portions to the lead guide cover without intersecting the lead guide cover when viewed from the axial direction.

Even with this configuration, the second lead portion of the second wire wound around the outer circumference of the bobbin on the side far from the lead pedestal is insulated from the first lead portion of the first wire of the second wire. It becomes easy to guide to the lead pedestal while preventing unwinding. Therefore, the inductance can be stabilized. Further, the reduction in resistance and the reduction in loss of the coil device can be further improved.

Preferably, one of the pair of the first reed portions and one of the pair of the second reed portions are pulled out side by side from the lead pedestal.
The other of the pair of the first lead portions and the other of the pair of the second lead portions are pulled out side by side from the lead pedestal.

With this configuration, one of the pair of the first lead portions and one of the pair of the second lead portions can be easily connected, and a specific circuit for non-contact power feeding can be provided. It can be easily configured. The other of the pair of the first lead portions and the other of the pair of the second lead portions may be connected.

Preferably, the coil device is
A core assembly in which a part is attached to a through hole formed along the axis of the bobbin.
A case in which the first wire and the second wire are wound to cover the outer peripheral portion of the bobbin to which the core assembly is attached.
A heat-conducting resin housed inside the case and capable of entering the gap between the case and the bobbin, the gap between the case and the core assembly, and the gap between the bobbin and the core assembly. Further has.

With such a configuration, the heat dissipation of the coil device is further improved.

The core assembly has at least a pair of split cores that are split at the split planes.
These split cores are integrated on both sides of the middle leg portion that enters the through hole of the bobbin, the base portion that is integrated with the middle leg portion and is located outside the through hole, and the base portion. Has an outer leg that is attached to the outside of the bobbin
The protrusion length of the middle leg portion from the base portion is shorter than the protrusion length of the outer leg portion from the base portion.
The gap for the gap formed at the protruding tip of the middle leg is filled with the heat transfer resin.

With such a configuration, it becomes possible to adjust the inductance of the coil device, and it becomes easy to dissipate the heat in the central portion of the core assembly, in which heat tends to be trapped, through the heat transfer resin.

FIG. 1 is an overall perspective view of a coil device according to an embodiment of the present invention. FIG. 2 is an exploded perspective view of the coil device shown in FIG. FIG. 3A is a cross-sectional view taken along the line IIIA-IIIA shown in FIG. FIG. 3B is a cross-sectional view taken along the line IIIB-IIIB shown in FIG. FIG. 3C is a partial cross-sectional view of the lead pedestal along the line IIIC-IIIC shown in FIG. FIG. 4 is a perspective view of the bobbin shown in FIG. FIG. 5 is a perspective view showing the wound state of the first wire and the second wire shown in FIG. 3B, and showing the relationship between these and the lead guide cover. FIG. 6 is a front view showing the relationship between the bobbin lead pedestal shown in FIG. 2, the lead guide cover, and the lead portion. It is a circuit diagram which shows the circuit example of the coil device shown in FIG. FIG. 8 is a perspective view showing a lead pedestal provided on the bobbin of the coil device according to another embodiment of the present invention. FIG. 9A is a perspective view showing a coil device according to still another embodiment of the present invention. FIG. 9B is a perspective view showing the relationship between the first wire and the second wire wound around the bobbin shown in FIG. 9A and the lead guide cover. FIG. 10 is a front view of the coil device shown in FIG. 9A as viewed from the X-axis direction. FIG. 11 is a perspective view of only the bobbin shown in FIG. 9A.

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

1st Embodiment As shown in FIGS. 1 and 2, the coil device 10 according to the present embodiment includes, for example, an in-vehicle 4-terminal coil filter device, an in-vehicle charging device inductor device, an isolation transformer, a line filter, a noise filter, and the like. Used as.

The coil device 10 has a bobbin 20, a core assembly 40, and a case 100 that surrounds a lower portion thereof in the Z-axis direction, and is attached to the upper surface of the housing. The housing is, for example, a plate-shaped member to which the coil device 10 is attached, and may be a part of an automobile part, and cooling water flows on the back surface (the side opposite to the attachment surface of the coil device 10). You may.

As shown in FIG. 2, the bobbin 20 includes a bobbin main body 24, a lead pedestal 22 integrally molded on the upper portion of one end of the bobbin main body 24 in the X-axis direction in the Z-axis direction, and a lead thereof. It has an auxiliary pedestal 23 integrally molded on the upper side in the Z-axis direction on the opposite side of the X-axis direction from the use pedestal 22.

In the present embodiment, the lead portions 37a and 37b of the first wire 37 and the lead portions 38a and 38b of the second wire 38, which will be described later, are attached to the lead pedestal 22. A terminal cover 25 is attached to the upper portion of the lead pedestal 22 to which these lead portions 37a, 37b, 38a, 38b are attached. In the present embodiment, the lead portion of any wire cannot be attached to the auxiliary pedestal 23.

A pair of partition covers 50 are attached to both sides of the bobbin body 24 in the Y-axis direction. The cover body 52 of the partition cover 50 has a shape that covers the outer periphery of the bobbin body 24 located between the lead pedestal 22 and the auxiliary pedestal 23 in the bobbin 20. Locking pieces 54 that are bent substantially vertically from the cover body 52 toward the bobbin body 24 are integrally molded at both ends of the cover body 52 in the Z-axis direction. A pair of locking pieces 54 formed on both sides of the cover main body 52 in the Z-axis direction are attached so as to sandwich the upper and lower surfaces of the bobbin main body 24 in the Z-axis direction.

Further, side leg guide pieces 56 extending in the Z-axis direction are integrally formed on the outer surfaces of both ends of the cover main body 52 in the X-axis direction. The inner surfaces of the side legs 48a and 48b of the core assembly 40, which will be described later, come into contact with the outer surface of the cover body 52 located between the pair of side leg guide pieces 56, and the side legs 48a and 48b are in the X-axis direction. Movement is restricted by a pair of side leg guide pieces 56. Further, a fitting piece 58 is formed on the inner surface of the cover main body 52 along the outer circumference of the bobbin main body 24. As shown in FIG. 3A, the fitting piece 58 is fitted into the fitting groove 34c formed on the outer periphery of the wound partition flange 34 to improve the insulation between the first wire 37 and the second wire 38. There is. These partition covers 50 are made of an insulating member such as plastic similar to the bobbin 20.

As shown in FIG. 2, in the present embodiment, the core assembly 40 has an upper core 40a and a lower core 40b. These cores 40a and 40b can be separated into two divided cores 42a, 42a and 42b, 42b having the same shape, respectively, on the divided surfaces 43a and 43b, respectively. In the present embodiment, the divided cores 42a, 42a and 42b, 42b all have the same shape, have an E-shaped cross section in a ZZ cross section, and are a kind of E-shaped core.

