JP2023034344A - Coil device - Google Patents

Abstract

To provide a coil device capable of being downsized.SOLUTION: A coil device 10 includes a winding core part 21 around which a first wire 41c and a second wire 42c are wound on an outer surface, a bobbin 20 having flange parts 22a, 22b formed on the end part in the axial direction of the winding core part 21, and a terminal block 70 formed separately from the bobbin 20 and is attached to the bobbin 20. The terminal block 70 is arranged in a location spaced apart from the outer surface of the winding core part 21 in the direction perpendicular to the axial direction of the winding core part 21.SELECTED DRAWING: Figure 3

Description

The present invention relates to a coil device.

2. Description of the Related Art Coil devices disclosed in, for example, Patent Documents 1 and 2 are known as coil devices used in transformers and the like. The coil device described in Patent Document 1 is a vertical coil device in which the winding axis of the coil is perpendicular to the surface of the mounting substrate. It is a horizontal coil device that is parallel to the plane of the substrate.

A vertical coil device as disclosed in Patent Document 1 has a problem that the height along the winding axis direction tends to be high, and it is difficult to reduce the height. On the other hand, a horizontal coil device as disclosed in Patent Document 2 can avoid the above problems and is advantageous in reducing the height.

However, in the coil device described in Patent Document 2, a first terminal block is formed below a first flange formed at one end of the bobbin in the axial direction, and is formed at the other end in the axial direction of the bobbin. A second terminal block is formed below the second flange. As a result, the size of the coil device increases in the axial direction of the bobbin and in the direction orthogonal thereto, making it difficult to achieve miniaturization.

JP 2014-36194 A JP 2018-67673 A

SUMMARY OF THE INVENTION An object of the present invention is to provide a coil device that can be miniaturized.

In order to achieve the above object, the coil device according to the present invention includes:
a bobbin having a winding core around which a wire is wound, and a flange formed at an axial end of the winding core;
a terminal block formed separately from the bobbin and attached to the bobbin;
The terminal block is arranged at a position separated from the outer peripheral surface of the core in a direction perpendicular to the axial direction of the core.

The coil device according to the present invention has a terminal block that is formed separately from the bobbin and attached to the bobbin. Therefore, when manufacturing the coil device, it is possible to wind the wire around the outer peripheral surface of the winding core with the terminal block removed from the bobbin, especially when the wire is wound using an automatic winding machine. WHEREIN: It can prevent that a terminal block interferes with the automatic winding by an automatic winding machine. In addition to the bobbin, the terminal block (only) is made of a highly heat-resistant resin, so that a heat-resistant coil device can be realized at a low cost.

Further, in the coil device according to the present invention, the terminal block is arranged at a position spaced apart from the outer peripheral surface of the core in the direction orthogonal to the axial direction of the core. Therefore, it is possible to dispose the terminal block on the side of the winding core. It is possible to reduce the size (length) of the coil device. In addition, the size (height) of the coil device can be made smaller in the direction perpendicular to the axial direction of the winding core (the height direction of the coil device) compared to the conventional technology in which the terminal block is formed below the flange. Is possible. Therefore, the coil device according to the present invention can be miniaturized.

Preferably, the terminal block is connected to one axial end of the winding core and the other axial end of the winding core, and is connected to the axial direction of the winding core. are arranged substantially parallel to each other. By adopting such a configuration, it is possible to prevent the terminal block from being arranged in a state of projecting unnecessarily in a direction orthogonal to the axial direction of the winding core (to the side of the winding core). The size of the coil device can be reduced in the direction orthogonal to the axial direction of the winding core.

Preferably, the terminal block has an arm portion projecting toward the bobbin and having a hook-shaped first hook portion formed at the tip thereof, and the collar portion is substantially perpendicular to the arm portion. A flange engaging portion is formed extending in a direction and engaged with the first hook portion. By engaging the arm portion of the terminal block with the flange engagement portion of the flange portion via the first hook portion, the terminal block can be attached to the bobbin with sufficient fixing strength without using an adhesive or the like. Therefore, it is possible to reduce the cost and speed up the manufacturing process. Further, the terminal block can be arranged at a position separated from the outer peripheral surface of the winding core in a direction perpendicular to the axial direction of the winding core by a distance corresponding to the length of the arm. The arrangement of the terminal block can be adjusted by appropriately changing the thickness.

Preferably, a second hook portion having a hook shape is formed at a tip portion of the collar engaging portion, and the first hook portion of the lead-out portion of the wire is engaged with the collar engaging portion. is pulled out toward the terminal block along the circumference of the arm portion. By pulling out the lead-out portion of the wire toward the terminal block along the circumference of the arm, it becomes possible to pull out the lead-out portion from the winding core to the terminal block in a short distance. It is possible to prevent the increase in the wire length of the part), improve the quality of the coil device, and contribute to the reduction of electric resistance or the suppression of resonance of the wire. Further, by forming the second hook portion on the flange engaging portion, it is possible to prevent the pull-out portion pulled out along the circumference of the arm from being displaced toward the tip of the flange engaging portion. .

Preferably, a terminal block fixing portion to which the terminal block is fixed is formed at an axial end portion of the bobbin, the terminal block fixing portion has a first stepped portion, and the terminal block is and a second stepped portion, wherein the first stepped portion and the second stepped portion are in contact with the first stepped lower surface of the first stepped portion and the second stepped lower surface of the second stepped portion. engages. With such a configuration, the first stepped portion and the second stepped portion are fixed to each other, and the terminal block is positioned relative to the terminal block fixing portion with respect to the respective normal directions of the first stepped lower surface and the second stepped lower surface. Positional deviation can be prevented, and the terminal block can be attached to the terminal block fixing portion with sufficient fixing strength.

Preferably, a terminal block fixing portion to which the terminal block is fixed is formed at an axial end portion of the bobbin, and the terminal block fixing portion has a projection projecting toward the terminal block. and the terminal block has a concave portion that engages with the convex portion. By engaging the convex portion of the terminal block fixing portion with the concave portion of the terminal block, the terminal block is displaced from the terminal block fixing portion with respect to the extending direction of the terminal block (the axial direction of the winding core portion). can be prevented.

Preferably, the flange is formed along the circumferential direction of the winding core, and the flange is formed with a notch through which the lead-out portion of the wire is inserted. By adopting such a configuration, it is possible to pull out the draw-out portion of the wire wound around the winding core portion from the inner side of the flange portion where the winding core portion is located to the outside through the notch portion. It is possible to prevent the occurrence of unnecessary routing.

Preferably, one lead-out portion of the wire is led out from the outside of the collar portion toward the terminal block through the notch portion, and the other lead-out portion of the wire is not passed through the notch portion. , is pulled out toward the terminal block from the inside of the collar portion. By adopting such a configuration, one lead-out portion of the wire passes through the outside of the flange, and the other lead-out portion of the wire passes through the inside of the flange. It is possible to insulate well between one lead-out portion and the other lead-out portion.

Preferably, the terminal block further includes a cover portion arranged around the terminal block, the wire is composed of a plurality of wires, and the terminal block is provided with a plurality of terminals to which lead portions of the plurality of wires are respectively connected. is attached along the axial direction of the winding core portion, and the cover portion includes a grip portion for gripping the terminal block, a bottom portion disposed below the plurality of terminals, and a side end of the bottom portion. and a side portion raised from the portion. By gripping the terminal block with the gripping portion, the cover portion can be attached to the terminal block with sufficient fixing strength without using an adhesive or the like, thereby reducing costs and speeding up manufacturing. . In addition, by providing the cover portion with the bottom portion and the side portion, the terminals attached to the terminal block can be protected from external forces and the like, and the terminals and the core can be well insulated via the bottom portion and the side portions.

Preferably, the axial direction of the core portion is substantially parallel to the mounting surface. With such a configuration, the height of the coil device can be suppressed, and the height of the coil device can be reduced.

Preferably, it further comprises a case in which the bobbin is accommodated, the case can be filled with a potting resin, and at least one through hole is formed in the outer peripheral surface of the winding core. . With such a configuration, heat generated by the bobbin or the like can be radiated to the outside through the case and the potting resin, and the coil device can be efficiently cooled. Further, by forming the through hole in the bobbin, the potting resin can be circulated inside and outside the bobbin through the through hole, and the potting resin can be distributed to every corner in the case.

FIG. 1 is a perspective view of a coil device according to a first embodiment of the invention. FIG. 2 is a perspective view of the coil device shown in FIG. 1 with the case and resin omitted. 3 is an exploded perspective view of the coil device shown in FIG. 1. FIG. 4A is a side view of the base portion of the core shown in FIG. 3 as viewed from the outside in the Y-axis direction. FIG. 4B is a side view of the middle leg portion and the outer leg portion of the core shown in FIG. 3 as seen from the inside in the Y-axis direction. FIG. 5 is a cross-sectional view of the coil device shown in FIG. 1 along line VV. 6 is a perspective view of the bobbin shown in FIG. 3. FIG. 7 is a side view of the first coil portion and the second coil portion shown in FIG. 3 installed on the bobbin shown in FIG. 6. FIG. 8 is a perspective view showing the terminals, the terminal block and the cover shown in FIG. 3. FIG. 9 is a perspective view when the terminal block and cover portion shown in FIG. 8 are attached to the bobbin shown in FIG. 6. FIG. 10 is a perspective view showing the configuration of the connecting portion between the terminal block and the bobbin shown in FIG. 9. FIG. FIG. 11 is a perspective view of a coil device according to a second embodiment of the invention. 12 is an exploded perspective view of the coil device shown in FIG. 11. FIG.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described based on embodiments shown in the drawings.