By combining the pair of split cores 42a and 42a arranged at the upper part in the Z-axis direction, the ZZ cross section has an E-shaped cross section, and a so-called E-shaped core is formed. The other pair of split cores 42b, 42b arranged at the lower part in the Z-axis direction also have an E-shaped cross section in the ZZ cross section by being combined to form a so-called E-shaped core.

Each of the divided cores 42a arranged on the upper side in the Z-axis direction includes a base portion 44a extending in the Y-axis direction and a pair of side leg portions 48a protruding in the Z-axis direction from both ends of the base portion 44a in the Y-axis direction. It has a middle leg portion 46a protruding in the Z-axis direction from an intermediate portion of the base portion 44a located between them. Each of the divided cores 42b arranged on the lower side in the Z-axis direction includes a base portion 44b extending in the Y-axis direction and a pair of side leg portions 48b protruding in the Z-axis direction from both ends of the base portion 44b in the Y-axis direction. , And a middle leg portion 46b protruding in the Z-axis direction from the intermediate portion of the base portion 44b located between them.

The pair of middle leg portions 46a are inserted into the core leg through hole 26 of the bobbin 20 from above in the Z-axis direction. Similarly, the pair of middle leg portions 46b are inserted into the core leg through hole 26 of the bobbin 20 from below in the Z-axis direction, and inside the through hole 26, a predetermined gap is formed at the tip of the middle leg portions 46a. It is configured to face each other with a gap 47 (see FIGS. 3A and 3B). The base portion 44a of the split core 42a and the base portion 42b of the split core 42b do not enter the through hole 26 and are located outside the bobbin main body 24 in the Z-axis direction.

As shown in FIG. 3A, the protrusion length of the middle leg portion 46a from the base portion 44a in the Z-axis direction is shorter than the protrusion length of the outer leg portion 48a from the base portion 44a of the split core 42a in the Z-axis direction. As a result, the gap 47 for the gap is formed. Alternatively, by making the protrusion length of the middle leg portion 46b from the base portion 44b in the Z-axis direction shorter than the protrusion length of the outer leg portion 48b from the base portion 44b of the split core 42b in the Z-axis direction, the gap is used. The gap 47 is formed.

The tips of the outer legs 48a and 48b in the Z-axis direction are abutted on the outside of the bobbin 20 in the Z-axis direction. A gap 47 is formed between the Z-axis direction tips of the middle leg portions 46a and 46b, which are formed shorter than the Z-axis direction protrusion lengths of the outer leg portions 48a and 48b. The gap 47 for the gap in the Z-axis direction is determined according to the leakage characteristics of the coil device 10 and the like. Unless otherwise specified in the specification, the terms "outside" and "inside" are used to mean outside or inside of the bobbin 20.

As shown in FIG. 2, inside the through hole 26, a pair of separation convex portions 27 (only one in FIG. 2) are formed along the Z-axis direction so as to divide the through hole 26 along the Y-axis direction. (Shown) is preferably formed. The separation convex portion 27 is interposed between the divided surfaces 43a of the pair of middle leg portions 42a and 42a, and is interposed between the divided surfaces 43b of the middle leg portions 42b and 42b. As a result, the middle leg portions 42a, 42a or the middle leg portions 42b, 42b are arranged so that the divided surfaces 43a (43b) face each other with a predetermined gap inside the through hole 26 and do not come into contact with each other. ..

A predetermined gap (divided gap in the X-axis direction) between the dividing surfaces 43a, 43a (43b, 43b) formed by the pair of separating convex portions 27 is adjusted by the thickness of the separating convex portion 27 in the X-axis direction. can do. By setting the gap within a predetermined range, the heat conductive resin 90 (see FIG. 3B) such as the potting resin described later can easily enter without lowering the inductance of the core more than necessary, and the heat dissipation is improved.

Further, the protruding length of the pair of separation convex portions 27 on the inner peripheral surface of the through hole 26 in the Y-axis direction is predetermined between the divided surfaces 43a, 43a (43b, 43b) formed inside the through hole 26. It is determined so that the gap (divided gap in the X-axis direction) is not closed, and the inner diameter of the through hole 26 in the Y-axis direction is preferably 1/10 to 1/3.

The middle leg portions 42a, 42a or the middle leg portions 42b, 42b, respectively, have an elliptical column shape long in the X-axis direction so as to match the shape of the inner peripheral surface of the through hole 26 in a combined state. The shape thereof is not particularly limited, and may be changed according to the shape of the through hole 26. Further, the side leg portions 48a and 48b have an inner concave curved surface shape that matches the shape of the outer peripheral surface of the bobbin main body 24, and the outer surface thereof has a plane parallel to the XZ plane. In the present embodiment, the materials of the divided cores 42a and 42b include soft magnetic materials such as metal and ferrite, but are not particularly limited.

In the drawings, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other, and the Z-axis coincides with the winding axis of the first wire 37 and the second wire 38 (the axis of the bobbin 20) described later. It corresponds to the height (thickness) of the coil device 10. In the present embodiment, the lower side of the coil device 10 in the Z-axis direction is the installation surface (surface of the housing) of the coil device. Further, the Y-axis coincides with the longitudinal direction of the divided surfaces 43a of the pair of divided cores 42a and 42a or the divided surfaces 43b of the pair of divided cores 42b and 42b. Further, the X-axis is adapted to coincide with the longitudinal direction of the through hole 26.

As shown in FIG. 3A, the end partition collars 31 and 32 extend outward in the radial direction at both ends of the winding cylinder portion 28 of the bobbin 20 in the coil device 10 of the present embodiment in the Z-axis direction. It is integrally molded substantially parallel to the XY plane. On the outer peripheral surface of the winding cylinder portion 28 located between the end partition flanges 31 and 32 in the Z-axis direction, the winding partition collars 33 to 35 are predetermined in the Z-axis direction so as to project outward in the radial direction. It is formed at intervals.

By the winding partition walls 33 to 35 formed between these end partition flanges 31 and 32, winding compartments S1 to S4 are formed between these partition flanges in order from the top in the Z-axis direction. NS. The number of winding bulkhead collars 33 to 34 and winding compartments S1 to S4 is not particularly limited.

In the present embodiment, the first wire 37 is continuously wound by α-winding in the winding sections S1 and S2, and the second wire 38 is continuously wound by α-winding in the sections S3 to S4. .. In the present embodiment, the first wire 37 constitutes the primary coil and the second wire 38 constitutes the secondary coil, but the reverse may be true.

Further, in the present embodiment, as shown in FIG. 3B, at least one connecting groove 33c that connects the adjacent compartments S1 and S2 to each other is formed in the wound partition wall 33. Through the connecting groove 33c, the first wire 37 of the compartment S1 is passed through the compartment S2, and these compartments S1 and S2
The bobbin 20 can be wound α around the outer circumference of the winding cylinder portion 28.

Further, at least one connecting groove 35c that connects the adjacent compartments S3 and S4 to each other is formed in the wound partition flange 35. Through the connecting groove 35c, the second wire 38 of the compartment S3 is passed through the compartment S4, and α winding is possible on the outer periphery of the winding cylinder portion 28 of the bobbin 20 in these compartments S3 and S4.

Regarding the wound bulkhead collar 34, in order to insulate the first wire 37 and the second wire 38, it is not necessary to form a connecting groove similar to these. In the present embodiment, in order to improve the insulation between the first wire 37 and the second wire 38, the thickness of the wound bulkhead collar 34 in the Z-axis direction is made thicker than that of the other wound bulkhead collar 33 or 35. There is. In the present embodiment, the connecting groove 33c for the first wire 37 and the connecting groove 35c for the second wire 38 are formed on the same side in the X-axis direction, but are formed on opposite sides to each other. You may.

As shown in FIG. 3A, the section width along the Z axis in each section S1 and S2 around which the first wire 37 is wound is set to a width that allows only one first wire 37 to enter in the Z axis direction. There is. However, the partition width may be set to a width that allows two or more first wires 37 to enter. Further, in the present embodiment, it is preferable that all the compartment widths are the same, but they may be slightly different.

Further, the section width along the Z axis in each section S3 to S4 around which the second wire 38 is wound is set to a width in which only one second wire 38 can be inserted in the Z axis direction, and each section is set. Each time, the wire winding parts can be separated from each other. In the present embodiment, the section width along the Z axis in each section S3 to S4 may be the same as or different from the section width according to the wire diameter of the second wire 38.

Further, the width (length in the radial direction with respect to the winding axis) of the partition collars 31 to 35 is set to a height at which one or more wires 37 or 38 can be inserted. , Preferably set to a height at which 2 to 8 layers of wire can be wound. The heights of the partition collars 31 to 35 are all preferably the same, but may be different. In the present embodiment, the winding method of the wire 37 or 38 wound around each of the compartments S1 to S4 is not particularly limited, and may be normal winding or α winding, but α winding is preferable.

The wires 37 and 38 may be composed of a single wire or a stranded wire, and are preferably composed of an insulating coated conductor. The outer diameters of the wires 37 and 38 are not particularly limited. The second wire 38 may be the same as the first wire 37, but may be different.

As shown in FIG. 4, bobbin legs 32a are integrally formed at both ends of the end partition wall 32 located at the lowermost portion in the Z-axis direction in the X-axis direction. Each bobbin leg 32a is formed so as to project downward in the Z-axis direction from both ends of the end partition wall 32 in the X-axis direction, and heat-dissipating fins 32b for enhancing heat dissipation are formed on the bottom surface of the leg 32a. You may have done so. Alternatively, a recess may be formed on the bottom surface of the leg portion 32a, and a heat conductive block may be mounted in the recess. The heat conductive block may be made of, for example, a metal similar to the heat dissipation cover. In this embodiment, the heat dissipation cover that covers the core assembly 40 to improve heat dissipation is not shown.

The bobbin 20 shown in FIG. 4 is made of plastic such as PPS, PET, PBT, LCP, and nylon, but may be made of other insulating members. However, in the present embodiment, the bobbin 20 is preferably made of, for example, a plastic having a thermal conductivity of 1 W / m · K or more, and is made of, for example, PPS, nylon, or the like.

As shown in FIGS. 3A and 3B, the bottom surface of the core assembly 40 preferably contacts the bottom plate 80 of the case 100. The bottom plate 80 is attached to the bottom of the case 100, and the inside of the case 100 can be filled with a heat-transmitting resin 90 such as a potting resin. The bottom plate 80 is preferably made of the same metal as the heat dissipation cover. Further, the case 100 may be made of the same resin as the bobbin 20, but the case 100 does not necessarily have to be the same resin. Further, the case 100 may be made of metal.

The potting resin is composed of a silicone resin, urethane resin, epoxy resin, etc. that are soft even after injection, and the longitudinal elastic modulus of the potting resin is preferably 0.1 to 100 MPa. The heat-conducting resin 90 made of the potting resin enters the gap between the case 100 and the bobbin 20, the gap between the case 100 and the core assembly 40, and the gap between the bobbin 20 and the core assembly 40. Further, the heat conductive resin 90 made of the potting resin also enters the gap between the wires 37 and 38 and the bobbin 20.

The lead portions 38a and 38b of the second wire 38 arranged below the first wire 37 in the Z-axis direction pass through the outside of the bobbin 20 around which the first wire 37 is wound, and are for leads shown in FIG. It is necessary to face the pedestal 22. Further, in the present embodiment, all the lead portions 37a, 37b, 38a, 38b are pulled out to the lead pedestal 22 at one end of the bobbin 20 in the X-axis direction. Moreover, these lead portions 37a, 37b, 38a, 38b need to have good insulation from each other.

In the present embodiment, in order to satisfy these requirements, as shown in FIG. 4, the lead pedestal 22 is integrally formed with the first pedestal portion 22a and the second pedestal portion 22b. A pair of first lead portions 37a and 37b, which are both ends of the first wire 37 shown in FIG. 5, are arranged on the first pedestal portion 22a so as to be insulated from each other. Further, the second pedestal portion 22b shown in FIG. 4 is arranged adjacent to the outside of the first pedestal portion 22a in the X-axis direction. A pair of second lead portions 38a and 38b, which are both ends of the second wire 38 shown in FIG. 5, are arranged on the second pedestal portion 22b so as to be insulated from each other and also to be insulated from the first lead portions 37a and 37b. NS.

In the first pedestal portion 22a shown in FIG. 4, a pair of first lead grooves 22a1, 22a2 through which the pair of first lead portions 37a and 37b shown in FIG. It is formed so as to be insulated from each other. Each of the first lead grooves 22a1, 22a2 has a Y-axis direction groove portion that faces the opposite outer side in the Y-axis direction and an X-axis direction groove portion that faces the outside in the X-axis direction from the inside of each Y-axis direction groove portion. Each has an L-shape. The bottom of each of the first lead grooves 22a1, 22a2 in the X-axis direction penetrates in the Z-axis direction, and the rising portions 37c and 37d of the lead portions 37a and 37b shown in FIG. 5 pass through in the Z-axis direction. It is possible. The portions of the lead portions 37a and 37b shown in FIG. 5 beyond the rising portions 37c and 37d are guided along the first lead grooves 22a1, 22a2 shown in FIG.