First Embodiment A coil device 10 according to this embodiment shown in FIG. (vehicles), power supply circuits for household or industrial electrical equipment, power supply circuits for computer equipment, and the like. A detailed configuration of the coil device 10 will be described below. In the following description, the Z-axis positive direction side is defined as the upper side, and the Z-axis negative direction side is defined as the lower side. In addition, the side facing the center of the coil device 10 is defined as the inner side, and the side away from the center of the coil device 10 is defined as the outer side.

As shown in FIG. 3, the coil device 10 includes a bobbin 20, a first coil portion 41 and a second coil portion 42, cores 50a and 50b, first terminals 61_1 and 61_2, and second terminals 62_1 and 62_2. , a terminal block 70 , a cover portion 80 and a case 90 . The coil device 10 is a horizontal coil device in which the winding axes of the first coil portion 41 and the second coil portion 42 are parallel to the surface of the mounting substrate (not shown). In addition, the mounting substrate is arranged above the coil device 10 shown in FIG. 1 (on the Z-axis positive direction side), and the upper side of the coil device 10 is the installation surface (mounting surface) of the coil device with respect to the mounting substrate.

The case 90 is made of a metal such as aluminum having excellent cooling properties, and has a case bottom portion 91 and a case side portion 92 . The upper part of the case 90 is open, and it is possible to accommodate the bobbin 20 and the like through an opening formed in the upper part of the case 90 . The case bottom portion 91 has a substantially rectangular shape and constitutes the bottom surface of the case 90 . The case side portion 92 has a substantially square tubular shape as a whole and is formed along the outer edge portion of the case bottom portion 91 .

More specifically, case side portion 91 extends upward from each of the four sides forming the outer edge of case bottom portion 91 . The case 90 is formed by bending a piece of metal plate or the like, and a joint portion 93 is formed on a case side portion 92 as a joint surface of the bent portion. Note that the joint portion 93 may be liquid-tightly sealed by applying an adhesive or the like to the joint portion 93 .

The accommodation space formed by the case bottom portion 91 and the case side portion 92 can accommodate the bobbin 20 and the like, and can be filled with a potting resin 100 as shown in FIG. The potting resin 100 is composed of silicone resin, urethane resin, epoxy resin, or the like. The potting resin 100 is filled up to the position of the opening of the case 90, and a portion of the bobbin 20, a portion of the first terminal 61_1, or a portion of the cover portion 80 is exposed from the upper surface of the hardened potting resin 100. are doing.

In this embodiment, the heat generated by the bobbin 20 and the like can be radiated to the outside through the case 90 and the potting resin 100, so that the coil device 10 can be efficiently cooled.

As shown in FIG. 3 , the first coil portion 41 is formed by winding a first wire 41 c around the outer peripheral surface of the winding core portion 21 of the bobbin 20 . The second coil portion 42 is formed by winding a second wire 42 c around the outer peripheral surface of the winding core portion 21 of the bobbin 20 . The first wire 41c and the second wire 42c are wound around the outer peripheral surface of the winding core 21 using, for example, an automatic winding machine.

The first coil portion 41 is formed of two layers in the direction (radial direction) orthogonal to its winding axis, and the second coil portion 42 is formed of two layers in the direction (radial direction) orthogonal to its winding axis. be done. The winding axes of the first coil portion 41 and the second coil portion 42 are substantially aligned and correspond to the Y-axis direction.

The first coil portion 41 is provided on one side of the core portion 21 in the Y-axis direction (positive Y-axis direction), and the second coil portion 42 is provided on the other side of the core portion 21 in the Y-axis direction (negative Y-axis direction). side). One of the first coil portion 41 and the second coil portion 42 constitutes a primary coil, and the other of the first coil portion 41 and the second coil portion 42 constitutes a secondary coil. The arrangement of the primary coils and the secondary coils in the core portion 21 may be either on one side or the other side of the core portion 21 in the Y-axis direction.

The first wire 41c and the second wire 42c are each composed of an insulation-coated wire, such as a conductor such as a copper wire. The first wire 41c and the second wire 42c may each be composed of a single wire, or may be composed of a twisted wire. The wire diameter (diameter) of the first wire 41c and the second wire 42c is preferably 1.0 to 3.0 mm, for example. The wire diameters of the first wire 41c and the second wire 42c may be equal or different. For example, of the first wire 41c and the second wire 42c, the wire diameter of the wire through which a large current flows may be made larger than the wire diameter of the other wire.

A lead portion 41 a is formed at one end of the first coil portion 41 and a lead portion 41 b is formed at the other end of the first coil portion 41 . For example, the lead portion 41 a is pulled out from the second layer of the first coil portion 41 , and the lead portion 41 b is pulled out from the first layer of the first coil portion 41 .

A lead portion 42 a is formed at one end of the second coil portion 42 , and a lead portion 42 b is formed at the other end of the second coil portion 42 . For example, the lead portion 42 a is pulled out from the second layer of the second coil portion 42 , and the lead portion 42 b is pulled out from the first layer of the second coil portion 42 .

The cores 50 a and 50 b are so-called E-shaped cores and attached to the bobbin 20 . Materials for the cores 50a and 50b include magnetic materials such as metal and ferrite, but are not particularly limited. Core 50a and core 50b each have the same shape. The core 50a has a base portion 51a, a pair of outer leg portions 52a, and a middle leg portion 53a. The core 50b has a base portion 51b, a pair of outer leg portions 52b, and a middle leg portion 53b. The configuration of the core 50a will be described below, but the description of the core 50a also applies to the core 50b. Therefore, the description of the configuration of the core 50b is omitted unless particularly necessary.

The base portion 51a has a predetermined thickness in the Y-axis direction, and has a predetermined length in each of the X-axis direction and the Z-axis direction, as shown in FIGS. 4A and 4B. Hereinafter, in the base portion 51a, the outer surface in the Y-axis direction is called an outer surface 510a, the inner surface in the Y-axis direction is called an inner surface 511a, the upper surface is called an upper surface 512a, and the lower surface is called an upper surface 512a. The surface is called a lower surface 513a. In the base portion 51b, the outer surface in the Y-axis direction is called an outer surface 510b, the inner surface in the Y-axis direction is called an inner surface 511b, the upper surface is called an upper surface 512b, and the lower surface is called an upper surface 512b. is called a lower surface 513b.

The upper surface 512a and the lower surface 513a are surfaces orthogonal to the outer surface 510a and the inner surface 511a. The upper surface 512b and the lower surface 513b are surfaces orthogonal to the outer surface 510b and the inner surface 511b.

In this embodiment, an upper recessed portion 54a recessed at the position of the middle leg portion 53a is formed in the upper surface 512a of the base portion 51a. The upper concave portion 54a is formed substantially in the center of the base portion 51a with respect to the X-axis direction, and has a predetermined width in the X-axis direction and the Y-axis direction. The width of the upper concave portion 54a in the X-axis direction is substantially equal to the width of the middle leg portion 53a in the X-axis direction. The width of the upper concave portion 54a in the Y-axis direction is substantially equal to the thickness of the base portion 51a in the Y-axis direction (see FIG. 3).

The upper recessed portion 54a is recessed downward from the upper surface 512a to a predetermined depth, and the upper bottom surface 540a, which is the bottom surface of the upper recessed portion 54a, is positioned at substantially the same height as the upper portion of the outer peripheral surface of the middle leg portion 53a. is formed in The upper bottom surface 540a is an upwardly convex curved surface, and the degree of curvature of the upper bottom surface 540a substantially matches the degree of curvature of the upper portion of the outer peripheral surface of the middle leg portion 53a. Therefore, the upper bottom surface 540a is connected along the Y-axis direction so as to be substantially flush with the upper portion of the outer peripheral surface of the middle leg portion 53a (see FIG. 3).

An upper tapered surface 541a is formed on an inner wall surface of the upper recessed portion 54a (surfaces raised from both sides of the upper bottom surface 540a in the X-axis direction). The upper tapered surface 541a connects the upper surface 512a and the upper bottom surface 540a while being inclined at a predetermined angle.

A lower recessed portion 55a recessed at the position of the middle leg portion 53a is formed in the lower surface 513a of the base portion 51a. The lower concave portion 55a is formed substantially in the center of the base portion 51a with respect to the X-axis direction, and has a predetermined width in the X-axis direction and the Y-axis direction. The width of the lower concave portion 55a in the X-axis direction is smaller than the width of the middle leg portion 53a in the X-axis direction, and is substantially equal to the width in the X-axis direction of the concave bottom portion 37a or 37b (FIG. 6) of the bobbin 20. . The width of the lower concave portion 55a in the Y-axis direction is substantially equal to the thickness of the base portion 51a in the Y-axis direction.

As shown in FIG. 4B, the lower recessed portion 55a is recessed upward from the lower surface 513a to a predetermined depth, and the depth of the lower recessed portion 55a is greater than the depth of the upper recessed portion 54a. A lower bottom surface 550a, which is the bottom surface of the lower concave portion 55a, is formed at a position spaced downward by a predetermined distance from the lower portion of the outer peripheral surface of the middle leg portion 53a. The lower bottom surface 550a is a substantially flat surface, and a step is formed between the lower bottom surface 550a and the lower portion of the outer peripheral surface of the middle leg portion 53a.

A lower tapered surface 551a is formed on the inner wall surface of the lower concave portion 55a (surfaces raised from both sides of the lower bottom surface 550a in the X-axis direction). The lower tapered surface 551a connects the lower surface 513a and the lower bottom surface 550a while being inclined at a predetermined angle. The shape of the lower recessed portion 55a substantially matches the shape of the recessed bottom portion 37a or 37b of the bobbin 20 (FIG. 6).

In this embodiment, as shown in FIG. 3, the inside of the case 90 is filled with a potting resin 100, and a resin layer made of the potting resin 100 is formed around the cores 50a and 50b. In this case, since the potting resin 100 enters the upper recessed portion 54a and the lower recessed portion 55a shown in FIG. , the heat generated in the cores 50a and 50b can be sufficiently dissipated.