The second pedestal portion 22b shown in FIG. 4 is formed with a pair of second lead grooves 22b1, 22b2 through which the pair of second lead portions 38a and 38b shown in FIG. The two lead grooves 22b1,22b2 are separated from each other by insulating walls 22c1,22c2 provided on the lead pedestal 22.

The second lead grooves 22b1 and 22b2 have a Y-axis direction groove portion that faces the opposite outer side in the Y-axis direction and an X-axis direction groove portion that faces the outside in the X-axis direction from the inside of each Y-axis direction groove portion. However, each has an L-shape. The bottom of each of the second lead grooves 22b1, 22b2 in the X-axis direction penetrates in the Z-axis direction, and the rising portions 38c and 38d of the lead portions 38a and 38b shown in FIG. 5 pass through in the Z-axis direction. It is possible. The portions of the lead portions 38a and 38b shown in FIG. 5 beyond the rising portions 38c and 38d are guided along the second lead grooves 22b1, 22b2 shown in FIG.

Each of the insulating walls 22c1, 22c2 has a Y-axis direction wall portion that faces the opposite outer side in the Y-axis direction, and an X-axis direction wall portion that faces the outside in the X-axis direction from the inside of each Y-axis direction wall portion. , Each has an L-shape. Each of the insulating walls 22c1, 22c2 is designed to secure insulation between the first lead grooves 22a1,22a2 and the second lead grooves 22b1,22b2, respectively.

In each insulating wall 22c1,22c2, engaging grooves 22d1,22d2 that open at the upper part in the Z-axis direction are formed at substantially the same depth (depth is not limited) as each lead groove 22a1,22a2, 22b1,22b2. The insulating creepage distance between the first lead grooves 22a1,22a2 and the second lead grooves 22b1,22b2 is lengthened. As shown in FIG. 3C, the engaging protrusions 25a integrally formed on the back surface of the terminal cover 25 are fitted into the engaging grooves 22d1, 22d2, and the first lead grooves 22a1, 22a2 and the second lead are fitted. The insulation between the grooves 22b1, 22b2 is further enhanced.

The lead guide cover 60 shown in FIG. 5 is attached to the outer periphery of the bobbin 20 where the lead pedestal 22 shown in FIG. 4 is located. The cover 60 includes a pair of first lead portions 37a and 37b of the first wire 37 on the way from the outer circumference of the bobbin 20 shown in FIG. 4 to the lead pedestal 22, and a lead pedestal from the outer circumference of the bobbin 20 shown in FIG. The pair of second lead portions 38a and 38b of the second wire 38 on the way to 22 are insulated from each other. That is, the rising portions 37c and 37d of the first lead portions 37a and 37b and the rising portions 38c and 38d of the second lead portions 38a and 38b are insulated from each other.

Further, as shown in FIG. 5, the lead guide cover 60 has a cover main body 62. The cover main body 62 mainly insulates the rising portions 37c and 37d of the first lead portions 37a and 37b and the rising portions 38c and 38d of the second lead portions 38a and 38b. The cover body 62 is integrally formed with a bulging portion 64 on the outside in the X-axis direction. The bulging portion 64 protrudes outward in the X-axis direction in a frame shape, has a trapezoidal shape that is upside down when viewed from the X-axis direction, and is in the middle of the second lead on both sides of the inverted trapezoidal bulging portion 64. A pair of guide edge plates 66 are integrally formed with the cover body 62 so as to form the grooves 68a and 68b. The guide cover 60 is made of the same plastic as the bobbin 20, for example, but does not necessarily have to be the same.

The second lead intermediate grooves 68a and 68b provided on both sides of the bulging portion 64 refer to the rising portions 38c and 38d of the pair of second lead portions 38a and 38b of the second wire 38 with the bobbin 20 shown in FIG. The wire is guided from the outer periphery of the bobbin toward the lead pedestal 22 in a direction away from each other. That is, the second lead intermediate grooves 68a and 68b are inclined in a substantially V shape when viewed from the X-axis direction.

In the lead guide cover 60 shown in FIG. 5, the first wire 37 and the second wire 38 shown in FIG. 5 are shown in FIG. 4 at the lower portion of the lead pedestal 22 shown in FIG. 4 in the Z-axis direction on the outer peripheral portion of the bobbin 20. It is attached after being wound around the outer circumference of the winding cylinder portion 28 of the bobbin 20. As shown in FIG. 4, on the outer circumference of the bobbin 20 where the lead pedestal 22 is located, an extension flange portion 35a extending outward in the X-axis direction is integrally molded with the wound partition flange 35. Further, the wound partition flange portion 34 is also integrally formed with an extension flange portion 34a extending outward in the X-axis direction. Further, the wound partition flange 33 is also integrally formed with an extension flange 33a extending outward in the X-axis direction.

Notches 33b to 35b are formed in the extension flange portions 33a to 35a located below the lead pedestal 22 in the Z-axis direction, and the notches 33b to 35b are formed in these notches, respectively, and the back surface of the lead guide cover 60 shown in FIG. 5 is formed in these notches. Is designed to be attached. Further, as shown in FIG. 3B, an engaging convex portion 63 is integrally molded on the back surface (inside) of the lead guide cover 60, and the convex portion 63 is an X of the extended flange portion 34a of the wound partition collar 34. By fitting into the fitting groove 34d formed on the edge of the shaft, the insulation between the first wire 37 and the second wire 38 is enhanced.

Further, in the extension flange portion 35a of the wound partition flange 35 shown in FIG. 4, the portions 38e and 38f immediately before the removal of the pair of second lead portions 38a and 38b shown in FIG. 5 are separated from each other in the Z-axis direction and insulated. , After crossing when viewed from the Z-axis direction, the lead guide cover 60 is guided to the second lead intermediate grooves 68a and 68b of the lead guide cover 60 shown in FIG. The pair of second lead portions 38a, 38b shown in FIG. 5 are insulated from each other in the Z-axis direction at the extension flange portion 35a of the wound bulkhead flange 35, and are insulated from the Z-axis direction. It is clear from FIG. 6 that they intersect each other. The portions 38e and 38f immediately before the removal are the parts immediately before the removal of the second lead portions 38a and 38b that are taken out from the second wire 38 wound around the outer circumference of the bobbin 20 toward the lead pedestal 22.

As shown in FIG. 6, in the present embodiment, one 37a of the pair of first lead portions 37a and 37b and one 38a of the pair of second lead portions 38a and 38a are separated from the lead pedestal 22. They are pulled out side by side in the Y-axis direction. Further, the other 37b of the pair of first lead portions 37a and 37b and the other 38b of the pair of second lead portions 38a and 38a are pulled out from the lead pedestal 22 side by side in the Y-axis direction. .. The pull-out direction of one of the lead portions 37a and 38a and the pull-out direction of the other lead portions 37b and 38b are opposite directions along the Y-axis direction.

In the coil device 10 of the present embodiment, as shown in FIG. 2, the divided cores 42a and 42a each have a middle leg portion 46a and a pair of outer leg portions 48a. Further, the divided cores 42b and 42b each have a middle leg portion 46b and a pair of outer leg portions 48b.

In the coil device 10 of the present embodiment, in order to form the gap gap 47 shown in FIGS. 3A and 3B, the protruding length of the middle leg portion 46a in the Z-axis direction is set from the protruding length of the outer leg portion 48a in the Z-axis direction. Is also shortly molded. Nevertheless, in the coil device 10 of the present embodiment, the split core 42a can easily stand on its own, and the split core 42a can be easily attached to the bobbin 20. Further, the split core 42a is not arranged at an angle to the bobbin 20, and a constant gap gap 47 can be easily formed.

Further, the heat transfer resin 90 is easily passed through the gap 47 through the division gap between the division surfaces 43a and 43a of the division cores 42a and 42a and the division gap between the division surfaces 43b and 43b of the division cores 42b and 42b. Flows in, and the gap 47 is filled with a heat transfer resin. The porosity of the heat-transmitting resin 90 filled in the gap gap 47 is preferably 5% by volume or less. The heat-conducting resin 90 filled in the gap gap 47 releases heat from the tips of the middle legs 46a and 46b, which are most likely to retain heat, to the outside of the core assembly 40, improving heat dissipation.

Further, since the bottom plate 80 of the case 100 is made of metal and the bottom surface of the core assembly 40 is in contact with the bottom plate 80 of the case 100, the heat inside the core assembly 40 is transferred to the bottom plate of the case 100. Heat is directly transferred to the housing through 80 and dissipated there. Further, the heat inside the core assembly 40 is transferred to the housing through the heat conductive resin 90 with which the core assembly 40 is in contact and the bottom plate 80 of the case 100 with which the core assembly 40 is in contact, and is dissipated there. .. Therefore, it is possible to cope with a large current of the coil device 10, heat dissipation is improved, and deterioration of magnetic characteristics due to overheating of the coil portion can be suppressed.

In the present embodiment, the pair of split cores 42a and 42a are arranged so that the split surfaces 43a face each other with a predetermined split gap, and the heat conductive resin 90 enters the gap gap 47 through the split gap and is split. The gap and the gap 47 are filled with the heat transfer resin 90.

Further, in the present embodiment, the length of the bobbin 20 along the X-axis (first axis) direction is longer than the length along the Y-axis (second axis) direction intersecting the X-axis, and the bobbin 20 is in the X-axis direction. Bobbin legs 32a are installed at the bottoms of both ends of the bobbin. The dividing surfaces 43a, 43a and 43b, 43b of the core assembly 40 are formed along the Z axis (third axis) and the Y axis. By forming the bobbin leg 32a and bringing the bobbin leg 32a into contact with or close to the bottom plate 80 of the case 100, it becomes possible to secure a heat transfer path from the bobbin 20 to the bottom plate 80 of the case 100, and heat dissipation is achieved. Is further improved.

The split surfaces 43a, 43a and 43b, 43b of the split cores 42a, 42a and 42b, 42b of the present embodiment are formed along the Y axis intersecting the X axis parallel to the direction connecting the pair of bobbin legs 32a. Therefore, the bobbin leg portion 32a and the bobbin collar portion 32 integrated with the bobbin leg portion 32a do not get in the way.

Therefore, the heat-transmitting resin 90 easily enters the gap gap 47 through the gap between the divided surfaces 43a, 43a and 43b, 43b of the divided cores 42a, 42a and 42b, 42b. Further, as shown in FIG. 2, since the bobbin 20 is short in the Y-axis direction, the distance from the outside of the bobbin 20 to the middle leg portions 46a of the split cores 42a and 42a is also short. From this point as well, the heat transfer resin 90 can easily enter the gap gap 47 through the gap between the divided surfaces 43a, 43a and 43b, 43b.

Further, in the present embodiment, the split leg portions 46a and 46b of the split cores 42a and 42b are inserted into the core leg through holes 26 of the bobbin 20. According to experiments by the present inventors, even if the core becomes large, the intersection between the middle leg and the base is located at the intersection of the middle leg and the base as compared with the case where the conventional E-type core is used. The generated local stress can be dispersed. Therefore, in the coil device 10 according to the present embodiment, it is possible to effectively suppress the occurrence of cracks and the like even if thermal stress is generated in the core.

Further, the middle leg portions 46a and 46b and the base portions 44a and 44b in the E-shaped core formed by combining the divided cores 42a and 42b are separated by the divided surfaces 43a and 43b of the divided cores 42a and 42b, and are divided. A predetermined gap can be formed between the surfaces 43a and 43b, and heat dissipation is also improved. Further, the E-type core is formed by combining a pair of divided cores 42a and 42b, each of which has a simple shape, so that the core can be easily manufactured and the manufacturing cost can be reduced. Moreover, since the split type E-type core has the same magnetic field lines as the E-type core as a whole, the magnetic characteristics of the core are the same as those of the general E-type core.

In particular, in the coil device 10 of the present embodiment, the pair of first lead portions 37a, 37b of the first wire 37 and the first lead portion 37a, 37b from the lead pedestal 22 provided at one end of the bobbin 20 rather than from both sides of the bobbin 20. The pair of second lead portions 38a and 38b of the two wires 38 are pulled out. Therefore, the coil device 10 that requires heat dissipation can be easily moved to one side instead of the center of the circuit board, the heat dissipation structure is simplified, and the heat dissipation characteristics are improved. Further, even if the coil device 10 is moved to the end of the circuit board or the circuit element group, the first lead portions 37a and 37b and the second lead portions 38a and 38b can be pulled out from the lead pedestal 22 at one end. It is possible, the resistance for wiring does not increase, and the inductance is stabilized. Further, the coil device 10 having low resistance and low loss can be realized at low cost.

Further, in the present embodiment, the first wire 37 and the second wire 38 are wound around the outer circumference of the bobbin 20 in order from the vicinity of the lead pedestal 22 along the Z axis, and the first wire 37 and the second wire 38 are wound more than the first pedestal portion 22a. The second pedestal portion 22b is arranged outside along the X axis. With this configuration, good insulation between the first lead portions 37a and 37b and the second lead portions 38a and 38b can be ensured, and the lead pedestal 22 can be arranged at one end of the bobbin 20. It will be easier.