In addition, by providing the upper recessed portion 54a with the upper tapered surface 541a and the lower recessed portion 55a with the lower tapered surface 551a, the surface area of the inner wall surface of each of the upper recessed portion 54a and the lower recessed portion 55a is increased, The contact area between the upper concave portion 54a and the lower concave portion 55a and the potting resin 100 can be increased.

Further, when the potting resin 100 is filled, for example, the potting resin 100 flows inside the upper concave portion 54a and the lower concave portion 55a from the inside (outside) to the outside (inside) of the base portion 51a in the Y-axis direction. (That is, because the upper recessed portion 54a and the lower recessed portion 55a function as flow paths for the potting resin 100), the potting resin 100 can be distributed throughout the case 90. As shown in FIG.

The middle leg portion 53a is arranged between the pair of outer leg portions 52a and connected to the inner surface 511a of the base portion 51a. The middle leg portion 53 a extends from the inner surface 511 a along the Y-axis direction by a predetermined length, and is arranged inside the through hole 211 formed in the winding core portion 21 of the bobbin 20 . The middle leg portion 53a of the core 50a and the middle leg portion 53b of the core 50b are arranged inside the through-hole 211 in a state where the tip portions thereof are butted against each other. A gap may be formed along the Y-axis direction between the tip of the middle leg portion 53a and the tip of the middle leg portion 53b.

As shown in FIG. 4B, the middle leg portion 53a is not formed in the center portion of the inner surface 511a of the base portion 51a, and is shifted upward (to one side in the Z-axis direction) from the center C1 of the inner surface 511a. is formed in The distance L1 between the center C2 of the middle leg portion 53a and the center C1 of the inner surface 511a of the base portion 51a (that is, the displacement width in the Z-axis direction of the center C2 of the middle leg portion 53a with respect to the center C1 of the inner surface 511a) is , the length L2 along the Z-axis direction of the base portion 51a (outer leg portion 52a). The ratio L1/L2 between L1 and L2 is preferably 0<L1/L2<1/4, more preferably 0<L1/L2<1/6. In this embodiment, as will be described later, the middle leg portion 53a is positioned at the center of the inner surface 511a mainly in order to secure a sufficient space below the inner surface 511a for forming the thick portion 56a in the outer leg portion 52a. It is arranged at a position shifted upward from C1.

The upper portion of the outer peripheral surface of the middle leg portion 53a is arranged at a position close to the upper surface 512a of the base portion 51a and positioned below the upper surface 512a. The shape of the upper portion of the outer peripheral surface of the middle leg portion 53a substantially matches the shape of the upper bottom surface 540a (FIG. 4A) of the base portion 51a. The lower portion of the outer peripheral surface of the middle leg portion 53a is arranged at a position close to the lower bottom surface 550a of the lower recessed portion 55a and positioned above the lower bottom surface 550a. That is, the middle leg portion 53a is positioned between the upper surface 512a and the lower recessed portion 55a (lower bottom surface 550a) in the Z-axis direction.

As shown in FIG. 3, the pair of outer leg portions 52a are arranged at predetermined intervals along the X-axis direction and are connected to the inner surface 511a of the base portion 51a. One of the pair of outer leg portions 52a is arranged at one end of the inner surface 511a in the X-axis direction, and the other of the pair of outer leg portions 52a is arranged at the other end of the inner surface 511 in the X-axis direction. .

The pair of outer leg portions 52 a extends from the inner surface 511 a along the Y-axis direction by a predetermined length and is arranged outside the winding core portion 21 of the bobbin 20 .

As shown in FIG. 4B, thick portions 56a are formed at the ends in the Z-axis direction of each of the pair of outer leg portions 52a. The thick portion 56a is formed at the lower end portion of the outer leg portion 52a (that is, the end portion on the opposite side in the Z-axis direction to the displacement direction (upward) of the middle leg portion 53a described above).

The thick portion 56a protrudes inward in the X-axis direction (the side where the center C1 of the inner surface 511a of the base portion 51a is located), and is formed to be thick in the X-axis direction. By forming the thick portion 56a in the outer leg portion 52a, a sufficient cross-sectional area of the outer leg portion 52a can be secured, and the coil device 10 having good inductance characteristics can be obtained.

In addition, since the cross-sectional area of the outer leg portion 52a increases by the amount of the thick portion 56a, when the length of the outer leg portion 52a along the X-axis direction or the Z-axis direction is reduced (that is, the core 50a Even if the volume is reduced), the required cross-sectional area can be sufficiently secured, and the miniaturization of the core 50a and further the miniaturization of the coil device 10 can be favorably achieved. Further, by making the core 50a small, it is possible to promote the potting resin 100 to flow around the core 50a when the potting resin 100 is filled around the core 50a.

A width W1 of the thick portion 56a along the X-axis direction increases downward. A ratio W1/W2 between the width W1 of the thick portion 56a along the X-axis direction and the maximum width W2 of the base portion 51a along the X-axis direction is preferably 0<W1/W2<1/2. By setting the value of W1/W2 within the above range, it is possible to sufficiently secure the volume of the thick portion 56a and to sufficiently secure the volume of the region where the thick portion 56a is not formed. , contribute to the improvement of the inductance characteristics of the coil device 10 .

An outer leg inner side surface 520a of the outer leg portion 52a curves inward in the X-axis direction toward the lower end portion of the outer leg portion 52a. That is, since the thick portion 56a is formed in the outer leg portion 52a, the inner side surface 520a of the outer leg curves toward the center C1 of the inner surface 511a of the base portion 51a at the position of the thick portion 56a. It will be. The curved portion of the outer leg inner side surface 520a is generally curved along the outer peripheral surface of the middle leg portion 53a. Further, as shown in FIG. 5, the curved portion of the inner side surface 520a of the outer leg is generally curved along the peripheral edge of the collar portion 22a of the bobbin 20 (the collar portion main body 220a). The outer surface of the outer leg portion 52a located on the opposite side in the X-axis direction to the outer leg inner surface 520a extends along the Z-axis direction, and the shape of the outer leg inner surface 520a It has a different shape than the side.

As shown in FIG. 4B, in this embodiment, the cross-sectional area S1 of the middle leg 53a is approximately equal to the sum of the cross-sectional area S2 of one of the pair of outer legs 52a and the cross-sectional area S3 of the other. In the present embodiment, as a result of forming the thick portion 56a in the outer leg portion 52a, the cross-sectional area of the outer leg portion 52a is increased. It is possible to make the sum (S2+S3) of the cross-sectional areas of the outer leg portions 52a nearly equal to the cross-sectional area S1 of the middle leg portion 53a.

By forming the thick portion 56a in the outer leg portion 52a and forming such a configuration, it becomes possible to effectively prevent the magnetic saturation of the magnetic flux passing through the middle leg portion 53a and the pair of outer leg portions 52a. , the inductance characteristics of the coil device 10 can be enhanced.

The bobbin 20 is made of plastic such as PPS, PET, PBT, LCP, or other insulating material (preferably heat-resistant material). As shown in FIG. 3, the bobbin 20 has a core portion 21, flange portions 22a and 22b, and terminal block fixing portions 23a and 23b.

A first wire 41 c and a second wire 42 c are wound around the outer peripheral surface of the core portion 21 to form a first coil portion 41 and a second coil portion 42 . The first coil portion 41 is arranged on one side of the winding core portion 21 in the Y-axis direction, between the flange portion 22a and projecting portions 33 and 34 (FIG. 7) described later.

One end of the first coil portion 41 in the winding axis direction is arranged adjacent to the flange portion 22a, and the other end of the first coil portion 41 in the winding axis direction is adjacent to the projecting portions 33 and 34. placed in position. One end of the second coil portion 42 in the winding axis direction is arranged adjacent to the flange portion 22b, and the other end of the second coil portion 42 in the winding axis direction is connected to the projecting portions 33 and 34. placed in adjacent positions.

The core portion 21 is formed of a cylindrical body having a substantially elliptical shape, and the axial direction of the core portion 21 coincides with the Y-axis direction. A through hole 211 is formed inside the winding core 21, and the inside of the through hole 211 can accommodate the middle legs 53a and 53b of the cores 50a and 50b. As described above, since the coil device 10 in the present embodiment is a horizontal coil device, the axial direction of the winding core portion 21 is relative to the mounting surface of the coil device 10 or the mounting surface of a mounting substrate (not shown). They are almost parallel. Therefore, the height of the coil device 10 can be suppressed, and the height of the coil device 10 can be reduced.

The cross-sectional shape of the winding core 21 (the cross-sectional shape of a plane parallel to the XZ plane) is substantially elliptical (see FIG. 5). The long-side surfaces of the core portion 21 (the upper and lower portions of the outer peripheral surface of the core portion 21) are substantially flat surfaces, and the short-side surfaces of the core portion 21 (the outer peripheral surface of the core portion 21) are substantially flat. The lateral part of the ) consists of a curved surface. The surface on the long side of the core 21 may be curved, but the degree of curvature is preferably smaller than the degree of curvature of the surface on the short side of the core 21 .

As shown in FIG. 6, through holes 35a and 35b are formed in the upper portion of the outer peripheral surface of the winding core 21 at predetermined intervals in the Y-axis direction. The through holes 35a and 35b are located in the central portion of the winding core 21 with respect to the X-axis direction. The through-hole portion 35a is located on one side of the protrusion 33 in the Y-axis direction (the position where the first coil portion 41 is arranged), and is located between the flange portion 22a and the protrusion 33 in the Y-axis direction. do. The through-hole portion 35b is located on the other side in the Y-axis direction (the position where the second coil portion 42 is arranged) relative to the projecting portion 33, and is located between the flange portion 22b and the projecting portion 33 in the Y-axis direction. do. The through-holes 35a and 35b have the same shape, and have substantially elliptical openings with long sides extending in the Y-axis direction.

Through holes 36a and 36b are formed at predetermined intervals in the Y-axis direction in the lower portion of the outer peripheral surface of the winding core portion 21 . The through holes 36a and 36b are located in the central portion of the winding core 21 with respect to the X-axis direction. The through-hole portion 36a is located on one side (the position where the first coil portion 41 is arranged) in the Y-axis direction relative to the projecting portion 34 (FIG. 7), and the flange portion 22a and the projecting portion 34 are located in the Y-axis direction. located between The through-hole portion 36b is located on the other side in the Y-axis direction (the position where the second coil portion 42 is arranged) relative to the projecting portion 34, and is located between the flange portion 22b and the projecting portion 34 in the Y-axis direction. do. The through-holes 36a and 36b have the same shape, and have substantially elliptical openings with long sides extending in the Y-axis direction. Regarding the Z-axis direction, the position of the through-hole portion 36a corresponds to the position of the through-hole portion 35a, and the position of the through-hole portion 36b corresponds to the position of the through-hole portion 35b.

By forming through holes 35a, 35b, 36a, and 36b in the core 21, the potting resin 100 (FIG. 1) flows inside and outside the bobbin 20 (core 21) through these through holes. Therefore, the potting resin 100 can be spread all over the inside of the case 90 .

The flange portion 22a is formed at one end portion of the core portion 21 in the axial direction, and the flange portion 22b is formed at the other end portion of the core portion 21 in the axial direction. The flanges 22a and 22b have the same shape. The flange portion 22a has a flange portion main body 220a extending in the circumferential direction along the outer peripheral surface of the core portion 21 at one end of the core portion 21 in the Y-axis direction. The flange portion 22b has a flange portion main body 220b extending in the circumferential direction along the outer peripheral surface of the core portion 21 at the other end of the core portion 21 in the Y-axis direction. The flange main body 220a is made of a plate having a predetermined thickness in the Y-axis direction, and protrudes outward along the radial direction of the winding core 21 . The flange main body 220b is made of a plate having a predetermined thickness in the Y-axis direction, and protrudes outward along the radial direction of the winding core 21 .

A pair of mounting portions 32a are formed below the flange main body 220a (see FIG. 5). One mounting portion 32a is formed on one side of the flange main body 220a in the X-axis direction, and the other mounting portion 32a is formed on the other side of the flange main body 220a in the X-axis direction. One mounting portion 32a and the other mounting portion 32a are arranged at a predetermined interval in the X-axis direction. The pair of mounting portions 32a extends substantially parallel to the flange main body 220a along the XZ plane, and the bottom surfaces of the pair of mounting portions 32a are substantially flat surfaces. The pair of mounting portions 32a are mounted on the case bottom portion 91 of the case 90 shown in FIG.

A pair of mounting portions 32b are formed below the flange main body 220b. Since the configuration and function of the pair of mounting portions 32b are the same as those of the pair of mounting portions 32a, detailed description thereof will be omitted. The core portion 21 of the bobbin 20 and the like can be supported via the pair of mounting portions 32a and the pair of mounting portions 32b.

A concave bottom portion 37a is formed between each of the pair of mounting portions 32a, and a concave bottom portion 37b is formed between each of the pair of mounting portions 32b. The recessed bottoms 37a and 37b have shapes recessed upward from the bottom surfaces of the mounting portions 32a and 32b. The bottoms of the concave bottoms 37a and 37b constitute the outer peripheral surfaces of the flange main bodies 220a and 220b, and part of the inner wall surfaces of the concave bottoms 37a and 37b are tapered. By forming the concave bottoms 37a and 37b in the flange main bodies 220a and 220b, when the potting resin 100 (FIG. 1) is filled, for example, from the inside (outside) to the outside (inside) of the concave bottoms 37a and 37b in the Y-axis direction. , the potting resin 100 flows inside the recessed bottoms 37a and 37b (that is, the recessed bottoms 37a and 37b function as flow paths for the potting resin 100), so that the potting resin 100 is directed particularly below the bobbin 20. can be passed on.

A flange engaging portion 24a is formed above the flange portion main body 220a. The collar engaging portion 24a is integrally connected above the collar portion main body 220a and extends substantially parallel to the collar portion main body 220a along the XZ plane. That is, the flange engaging portion 24a has a shape extending upward from the flange main body 220a, and constitutes a part of the flange main body 220a. The flange engaging portion 24a is formed on the X-axis negative direction side of the upper end portion of the flange portion main body 220a, and protrudes upward from the fixing body portion 230a of the terminal block fixing portion 23a.

The flange engaging portion 24a has a predetermined thickness in the Y-axis direction and a surface substantially parallel to the XZ plane. The flange engaging portion 24a extends in a direction substantially orthogonal to the longitudinal direction (X-axis direction) of an arm portion 72a (FIG. 8) of the terminal block 70, which will be described later. A terminal block hook portion 73a (FIG. 8) formed at the tip of the arm portion 72a can be engaged with the flange engaging portion 24a.

A bobbin hook portion 25a having a hook shape is formed at the tip (upper end) of the flange engaging portion 24a. The bobbin hook portion 25a is configured to protrude inward in the X-axis direction and outward in the Z-axis direction from the upper end portion of the flange engaging portion 24a. More specifically, the bobbin hook portion 25a protrudes outward in the Y-axis direction from the outer surface of the flange engaging portion 24a in the Y-axis direction. The bobbin hook portion 25a protrudes inward in the X-axis direction from the inner surface of the flange engaging portion 24a in the X-axis direction. The cross-sectional area along the XY plane of the bobbin hook portion 25a is larger than the cross-sectional area along the XY plane of the flange engaging portion 24a. The bobbin hook portion 25a has a function of preventing the lead portion 41a or 41b of the first coil portion 41 pulled out along the periphery of the flange engaging portion 24a from being displaced upward from the flange engaging portion 24a ( locking function).

The structures and functions of the flange engaging portion 24b formed above the flange main body 220b and the bobbin hook portion 25b formed at the tip of the flange engaging portion 24b are the same as those of the above-described flange engaging portion 24a and the bobbin hook, respectively. Since the configuration and function are the same as those of the unit 25a, detailed description thereof will be omitted. The bobbin hook portion 25b prevents the lead portion 42a or 42b of the second coil portion 42 pulled out along the periphery of the flange engaging portion 24b from being displaced upward from the flange engaging portion 24b. It has a function (locking function).

One end of the bobbin 20 in the Y-axis direction is formed with a terminal block fixing portion 23a to which one end of the terminal block 70 (FIG. 8) in the Y-axis direction is fixed. A terminal block fixing portion 23b to which the other end portion of the terminal block 70 in the Y-axis direction is fixed is formed in the portion. The terminal block fixing portions 23a and 23b have a function of fixing the terminal block 70, and are used for automatic winding when the first wire 41c and the second wire 42c are wound around the winding core portion 21 by an automatic winding machine. Plays a role in fixing a part of the line machine.

The terminal block fixing portion 23a has a fixing body portion 230a, a bobbin convex portion 30a, and a bobbin stepped portion 31a. The terminal block fixing portion 23b has a fixing body portion 230b, a bobbin convex portion 30b, and a bobbin step portion 31b.

The fixing main bodies 230a and 230b are formed in a substantially flat plate shape having surfaces substantially parallel to the XY plane, and have a predetermined thickness in the Z-axis direction. The width of the fixed body portions 230a and 230b along the X-axis direction is larger than the width of the winding core portion 21 along the X-axis direction, and is substantially equal to the width along the X-axis direction of the flange portion bodies 220a and 220b. The fixed main body portion 230a is integrally connected to the outer surface of the flange portion main body 220a of the flange portion 22a in the Y-axis direction, and protrudes outward from the surface in the Y-axis direction. The fixed body portion 230b is integrally connected to the outer surface in the Y-axis direction of the collar portion body 220b of the collar portion 22b, and protrudes outward in the Y-axis direction from the surface.

The bobbin protrusions 30a and 30b are protruding pieces having a protruding shape, and protrude outward in the X-axis direction from the side portions (side surfaces) of the fixed body portions 230a and 230b in the X-axis direction by a predetermined length. . The projecting directions of the bobbin protrusions 30a and 30b respectively correspond to the directions in which the terminal block 70 is arranged.

The bobbin protrusions 30a and 30b have a substantially flat rectangular parallelepiped shape, and the thickness of the bobbin protrusions 30a and 30b in the Z-axis direction is smaller than the thickness in the Z-axis direction of the fixing main bodies 230a and 230b. there is The bobbin projection 30a engages with the terminal block recess 75a (FIG. 8) of the terminal block 70, and the bobbin projection 30b engages with the terminal block recess 75b (FIG. 8) of the terminal block 70. As shown in FIG.

The bobbin stepped portion 31a is formed on the back surface of the fixed body portion 230a, and is a corner portion where the end (side portion) of the fixed body portion 230a on the negative side of the X-axis and the end on the positive side of the Y-axis intersect. is formed in The bobbin stepped portion 31b is formed on the back surface of the fixed body portion 230b, and is a corner portion where the end (side portion) of the fixed body portion 230b on the negative side of the X-axis and the end on the negative side of the Y-axis intersect. is formed in

The bobbin stepped portion 31a is formed adjacent to the bobbin convex portion 30a, and the bobbin stepped portion 31b is formed adjacent to the bobbin convex portion 30b. The bobbin projection 30a is formed between the flange engaging portion 24a and the bobbin stepped portion 31a in the Y-axis direction. It is formed between the stepped portion 31b.