Further, in the present embodiment, the lead guide cover 60 is attached to the outer periphery of the bobbin main body 24 of the bobbin 20 where the lead pedestal 22 is located. With this configuration, good insulation between the first lead portions 37a and 37b and the second lead portions 38a and 38b is ensured, and the lead pedestal 22 is provided at one end of the bobbin 20 in the X-axis direction. Easy to place.

Further, in the present embodiment, as shown in FIG. 5, the lead guide cover 60 has a pair of second lead portions 38a and 38b of the second wire 38 directed from the outer periphery of the bobbin 20 toward the lead pedestal 22, respectively. The second lead intermediate grooves 68a and 68b for guiding in the directions away from each other are provided. With this configuration, the second lead portions 38a and 38b of the second wire 38 wound around the outer circumference of the bobbin main body 24 on the side far from the lead pedestal 22 can be replaced with the first lead portion 37a of the first wire 37. , 37b and in an insulated state, it becomes easy to guide the second wire 38 to the lead pedestal 22 while preventing the second wire 38 from unwinding. Therefore, the inductance can be stabilized. Further, the reduction in resistance and the reduction in loss of the coil device 10 can be further improved.

Further, on the outer circumference of the bobbin main body 24 where the lead pedestal is located, a pair of second lead portions 38 are separated from each other in the Z-axis direction and insulated, and crossed when viewed from the axis direction to form a lead guide cover 22. An extension collar portion 35a for guiding to is provided. With this configuration, the second lead portions 38a and 38b of the second wire 38 wound around the outer circumference of the bobbin main body 24 on the side far from the lead pedestal 22 can be replaced with the first lead portion 37a of the first wire 37. , 37b and in an insulated state, it becomes easy to guide the second wire 38 to the lead pedestal 22 while preventing the second wire 38 from unwinding. Therefore, the inductance can be stabilized. Further, the reduction in resistance and the reduction in loss of the coil device 10 can be further improved.

Since the first wire 37 is wound around the outer circumference of the bobbin main body 24 on the side close to the lead pedestal 22, the first lead portions 37a and 37b of the first wire 37 are the second leads of the second wire 38. Unlike the portions 38a and 38b, the first wire 37 can be easily guided to the lead pedestal 22 while preventing the first wire 37 from unwinding without overlapping with each other when viewed from the Z axis.

Further, in the present embodiment, as shown in FIG. 5, one 37a of the pair of first lead portions 37a and 37b and one 38a of the pair of the second lead portions 38a and 38b are the lead pedestals 22. Are pulled out side by side in the Y-axis direction. Further, the other 37b of the pair of first lead portions 37a and 37b and the other 38b of the pair of second lead portions 38a and 38b are pulled out from the lead pedestal 22 side by side in the Y-axis direction. .. These orientations are opposite to each other along the Y axis.

With this configuration, for example, as shown in the circuit shown in FIG. 7, one 37a of the pair of first lead portions 37a and 37b and one 38a of the pair of second lead portions 38a and 38b are formed. It can be easily connected, and a specific circuit for non-contact power supply can be easily configured. The other 37b of the pair of first lead portions 37a and 37b and the other 38b of the pair of second lead portions 38a and 38b may be connected.

In the coil device 10 of the present embodiment, as shown in FIG. 8, routing grooves 22f1,22f2 are provided in the middle of the second lead grooves 22b1,22b2 of the second pedestal portion 22b, and the second leads are provided therein. These may be pulled out to the outside in the X-axis direction through the portions 38a and 38b. In accordance with this, the first lead portions 37a and 37b drawn from the first lead grooves 22a1, 22a2 of the first pedestal portion 22a may also be pulled out to the outside in the X-axis direction. Even in this case, the first lead portion 37a and the second lead portion 38a are pulled out side by side in parallel, and the first lead part 37b and the second lead part 38b are pulled out side by side in parallel.

Second Embodiment As shown in FIGS. 9A to 11, the coil device 110 according to the second embodiment of the present invention is the same as the coil device 10 of the first embodiment described above except for the following, and is common. The description of the part to be used is omitted. Further, in the drawings, members or parts common to those in the first embodiment are designated by common reference numerals.

The coil device 110 of the present embodiment has a different configuration of the bobbin 120 as compared with the coil device 10 of the first embodiment described above. Further, the coil device 110 may not be provided with the case 100 shown in FIG. The bobbin 120 has a lead pedestal 122 and an auxiliary pedestal 123. The height of these pedestals 122 and 123 in the Z-axis direction is set lower than that of the pedestals 22 and 23 of the first embodiment, which contributes to lowering the height of the coil device 110.

In the present embodiment, the lead portions 37a and 37b of the first wire 37 and the lead portions 38a and 38b of the second wire 38 are attached to the lead pedestal 122. A terminal cover (corresponding to the terminal cover 25 shown in FIG. 2) (not shown) is attached to the upper portion of the lead pedestal 122 to which these lead portions 37a, 37b, 38a, 38b are attached. Also in this embodiment, the lead portion of any wire cannot be attached to the auxiliary pedestal 123.

A pair of partition covers 50 (see FIG. 10) are attached to both sides of the bobbin body 124 in the Y-axis direction. Further, although the illustration of the core assembly is omitted in FIG. 9A, the core assembly 40 as shown in FIG. 2 is assembled to the bobbin 120.

In the present embodiment, as shown in FIG. 11, the lead pedestal 122 is integrally formed with the first pedestal portion 122a and the second pedestal portion 122b. In the present embodiment, the second pedestal portion 122b is arranged so as to surround the first pedestal portion 122a on one side in the X-axis direction and on both sides in the Y-axis direction.

A pair of first lead portions 37a and 37b, which are both ends of the first wire 37 shown in FIG. 9B, are arranged on the first pedestal portion 122a so as to be insulated from each other. Further, the second pedestal portion 122b shown in FIG. 11 is arranged adjacent to both sides of the first pedestal portion 122a in the Y-axis direction. A pair of second lead portions 38a and 38b, which are both ends of the second wire 38 shown in FIG. 9B, are arranged on the second pedestal portion 122b so as to be insulated from each other and also to be insulated from the first lead portions 37a and 37b. NS.

In the first pedestal portion 122a shown in FIG. 11, a pair of first lead grooves 122a1 and 122a2 through which the pair of first lead portions 37a and 37b shown in FIG. It is formed so as to be insulated from each other. Each of the first lead grooves 122a1 and 122a2 has a Y-axis direction groove portion that faces the opposite outer side in the Y-axis direction and a pair of X-axis direction groove portions that face outward in the X-axis direction from both sides of each Y-axis direction groove portion. And each has a substantially U-shape.