The flange engaging portion 24a, the bobbin convex portion 30a, and the bobbin stepped portion 31a all function to form an engaged state with the terminal block 70. formed by concentrating on the Further, the flange engaging portion 24b, the bobbin convex portion 30b, and the bobbin stepped portion 31b all function to form an engaged state with the terminal block 70, and are arranged in the X-axis direction of the fixed body portion 230b. are concentrated at the ends of the

The bobbin stepped portions 31a and 31b form steps with respect to the rear surfaces of the fixed body portions 230a and 230b. The bobbin stepped portions 31a and 31b have a stepped shape (concave shape) recessed at a predetermined depth in the Z-axis direction from the rear surfaces of the fixed body portions 230a and 230b. has a substantially rectangular shape (see FIG. 10).

The bobbin stepped portion 31a has a stepped lower surface 310a that is substantially parallel to the back surface of the fixed body portion 230a (substantially rectangular surface having predetermined lengths in the X-axis direction and the Y-axis direction). The bobbin stepped portion 31b has a stepped lower surface 310b formed of a surface (substantially rectangular surface having predetermined lengths in the X-axis direction and the Y-axis direction) substantially parallel to the back surface of the fixed main body portion 230b. The stepped lower surfaces 310a and 310b constitute the stepped lower surfaces that form the bobbin stepped portions 31a and 31b. The upper surface of the steps forming the bobbin step portions 31a and 31b is the back surface of the fixed body portion 230a. The bobbin stepped portion 31a is engaged with the terminal block stepped portion 74a (FIG. 8) of the terminal block 70, and the bobbin stepped portion 31b is engaged with the terminal block stepped portion 74b of the terminal block 70 (FIG. 8).

An extended collar portion 27a is formed above the collar portion main body 220a. The extended collar portion 27a is integrally connected to the upper part of the collar portion main body 220a and extends substantially parallel to the collar portion main body 220a along the XZ plane. That is, the extended collar portion 27a has a shape in which the collar portion main body 220a is extended upward, and constitutes a part of the collar portion main body 220a. The extended flange portion 27a has a predetermined thickness in the Y-axis direction and a surface substantially parallel to the XZ plane.

The above-described flange engaging portion 24a is formed at the end on the X-axis negative direction side of the upper end portion of the flange main body 220a. Among them, it is formed at the end on the positive side of the X-axis. The extended flange portion 27a is arranged at a predetermined interval along the X-axis direction with respect to the flange engaging portion 24a, and protrudes upward from the fixing body portion 230a of the terminal block fixing portion 23a.

A partition portion 26a is formed between the flange engaging portion 24a and the extended flange portion 27a. The flange engaging portion 24a, the extended flange portion 27a, and the partition portion 26a are arranged along the X-axis direction. The partition portion 26a is integrally connected to the upper portion of the collar portion main body 220a and extends substantially parallel to the collar portion main body 220a along the XZ plane. That is, the partition portion 26a has a shape extending upward from the flange main body 220a, and constitutes a part of the flange main body 220a. The partition 26a has a predetermined thickness in the Y-axis direction and a surface substantially parallel to the XZ plane.

An extended collar portion 27b and a partition portion 26b are formed above the collar portion main body 220b. Since the configurations of the extended collar portion 27b and the partition portion 26b are the same as the configurations of the extended collar portion 27a and the partition portion 26a, detailed description thereof will be omitted.

A notch portion 28a is formed between the flange engaging portion 24a and the partition portion 26a, and a notch portion 29a is formed between the extended flange portion 27a and the partition portion 26a. Either one of the lead portions 41a and 41b of the first wire 41c (FIG. 3) can be inserted through the notch portion 28a. The same applies to the notch 29a.

A notch portion 28b is formed between the flange engaging portion 24b and the partition portion 26b, and a notch portion 29b is formed between the extended flange portion 27b and the partition portion 26b. Either one of the lead portions 42a and 42b of the second wire 42c (FIG. 3) can be inserted through the notch portion 28b. The same applies to the notch 29b.

In the present embodiment, as shown in FIG. 2, of the lead portions 41a and 41b, the lead portion 41a is inserted through the notch portion 29a, and the lead portion 41a extends through the notch portion 29a in the Y-axis direction of the collar portion 22a. , and is pulled out toward the terminal block 70 from the outside in the Y-axis direction of the collar portion 22a. Therefore, when the lead portion 41a is pulled out toward the terminal block 70, unnecessary routing of the lead portion 41a can be prevented.

On the other hand, the lead portion 41b is pulled out toward the terminal block 70 from the inner side of the flange portion 22a in the Y-axis direction without passing through either of the cutout portions 28a and 29a. As a result, the lead portion 41a passes through the outer side of the flange engaging portion 24a in the Y-axis direction, and the lead portion 41b passes through the inner side of the flange engaging portion 24a in the Y-axis direction. The lead portion 41a and the lead portion 41b can be well insulated through the .

Moreover, since the partition portion 26a is formed between the notch portion 28a and the notch portion 29a, the position of the lead portion 41a inserted through the notch portion 29a is adjusted by the partition portion 26a, and the displacement of the lead portion 41a is prevented. It is possible to prevent

Of the lead portions 42a and 42b, the lead portion 42a is inserted through the cutout portion 28b, and the lead portion 42a is pulled out from the inner side of the collar portion 22b in the Y-axis direction to the outer side through the cutout portion 28b. It is pulled out toward the terminal block 70 from the outside of the portion 22b in the Y-axis direction. Therefore, when the lead portion 42a is pulled out toward the terminal block 70, unnecessary routing of the lead portion 42a can be prevented.

On the other hand, the lead portion 42b is pulled out toward the terminal block 70 from the inner side of the collar portion 22b in the Y-axis direction without passing through either of the cutout portions 28b and 29b. As a result, the lead portion 42a passes through the outer side of the flange engaging portion 24b in the Y-axis direction, and the lead portion 42b passes through the inner side of the flange engaging portion 24b in the Y-axis direction. The lead portion 42a and the lead portion 42b can be well insulated through the .

Since the partition portion 26b is formed between the notch portion 28b and the notch portion 29b, the position of the lead portion 42a inserted through the notch portion 28b is adjusted by the partition portion 26b, and misalignment of the lead portion 42a is partitioned. It is possible to prevent this at the portion 26b.

As shown in FIGS. 6 and 7, the winding core 21 has projecting portions 33 and 34 in this embodiment. The protruding portions 33 and 34 differ from the first coil portion 41 (FIG. 3) in accordance with the length along the circumferential direction (or the length along the X-axis direction) or the length (thickness) along the Y-axis direction. It has a function of adjusting leakage characteristics with the second coil portion 42 .

Protrusions 33 and 34 are integrally formed on the outer peripheral surface of core 21 , extend outward from the outer peripheral surface of core 21 , and protrude along the circumferential direction of core 21 . extended. The protruding portions 33 and 34 are formed on the outer peripheral surface of the winding core portion 21 on the longer side. That is, the projecting portion 33 is formed on the upper portion of the outer peripheral surface of the winding core portion 21 , and the projecting portion 34 is formed on the lower portion of the outer peripheral surface of the winding core portion 21 . Note that the upper and lower portions of the outer peripheral surface of the core portion 21 are substantially flat surfaces, and the protruding portions 33 and 34 are positioned above the curved portions (side portions) of the core portion 21 as described above. It is preferably formed on a substantially flat surface of the winding core portion 21 .

The protruding portions 33 and 34 are formed substantially in the central portion of the winding core portion 21 in the axial direction (Y-axis direction). The projecting portion 33 and the projecting portion 34 are arranged on opposite sides of the core portion 21 along the radial direction, and are formed at corresponding positions in the Z-axis direction.

The protruding portions 33 and 34 have the same shape, and are formed in a substantially rectangular parallelepiped shape (flat shape) having a longitudinal direction perpendicular to the axial direction of the winding core portion 21 (the X-axis direction). The length of the protrusions 33 and 34 along the X-axis direction is greater than the length (height) of the protrusions 33 and 34 along the Z-axis direction, and the length of the protrusions 33 and 34 along the Z-axis direction is , is larger than the thickness of the protrusions 33 and 34 along the Y-axis direction. The end (upper end) of the protrusion 33 in the Z-axis direction is formed with a curved surface (beveled), but the shape of the protrusion 33 is not limited to this. Although detailed illustration is omitted, the shape of the projecting portion 34 is the same.

The length of the protruding portion 33 along the circumferential direction of the core portion 21 (or the length of the protruding portion 33 along the X-axis direction) is smaller than the length of the core portion 21 along the circumferential direction. As shown in FIG. 9, the length of the protruding portion 33 along the circumferential direction of the core portion 21 (or the length of the protruding portion 33 along the X-axis direction) L3 and the length of the core portion 21 along the circumferential direction The ratio L3/L4 to the height (total length) L4 (not shown) is preferably 0<L3/L4<1/2, more preferably 0<L3/L4<1/4, and particularly preferably 1 /10<L3/L4<1/5. By appropriately adjusting the value of L3/L4 within the above range, the leakage characteristic between the first coil portion 41 (FIG. 3) and the second coil portion 42 can be appropriately adjusted to a desired value. can be done. The same applies to the ratio between the length of the protruding portion 34 along the circumferential direction of the core portion 21 (or the length of the protruding portion 34 along the X-axis direction) and the length of the core portion 21 along the circumferential direction. is.

The length of the protruding portion 33 along the circumferential direction of the core portion 21 (or the length of the protruding portion 33 along the X-axis direction) is smaller than the length of the core portion 21 along the X-axis direction. Ratio L3 between the length L3 of the protruding portion 33 along the circumferential direction of the core portion 21 (or the length of the protruding portion 33 along the X-axis direction) and the length L5 of the core portion 21 along the X-axis direction /L5 is preferably 0<L3/L5<1, more preferably 0<L3/L5<3/4, and particularly preferably 1/6<L3/L5<2/3. By appropriately adjusting the value of L3/L5 within the above range, the leakage characteristic between the first coil portion 41 (FIG. 3) and the second coil portion 42 can be appropriately adjusted to a desired value. can be done. Note that the ratio between the length of the protruding portion 34 along the circumferential direction of the core portion 21 (or the length of the protruding portion 34 along the X-axis direction) and the length of the core portion 21 along the X-axis direction is also It is the same.

The length L6 of the protrusion 33 along the Z-axis direction is determined, for example, according to the wire diameter of the first wire 41c (FIG. 3) or the wire diameter of the second wire 42c. In the present embodiment, the first wire 41c and the second wire 42c are each formed in two layers in the radial direction of the winding core portion 21 . Therefore, the length L6 is the wire diameter of the first wire 41c (FIG. 3) or It is preferably at least twice the wire diameter. That is, the length L6 is preferably larger than the height of the first coil portion 41 or the second coil portion 42 from the outer peripheral surface of the core portion 21 . The same applies to the length of the projecting portion 34 along the Z-axis direction.

By determining the length L6 of the protrusion 33 along the Z-axis direction as described above, the protrusion 33 moves the first wire 41c and the second wire 42c along the Y-axis direction at the position of the protrusion 33. Displacement can be effectively prevented. Moreover, by fixing the first wire 41c and the second wire 42c to the protruding portion 33, it is possible to prevent the first coil portion 41 and the second coil portion 42 from becoming loose. Further, the first wire 41c and the second wire 42c are wound around the outer peripheral surface of the core portion 21 so as to reciprocate between the axial ends of the core portion 21 and the projecting portions 33 and 34. In this case, the first wire 41c and the second wire 42c can be folded back while being fixed to the projecting portions 33 and 34, thereby reducing variations in the positions and number of turns of the first coil portion 41 and the second coil portion 42. can be prevented.

As shown in FIG. 7, the length L7 of the projecting portion 33 along the axial direction of the winding core portion 21 is preferably smaller than the wire diameter of the first wire 41c or the second wire 42c. In this embodiment, the length L7 of the projecting portion 33 is substantially equal to the thickness of the flange portion 22a or 22b along the Y-axis direction.

As shown in FIGS. 2 and 7, the first coil portion 41 is arranged on one side of the projections 33 and 34 in the Y-axis direction, and the second coil portion 41 is arranged on the other side of the projections 33 and 34 in the Y-axis direction. 2 coil part 42 is arranged. That is, the projecting portions 33 and 34 are arranged between the first coil portion 41 and the second coil portion 42 in the Y-axis direction.

The first coil portion 41 and the second coil portion 42 are partially in contact with each other along the circumferential direction of the winding core portion 21 with the projecting portions 33 and 34 interposed therebetween. That is, when viewed along the circumferential direction of the core portion 21, the projecting portion 33 is interposed between the first coil portion 41 and the second coil portion 42 at the position where the projecting portion 33 is formed. Therefore, the first coil portion 41 and the second coil portion 42 do not come into contact with each other. That is, the projecting portion 33 separates the first coil portion 41 and the second coil portion 42 in the Y-axis direction. is formed.

Moreover, since the protrusion 34 is interposed between the first coil portion 41 and the second coil portion 42 at the position where the protrusion 34 is formed, the first coil portion 41 and the second coil portion 42 are separated from each other. no contact. That is, the projecting portion 34 separates the first coil portion 41 and the second coil portion 42 in the Y-axis direction. is formed.

On the other hand, at positions where the projecting portions 33 and 34 are not formed, the projecting portions 33 and 34 are not interposed between the first coil portion 41 and the second coil portion 42. contact with the coil portion 42 . Therefore, a contact region 43 is formed between the first coil portion 41 and the second coil portion 42 .

The contact area 43 is formed so as to be sandwiched between the non-contact area 44 and the non-contact area 45 and is formed in a part of the winding core 21 along the circumferential direction. The contact area 43 is formed across the side portion of the outer peripheral surface of the core portion 21 and the upper portion and the lower portion of the outer peripheral surface of the core portion 21, and along the outer peripheral surface of the core portion 21, It extends by a predetermined length so as to be bent in a substantially C shape. The contact regions 43 are discontinuously formed on one side and the other side of the core portion 21 in the X-axis direction. The non-contact areas 44 and 45 are respectively formed on the upper and lower portions of the outer peripheral surface of the winding core 21 and extend for a predetermined length along the X-axis direction. The contact regions 43 and the non-contact regions 44 or 45 are alternately formed along the circumferential direction of the core portion 21 .

The length of the contact region 43 along the circumferential direction of the core portion 21 is longer than the length of the non-contact region 44 or 45 along the circumferential direction of the core portion 21, and the first coil portion 41 and the second coil Most of the portion 42 is in contact with the winding core portion 21 along the circumferential direction. By partially forming non-contact regions 44 and 45 between the first coil portion 41 and the second coil portion 42 along the circumferential direction of the winding core portion 21, the first coil portion 41 and the second coil The leakage characteristic between the portion 42 can be appropriately adjusted to a desired value.

As shown in FIG. 3 , the terminal block 70 is formed separately from the bobbin 20 and is detachably attached to the bobbin 20 . Although the terminal block 70 may be made of the same insulating material as the bobbin 20, it is preferably made of an insulating material having excellent formability or heat resistance. The terminal block 70 is located on the side of the core portion 21 in the negative direction of the X axis, and is spaced from the outer peripheral surface of the core portion 21 in a direction perpendicular to the axial direction of the core portion 21 (X-axis direction). placed in Therefore, a gap G (FIG. 9) having a predetermined length in the X-axis direction is formed along the axial direction of the core portion 21 between the side portion of the outer peripheral surface of the core portion 21 and the terminal block 70. It is

As shown in FIG. 8, the terminal block 70 includes a terminal block base portion 71, arm portions 72a and 72b, terminal block hook portions 73a and 73b, terminal block stepped portions 74a and 74b, and terminal block concave portions 75a and 75b. , lead insertion grooves 76 a and 76 b , terminal fixing portions 77 a _ 1 and 77 a _ 2 , terminal fixing portions 77 b _ 1 and 77 b _ 2 , cover mounting portion 78 , and bottom fixing portion 79 .

The terminal block base portion 71 is formed of a substantially rectangular parallelepiped columnar body having a longitudinal direction in the Y-axis direction, and extends to the side of the winding core portion 21 in the X-axis direction and substantially parallel to the axial direction of the winding core portion 21 . placed. The length of the terminal block base portion 71 along the Y-axis direction is substantially equal to the length of the bobbin 20 along the Y-axis direction. As shown in FIG. 5 , the terminal block base portion 71 (bottom surface of the terminal block base portion 71 ) is located at a position spaced apart from the side portion of the outer peripheral surface of the core portion 21 in the X-axis direction. It is arranged above the central portion in the axial direction and above the upper portion of the outer peripheral surface of the winding core portion 21 . However, the height position at which the terminal block base portion 71 is installed is not limited to this. It may be arranged at a height position substantially equal to the portion, or may be arranged at a position lower than this.

As shown in FIGS. 5 and 9, the terminal block base portion 71 is arranged at a position separated by a gap G laterally in the X-axis direction from the outer peripheral surface of the winding core portion 21. Therefore, the terminal block base portion 71 , and the outer peripheral surface of the winding core 21 do not overlap in the Z-axis direction.

However, the position of the terminal block base portion 71 is shifted in the positive X-axis direction so that the end of the terminal block base portion 71 on the positive X-axis direction and the outer peripheral surface of the winding core portion 21 move in the Z-axis direction (Z-axis viewed from any direction) may be arranged overlappingly. That is, if the terminal block base portion 71 is arranged at a position spaced apart from the outer peripheral surface of the core portion 21 along the radial direction of the core portion 21 by a predetermined distance, the position of the terminal block base portion 71 is particularly It is not limited. For example, the terminal block base portion 71 is arranged at a position spaced apart from an arbitrary position on the outer peripheral surface of the winding core portion 21 by a predetermined distance to the side of the winding core portion 21 (X-axis negative direction side). It may be arranged at a position separated by a predetermined distance above the winding core 21 (on the Z-axis positive direction side) from the position on the outer peripheral surface of the core 21 .

The position of the end (side) of the terminal block base portion 71 on the positive direction side of the X axis is substantially equal to the position of the ends of the flange engaging portions 24a and 24b of the bobbin 20 on the negative direction side of the X axis. They are placed in close proximity.

As shown in FIG. 8, the arm portion 72a is formed on one side of the terminal block base portion 71 in the Y-axis direction, and the arm portion 72b is formed on the other side of the terminal block base portion 71 in the Y-axis direction. The arm portions 72a and 72b protrude toward the bobbin 20 by a predetermined length from the end (side portion) of the terminal block base portion 71 in the X-axis direction. As shown in FIG. 9, the length of the arm portions 72a and 72b along the X-axis direction is longer than the length of the above-described gap G in the X-axis direction, and the length of the flange engaging portions 24a and 24b of the bobbin 20 is longer than the X-axis length. It is approximately equal to the length along the direction.

As shown in FIG. 8, a terminal block hook portion 73a having a hook shape is formed at the tip of the arm portion 72a, and a terminal block hook portion 73b having a hook shape is formed at the tip portion of the arm portion 72b. . The terminal block hook portions 73a and 73b protrude by a predetermined length from the tip portions of the arm portions 72a and 72b in a direction toward each other (inside the terminal block 70) along the Y-axis direction. The protruding direction of the terminal block hook portions 73a and 73b and the longitudinal direction of the arm portions 72a and 72b are substantially orthogonal.