The bottom of the X-axis direction groove portion located inside the first lead grooves 122a1 and 122a2 in the Y-axis direction penetrates in the Z-axis direction, and the lead portions 37a and 37b shown in FIG. 9B are in the Z-axis direction. The rising portions 37c and 37d can pass through. The portions of the lead portions 37a and 37b shown in FIG. 5 beyond the rising portions 37c and 37d are outside the X-axis direction (direction away from the bobbin 120) along the first lead grooves 122a1 and 122a2 shown in FIG. ) Will guide you.

The second pedestal portion 122b shown in FIG. 11 is formed with a pair of second lead grooves 122b1 and 122b2 through which the pair of second lead portions 38a and 38b shown in FIG. The two lead grooves 122b1 and 122b2 are separated from each other by a substantially C-shaped insulating wall 122c provided on the lead pedestal 122.

The second lead grooves 122b1 and 122b2 located on both sides of the first pedestal portion 122a in the Y-axis direction are from the Y-axis direction groove portions facing the opposite outer sides in the Y-axis direction and from both sides of each Y-axis direction groove portion. It has a pair of X-axis direction groove portions facing outward in the X-axis direction, and each has a substantially U-shape. The bottom of the X-axis direction groove portion located inside each of the second lead grooves 122b1 and 122b2 penetrates in the Z-axis direction, and the rising portions 38c of the lead portions 38a and 38b shown in FIG. 9B in the Z-axis direction. , 38d can pass through. The portions of the lead portions 38a and 38b shown in FIG. 9B beyond the rising portions 38c and 38d are guided outward in the X-axis direction along the second lead grooves 122b1 and 122b2 shown in FIG.

The insulating wall 22c has a Y-axis direction wall portion and a pair of X-axis direction wall portions extending outward in the X-axis direction from both sides of the Y-axis direction wall portion, and has a substantially U-shape. The insulating wall 122c is adapted to ensure insulation between the first lead grooves 122a1, 122a2 and the second lead grooves 122b1, 122b2.

In the insulating wall 122c, an engaging groove 122d that opens to the upper part in the Z-axis direction is formed to have substantially the same depth (the depth is not limited) as the bottomed lead grooves 122a1, 122a2, 122b1, 122b2. The insulation creepage distance between the first lead grooves 122a1, 122a2 and the second lead grooves 122b1, 122b2 is lengthened. The engaging protrusions 25a integrally formed on the back surface of the terminal cover 25 shown in FIG. 3C are fitted into the engaging grooves 122d1, 122d2, and the first lead grooves 122a1, 122a2 and the second lead grooves 122b1, The insulation between 122b2 is further enhanced.

The lead guide cover 160 shown in FIG. 9B is attached to the outer periphery of the bobbin 120 where the lead pedestal 122 shown in FIG. 11 is located. The 1 cover 160 includes a pair of first lead portions 37a and 37b (see FIG. 9B) of the first wire 37 on the way from the outer circumference of the bobbin 20 shown in FIG. 11 to the lead pedestal 122, and the bobbin 120 shown in FIG. The pair of second lead portions 38a and 38b (see FIG. 9B) of the second wire 38 on the way from the outer periphery of the lead wire 38 to the lead pedestal 122 are insulated from each other. That is, the rising portions 37c and 37d of the first lead portions 37a and 37b and the rising portions 38c and 38d of the second lead portions 38a and 38b are insulated from each other.

Further, as shown in FIG. 9B, the lead guide cover 160 has a cover main body 162. The cover body 162 mainly insulates the rising portions 37c and 37d of the first lead portions 37a and 37b and the rising portions 38c and 38d of the second lead portions 38a and 38b. An insulating partition wall 164 is integrally formed on the outside of the cover body 162 in the X-axis direction. The insulating partition wall 164 protrudes outward in the X-axis direction, and a pair of guide edge plates 166 are integrally integrated with the cover body 162 so as to form second lead intermediate grooves 168a and 168b on both sides when viewed from the X-axis direction. It is molded. The guide cover 160 is made of the same plastic as the bobbin 120, for example, but does not necessarily have to be the same.

The second lead intermediate grooves 168a and 168b provided on both sides of the partition wall 164 show the rising portions 38c and 38d of the pair of second lead portions 38a and 38b of the second wire 38 shown in FIG. 9B in FIG. As shown, the bobbins 120 are guided from the outer periphery toward the lead pedestal 122 in directions away from each other. That is, the second lead intermediate grooves 168a and 168b are inclined in a substantially V shape when viewed from the X-axis direction.

The lead guide cover 160 is formed on the outer peripheral portion of the bobbin 120 at the lower portion of the lead pedestal 122 shown in FIG. 9A in the Z-axis direction, and the first wire 37 and the second wire 38 shown in FIG. 9B wind the bobbin 120 shown in FIG. 9A. It is attached after being wound around the outer circumference of the bobbin 28. As shown in FIG. 10, the portions 38e and 38f immediately before taking out of the pair of second lead portions 38a and 38b are separated from each other in the Z-axis direction and insulated, and the second lead portions 38a and 38b are viewed from the Z-axis direction. The guide cover 160 is hooked on each guide inclined wall 166a without intersecting the guide cover 160, and is guided to the grooves 168a and 168b in the middle of the second lead.

As shown in FIGS. 9A and 9B, in the present embodiment, the pair of first lead portions 37a and 37b and the pair of second lead portions 38a and 38a on both sides in the Y-axis direction are formed from the lead pedestal 122. , All lined up and pulled out in the X-axis 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, in the above-described embodiment, the core assembly 40 is composed of an upper core 40a and a lower core 40b, each of which is composed of divided cores 42a and 42b, but at least one of the upper core and the lower core It suffices to have a pair of split cores 42a, 42a or 42b, 42b. In particular, by dividing the upper core 40a in the dividing direction along the Y-axis direction, it becomes easy to attach the divided cores 42a and 42a to the bobbin 20 without tilting them, and the predetermined gap gap 47 shown in FIG. Can be easily formed.

The number of divisions in the core assembly 40 is not particularly limited, and the upper core 40a may be divided into two or more in the X-axis direction, or the lower core 40b may be divided into two or more in the X-axis direction. It may have been done. The division is a division along the direction from one outer leg portion 48a, 48b of the core assembly 40 through the middle leg portions 46a, 46b toward the other outer leg portions 48a, 48b, and crosses these directions. Not a split.

Further, in the present embodiment, either the upper core or the lower core may be a plate-shaped core, and the plate-shaped core may or may not be divided. As in the above-described embodiment, preferably, both the upper core 40a and the lower core 40b are divided into two or more.