As shown in FIG. 10, in a state in which the terminal block 70 is fixed to the terminal block fixing portions 23a and 23b of the bobbin 20, the arm portion 72a extends along the outer surface of the flange engaging portion 24a of the bobbin 20 in the Y-axis direction. The terminal block hook portion 73a engages with the side portion of the flange engaging portion 24a on the positive direction side of the X axis. The arm portion 72b is arranged along the Y-axis direction outer surface of the flange engaging portion 24b of the bobbin 20, and the terminal block hook portion 73b is engaged with the side portion of the flange engaging portion 24b on the X-axis positive direction side. match. Accordingly, the terminal block 70 can be attached to the terminal block fixing portions 23a and 23b via the arm portions 72a and 72b.

With the terminal block hook portion 73a engaged with the flange engaging portion 24a, the lead portion 41a of the first wire 41c shown in FIG. 2 is pulled out toward the terminal block 70 along the circumference of the arm portion 72a. . Further, in a state in which the terminal block hook portion 73b is engaged with the flange engaging portion 24b, the lead portion 42a of the second wire 42c shown in FIG. 2 is pulled out toward the terminal block 70 along the circumference of the arm portion 72b. . Since the lead portions 41a and 41b are pulled out along the outer surfaces (outer surfaces in the Y-axis direction) of the arm portions 72a and 72b, respectively, the arm portions 72a and 72b connect the lead portions 41a and 41b to the terminal block 70. act as a guide.

As shown in FIG. 8, the terminal block stepped portion 74a is formed at one end of the terminal block base portion 71 in the Y-axis direction, and the terminal block stepped portion 74b is formed at the other end of the terminal block base portion 71 in the Y-axis direction. It is The terminal block stepped portions 74a and 74b are arranged outside the arm portions 72a and 72b in the Y-axis direction.

The terminal block stepped portion 74a has a stepped lower surface 740a that is substantially parallel to the upper or lower surface of the terminal block base portion 71 (substantially rectangular surface having predetermined lengths in the X-axis direction and the Y-axis direction). The terminal block stepped portion 74b has a stepped lower surface 740b that is substantially parallel to the upper or lower surface of the terminal block base portion 71 (substantially rectangular surface having predetermined lengths in the X-axis direction and the Y-axis direction). The stepped lower surfaces 740a and 740b constitute the stepped lower surfaces that form the terminal block stepped portions 74a and 74b.

Terminal block steps 74a and 74b engage bobbin steps 31a and 31b of bobbin 20, as shown in FIGS. More specifically, in a state in which step lower surfaces 740a and 740b of terminal block stepped portions 74a and 74b are in contact with stepped lower surfaces 310a and 310b of bobbin stepped portions 31a and 31b, terminal block stepped portions 74a and 74b and bobbin It engages with the steps 31a and 31b.

As shown in FIG. 8, the terminal block recess 75a is formed at one end of the terminal block base portion 71 in the Y-axis direction, and the terminal block recess 75b is formed at the other end of the terminal block base portion 71 in the Y-axis direction. It is The terminal block recess 75a is arranged between the arm portion 72a and the terminal block stepped portion 74a in the Y-axis direction, and the terminal block recessed portion 75b is arranged between the arm portion 72b and the terminal block stepped portion 74b in the Y-axis direction. are placed in The terminal block recesses 75a and 75b are recesses having a predetermined depth, and the terminal block recesses 75a and 75b are open on the X-axis positive direction side. The depth of the terminal block recesses 75a and 75b is substantially equal to the thickness of the bobbin protrusions 30a and 30b (FIG. 6) of the bobbin 20 along the Z-axis direction.

The terminal block recesses 75a and 75b are recessed by a predetermined length from the end (side portion) of the terminal block base portion 71 on the X-axis positive direction side toward the X-axis negative direction side. The bottom surfaces of the terminal block recesses 75a and 75b are substantially rectangular and correspond to the shape of the top and bottom surfaces of the bobbin projections 30a and 30b of the bobbin 20. As shown in FIG.

9 and 10, terminal block recesses 75a and 75b engage bobbin protrusions 30a and 30b of bobbin 20. As shown in FIGS. More specifically, the terminal block recesses 75a and 75b are engaged with the bobbin projections 30a and 30b by accommodating the bobbin projections 30a and 30b inside the terminal block recesses 75a and 75b, respectively.

As described above, in this embodiment, by engaging the terminal block hook portions 73a and 73b and the flange engaging portions 24a and 24b as the first engaging portions, the terminal block 70 is secured to the terminal block fixing portions 23a and 23b. positional deviation along the X-axis direction can be prevented.

Further, by engaging the terminal block stepped portions 74a and 74b with the bobbin stepped portions 31a and 31b as second engaging portions, positional displacement of the terminal block 70 with respect to the terminal block fixing portions 23a and 23b along the Z-axis direction can be prevented. It is possible to prevent

Further, by engaging the terminal block recesses 75a and 75b with the bobbin projections 30a and 30b as third engaging portions, positional deviation of the terminal block 70 with respect to the terminal block fixing portions 23a and 23b along the Y-axis direction can be prevented. It is possible to prevent it. Accordingly, the terminal block 70 can be attached to the terminal block fixing portions 23a and 23b with sufficient fixing strength.

Moreover, the terminal block 70 is connected to one end portion and the other end portion of the winding core portion 21 in the axial direction by the engagement at each of the engaging portions described above, and It is possible to arrange them substantially in parallel. The terminal block 70 is fixed to the terminal block fixing portions 23a and 23b by three-point support at each of the above-described engaging portions, and there is no need to use an adhesive or the like for fixing. Note that any one of the above-described engaging portions may be omitted. In addition, fixing (reinforcing) with an adhesive or the like may be performed as necessary.

As shown in FIG. 8, the cover mounting portion 78 is formed substantially in the center of the terminal block base portion 71 in the Y-axis direction. The cover mounting portion 78 has an upper surface and a lower surface which are substantially flat surfaces, and the grip portion 84 of the cover portion 80 is fixed to the cover mounting portion 78 .

The terminal fixing portions 77a_1 and 77a_2 are formed on one side of the cover mounting portion 78 in the Y-axis direction. The terminal fixing portion 77a_1 is arranged outside the terminal fixing portion 77a_2 in the Y-axis direction. The terminal fixing portions 77a_1 and 77a_2 are formed thicker than the surrounding portions, and terminals 61_1 and 61_2 can be fixed to the terminal fixing portions 77a_1 and 77a_2, respectively.

Terminal insertion grooves 770a_1 and 770a_2 are formed in the terminal fixing portions 77a_1 and 77a_2, respectively. The terminal insertion grooves 770a_1 and 770a_2 are grooves bent in a substantially L shape corresponding to the shape of the terminals 61_1 and 61_2. The terminals 61_1 and 61_2 are fixed to the terminal fixing portions 77a_1 and 77a_2 by integral molding (insert molding).

The terminal fixing portions 77b_1 and 77b_2 are formed on the other side of the cover mounting portion 78 in the Y-axis direction. The terminal fixing portion 77b_1 is arranged outside the terminal fixing portion 77b_2 in the Y-axis direction. The terminal fixing portions 77b_1 and 77b_2 are formed thicker than the surrounding portions, and terminals 62_1 and 62_2 can be fixed to the terminal fixing portions 77b_1 and 77b_2, respectively.

Terminal insertion grooves 770b_1 and 770b_2 are formed in the terminal fixing portions 77b_1 and 77b_2, respectively. The terminal insertion grooves 770b_1 and 770b_2 are grooves that are bent in a substantially L shape corresponding to the shape of the terminals 62_1 and 62_2. The terminals 62_1 and 62_2 are fixed to the terminal fixing portions 77b_1 and 77b_2 by integral molding (insert molding).

The lead insertion groove 76a is formed between the terminal fixing portions 77a_1 and 77a_2, and the lead insertion groove 76b is formed between the terminal fixing portions 77b_1 and 77b_2. The lead insertion grooves 76 a and 76 b are recesses recessed from the end of the terminal block base portion 71 on the positive side of the X-axis, and extend from the upper end to the lower end of the terminal block base portion 71 . The lead portion 41b of the first wire 41c is inserted through the lead insertion groove 76a, and the lead portion 42b of the second wire 41c is inserted through the lead insertion groove 76b (see FIG. 2).

The bottom surface fixing portion 79 is formed stepwise on the bottom surface of the terminal block base portion 71 at the end of the terminal block base portion 71 on the negative side of the X axis (the side opposite to the side on which the bobbin 20 is arranged). . The bottom fixing portion 79 has a substantially flat surface and has a predetermined length along the X-axis direction and a predetermined length along the Y-axis direction. The bottom fixing portion 79 is formed along the Y-axis direction from one end to the other end of the terminal block base portion 71 in the Y-axis direction. An end portion of the cover bottom portion 81 of the cover portion 80 in the X-axis direction is fixed to the bottom surface fixing portion 79 .

The terminal 61_1, the terminal 61_2, the terminal 62_1, and the terminal 62_2 are attached to the terminal block 70 at predetermined intervals along the Y-axis direction. The terminals 61_1 and 61_2 have the same shape and are fixed to the terminal fixing portion 77a_1 and the terminal fixing portion 77a_2. The lead portion 41a of the first wire 41c is connected to the terminal 61_1, and the lead portion 41b of the first wire 41c is connected to the terminal 61_2.

The terminals 62_1 and 62_2 have the same shape and are fixed to the terminal fixing portion 77b_1 and the terminal fixing portion 77b_2. The lead portion 42a of the second wire 42c is connected to the terminal 62_1, and the lead portion 42b of the second wire 42c is connected to the terminal 62_2.

The terminal 61_1 has an external connection portion 610_1, a connecting portion 611_1, a connecting wire bottom portion 612_1, and a connecting wire folded portion 613_1. The external connection portion 610_1 is a portion connected to the mounting board, protrudes from the upper portion of the terminal fixing portion 77a_1 (terminal insertion groove 770a_1), and extends upward. The external connection portion 610_1 protrudes upward from the upper edge of the case 90 (FIG. 1).