In the above-described embodiment, as the number of divisions of the upper core or the lower core increases, the core loss tends to be reduced and the division gap into which the heat transfer resin 90 enters tends to increase. The number of divisions is preferably 2 to 4 in each of the upper core 40a and the lower core 40b. By setting the number of divisions within such a range, the core loss is reduced, the heat-transmitting resin 90 easily enters the central portion of the core assembly 40, the heat-conducting property is improved, and sufficient inductance is secured. be able to.

Further, in the present embodiment, the shape and structure of the bobbin 20, the number of windings of the wires 37 and 38, the winding method, and the like are not limited to the illustrated embodiment, and may be variously modified. Further, the bottom plate 80 may be provided with a heat sink such as a heat radiating fin.

Further, in the above-described embodiment, the gap gap 47 is formed at the protruding tip of the middle leg portions 46a and 46b, but in the coil device 10 of the present embodiment, the gap gap 47 does not have to be formed. Further, in the above-described embodiment, the core assembly 40 is divided into a plurality of parts in the X-axis direction, but may be divided into a plurality of pieces in the Y-axis direction.

10, 110 ... Coil devices 20, 120 ... Bobbins 22, 122 ... Lead pedestals 22a, 122a ... First pedestal portion 22a 1,22a 2, 122a 1, 122a 2 ... First lead groove 22b, 122b ... Second pedestal portion 22b 1, 22b 2, 122b1, 122b2 ... 2nd lead groove 22c1,22c2,122c ... Insulation wall 22d1,22d2,122d ... Engagement groove 22e, 122e ... Separation protrusion 22f1,22f2 ... 25 ... Terminal cover 25a ... Engagement convex portion 26 ... Through hole for core leg 28 ... Winding cylinder portion 31, 32 ... End partition partition flange 32a ... Support leg portion 32b ... Heat dissipation fins 33 to 35 ... Winding partition partition flange 34a ... Extension flange 34b ... Notch 34c, 34d ... Fitting groove 35a ... Extension flange 35b ... Notch 37 ... First wire 38 ... Second wire 40 ... Core assembly 40a ... Upper core 40b ... Lower core 42a, 42b ... Divided cores 43a, 43b ... Divided surfaces 44a, 44b ... Base portions 46a, 46b ... Middle legs 47 ... Gap gaps 48a, 48b ... Side legs 50 ... Partition cover 52 ... Cover body 54 ... Locking pieces 56 ... Side legs Guide piece 58 ... Fitting piece 60, 160 ... Lead guide cover 62, 162 ... Cover body 63 ... Fitting convex part 64 ... Protruding part 164 ... Partition wall 66, 166 ... Guide edge plate 166a ... Guide inclined wall 68a, 68b , 168a, 168b ... 2nd lead intermediate groove 80 ... Bottom plate 90 ... Heat transfer resin (potting resin)
100 ... Case

Claims (10)

The first wire wound around the bobbin and
A second wire that is insulated from the first wire and wound around the outer circumference of the bobbin,
A coil device having a lead pedestal provided at one end along a first axis substantially perpendicular to the bobbin shaft core.
The lead pedestal is
A first pedestal portion in which a pair of first reed portions at both ends of the first wire are arranged so as to be insulated from each other, and a first pedestal portion.
Adjacent to the first pedestal portion, a pair of second lead portions at both ends of the second wire are insulated from each other and the first lead portion is also insulated from the second pedestal portion. Have and
A pair of first reed grooves through which the pair of the first reed portions pass is formed in the first pedestal portion.
A pair of second lead grooves through which the pair of the second lead portions pass is formed in the second pedestal portion.
In the first lead groove, the shaft core and the inside along the second axis perpendicular to the first axis are connected to the first axial groove portion through which the rising portion of the first lead portion passes.
In the second lead groove, the inside along the second axis is connected to the first axial groove portion through which the rising portion of the second lead portion passes.
The first axial groove portion of the second lead groove is a coil device arranged outside the first axial groove portion of the first lead groove when viewed from the first axial direction. The coil device according to claim 1, wherein the 1 lead groove and the 2nd lead groove are separated by an insulating wall provided on the lead pedestal. The coil device according to claim 1 or 2, wherein the first wire and the second wire are wound around the bobbin in order from the vicinity of the lead pedestal along the shaft core. A lead guide cover is attached to the outer circumference of the bobbin where the lead pedestal is located, and a pair of first lead portions of the first wire on the way from the outer circumference of the bobbin to the lead pedestal, and the above. The coil device according to any one of claims 1 to 3, which insulates a pair of second lead portions of the second wire on the way from the outer circumference of the bobbin to the lead pedestal. The lead guide cover is provided with a second lead intermediate groove that guides a pair of second lead portions of the second wire from the outer periphery of the bobbin toward the lead pedestal in directions away from each other. The coil device according to claim 4. A pair of the second lead portions are separated from each other in the axial direction to insulate the outer circumference of the bobbin on which the lead pedestal is located, and intersect with each other when viewed from the axial direction to form the lead guide cover. There is a collar that guides you to
The fourth or fifth aspect of the present invention, wherein the rising portion of the second lead portion is inclined in a V shape when viewed from the first axial direction and is drawn out to the first axial groove portion of the second lead groove. Coil device. The lead guide cover is provided with a guide inclined wall that guides the pair of the second lead portions to the lead guide cover without intersecting the lead guide cover when viewed from the axial direction.
The coil device according to claim 4 or 5, wherein the second lead groove is arranged on both sides of the first lead groove in the second axial direction. One of the pair of the first reed portions and one of the pair of the second reed portions are pulled out side by side from the lead pedestal.
The coil device according to any one of claims 1 to 7, wherein the other of the pair of the first lead portions and the other of the pair of the second lead portions are drawn side by side from the lead pedestal. A core assembly in which a part is attached to a through hole formed along the axis of the bobbin.
A case in which the first wire and the second wire are wound to cover the outer peripheral portion of the bobbin to which the core assembly is attached.
A heat-conducting resin housed inside the case and capable of entering the gap between the case and the bobbin, the gap between the case and the core assembly, and the gap between the bobbin and the core assembly. The coil device according to any one of claims 1 to 8, further comprising. The core assembly has at least a pair of split cores that are split at the split planes.
These split cores are integrated on both sides of the middle leg portion that enters the through hole of the bobbin, the base portion that is integrated with the middle leg portion and is located outside the through hole, and the base portion. Has an outer leg that is attached to the outside of the bobbin
The protrusion length of the middle leg portion from the base portion is shorter than the protrusion length of the outer leg portion from the base portion.
The coil device according to claim 9, wherein the gap for a gap formed at the protruding tip of the middle leg is filled with the heat-transmitting resin.

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