The connecting portion 611_1 is a portion that connects the external connecting portion 610_1 and the connecting wire bottom portion 612_1, and extends toward the X-axis negative direction side while bending outward in the Y-axis direction.

The connecting wire bottom portion 612_1 and the connecting wire folded portion 613_1 are portions for connecting the lead portion 41a. ing. The wire connection folded portion 613_1 is integrally connected to the Y-axis direction outer end portion of the wire connection bottom portion 612_1, and is arranged to face the wire connection bottom portion 612_1 in the Z-axis direction. The line folded portion 613_1 has a curved surface, but may be formed in a substantially flat shape.

The terminal 61_2 has an external connection portion 610_2, a connecting portion 611_2, a connecting wire bottom portion 612_2, and a connecting wire folded portion 613_2. Since the shape and function of each part forming the terminal 61_2 are the same as the shape and function of each part forming the terminal 61_1, detailed description thereof will be omitted.

The terminal 62_1 has an external connection portion 620_1, a connecting portion 621_1, a connecting wire bottom portion 622_1, and a connecting wire folded portion 623_1. The terminal 62_1 is different from the terminal 61_1 in that it is formed line-symmetrically with respect to the X-axis, and since other points are common to the terminal 61_1, detailed description of the terminal 62_1 is omitted. .

The terminal 62_2 has an external connection portion 620_2, a connecting portion 621_2, a connecting wire bottom portion 622_2, and a connecting wire folded portion 623_2. The terminal 62_2 is different from the terminal 61_2 in that it is formed line-symmetrically with respect to the X-axis, and since other points are common to the terminal 61_2, detailed description of the terminal 62_2 is omitted. .

The cover portion 80 has a cover bottom portion 81 , an insulating portion 82 , cover side portions 83 a and 83 b and a grip portion 84 . The cover part 80 is formed separately from the terminal block 70 and is detachably attached to the terminal block 70 so as to be arranged around the terminal block 70 .

Cover bottom 81 has a plate surface substantially parallel to the XY plane, and is arranged below terminals 61_1 and 61_2 and terminals 62_1 and 62_2 attached to terminal block 70 . The tip portion of the cover bottom portion 81 in the X-axis direction is fixed while being engaged with the bottom surface fixing portion 79 of the terminal block 70 . By fixing the cover bottom portion 81 to the bottom surface fixing portion 79, it is possible to prevent the positional deviation of the cover portion 80 with respect to the terminal block 70 in the Z-axis direction.

The insulating portion 82 is formed substantially in the center of the cover portion 80 in the Y-axis direction. An insulating recess 820 is formed in the insulating portion 82 . The insulating recessed portion 820 is recessed downward from the upper surface of the insulating portion 820 and recessed from the side surface of the insulating recessed portion 820 on the negative X-axis direction side toward the positive X-axis direction. A terminal 61_2 is arranged on one side of the insulating portion 82 in the Y-axis direction, and a terminal 62_2 is arranged on the other side of the insulating portion 82 in the Y-axis direction.

By forming the insulating portion 82 having the insulating concave portion 820 in the cover portion 80, the terminal 61_2 to which the lead portion 41b of the first wire 41c is connected and the terminal 62_2 to which the lead portion 42b of the second wire 42c is connected are separated. It is possible to extend the insulation distance between them, and it is possible to achieve good insulation between these wires (primary coil and secondary coil).

The cover side portions 83 a and 83 b extend upward and are raised from the end of the cover bottom portion 81 on the negative side of the X-axis so as to be substantially orthogonal to the cover bottom portion 81 . The cover side portion 83a is formed on one side of the insulating portion 82 in the Y-axis direction, and the cover side portion 83b is formed on the other side of the insulating portion 82 in the Y-axis direction.

By forming the cover bottom portion 81 and the cover side portions 83a and 83b in the cover portion 80, the terminals 61_1 and 61_2 and the terminals 62_1 and 62_2 attached to the terminal block 70 can be protected from external forces and the like. In addition, the terminals 61_1 and 61_2 are well insulated from the core 50a (FIG. 3) through the cover bottom portion 81 and the cover side portion 83a, and the terminals 62_1 and 62_1 and the terminal 62_1 through the cover bottom portion 81 and the cover side portion 83b. 62_2 and core 50b (FIG. 3) can be well insulated.

The grip portion 84 is formed substantially in the center of the cover bottom portion 81 in the Y-axis direction, and protrudes from the position of the insulating portion 82 toward the terminal block 70 . The gripping portion 84 is for gripping the cover mounting portion 78 of the terminal block 70 .

The grasping portion 84 has an upper arm 841 and a lower arm 842 . The upper arm portion 841 is formed at the upper end portion of the insulating portion 82 and extends toward the terminal block 70 . The lower arm 842 is formed at the lower end portion of the insulating portion 82 (at the position of the cover bottom portion 81 ) and extends toward the terminal block 70 so as to be substantially parallel to the upper arm 841 . The distal end portions of the upper arm 841 and the lower arm 842 are hook-shaped and bent toward each other. The upper arm 841 and the lower arm 842 grip the upper surface and the lower surface of the cover mounting portion 78 , respectively, so that the grip portion 84 can be attached to the cover mounting portion 78 .

By gripping the cover attachment portion 78 of the terminal block 70 with the upper arm 841 and the lower arm 842, the cover portion 80 can be attached to the cover attachment portion 78 with sufficient fixing strength without using an adhesive or the like. As a result, the cost can be reduced and the production can be speeded up.

Next, a method for manufacturing the coil device 10 will be described with reference to FIG. 3 and the like. First, each member shown in FIG. 3 is prepared. Terminals 61_1 and 61_2 and terminals 62_1 and 62_2 are attached in advance to the terminal block 70 by insert molding or the like. Also, a cover portion 80 is attached to the terminal block 70 . These attachments are performed by gripping the cover attachment portion 78 of the terminal block 70 with the grip portion 84 of the cover portion 80, and there is no particular need to use an adhesive or the like.

Next, the first wire 41c and the second wire 42c are wound around the outer peripheral surface of the core portion 21 of the bobbin 20 to form the first coil portion 41 on one side in the Y-axis direction of the projecting portions 33 and 34, A second coil portion 42 is formed on the other side. The lead portions 41a and 41b of the first wire 41c are pulled out from one end portion of the core portion 21 in the axial direction. Further, the lead portions 42a and 42b of the second wire 42c are pulled out from the other end portion of the winding core portion 21 in the axial direction.

Next, one end portion of the terminal block 70 in the Y-axis direction is fixed to the terminal block fixing portion 23a of the bobbin 20, and the other end portion of the terminal block 70 in the Y-axis direction is fixed to the terminal block fixing portion 23b of the bobbin 20. , the terminal block 70 is arranged at a position spaced apart from the outer peripheral surface of the core portion 21 by a predetermined distance outward (laterally) in the X-axis direction.

Next, the lead portion 41a is connected to the terminal 61_1 by crimping or the like, the lead portion 41b is connected to the terminal 61_2 by crimping or the like, the lead portion 42a is connected to the terminal 62_1 by crimping or the like, and the lead portion 42b is crimped to the terminal 62_2. etc. (see FIG. 2). Next, the cores 50a and 50b are attached to the bobbin 20 by inserting the middle leg portion 53a and the middle leg portion 53b of the core 50b into the through hole 211 of the bobbin 20. As shown in FIG.

Next, by housing the bobbin 20 and the like inside the case 90 and filling the case 90 with the potting resin 100, the coil device 10 shown in FIG. 1 can be obtained.

As described above, the coil device 10 according to the present embodiment has the terminal block 70 formed separately from the bobbin 20, as shown in FIG. Therefore, when the coil device 10 is manufactured, the first wire 41c and the second wire 42c can be wound around the outer peripheral surface of the winding core portion 21 with the terminal block 70 removed from the bobbin 20. When winding the first wire 41c and the second wire 42c using a winding machine, the terminal block 70 can be prevented from interfering with automatic winding by the automatic winding machine. In addition, by forming only the terminal block 70 from a highly heat-resistant resin separately from the bobbin 20, the coil device 10 having heat resistance can be realized at a low cost.

Moreover, the terminal block 70 is arranged at a position spaced apart from the outer peripheral surface of the winding core portion 21 in the X-axis direction. Therefore, the terminal block 70 can be arranged on the side of the core portion 21 in the X-axis direction, and the size of the coil device 10 can be reduced in the X-axis direction and the Z-axis direction. Miniaturization of the device 10 can be realized.

Also, the terminal block 70 is arranged substantially parallel to the axial direction of the winding core portion 21 . Therefore, it is possible to prevent the terminal block 70 from being arranged in a state of projecting unnecessarily on the side of the core portion 21 in the X-axis direction, thereby reducing the size of the coil device 10 in the X-axis direction. be able to.

Further, in this embodiment, as shown in FIG. 8, the arm portions 72a and 72b are engaged with the flange engaging portions 24a and 24b (FIG. 6) via the terminal block hook portions 73a and 73b. It is possible to attach the terminal block 70 to the bobbin 20 with a sufficient fixing strength without using a fixing member or the like, and it is possible to reduce the cost and speed up the manufacturing process. In addition, the terminal block 70 can be arranged at a position separated in the X-axis direction from the outer peripheral surface of the core portion 21 by a distance corresponding to the length of the arm portions 72a and 72b. By appropriately changing the length, the arrangement of the terminal block 70 can be adjusted.

Further, in the present embodiment, the lead portion 41a of the first wire 41c and the lead portion 42a of the second wire 42c are pulled out toward the terminal block 70 along the circumferences of the arm portions 72a and 72b, respectively (FIGS. 2 and 4). 9 and FIG. 10), the lead portions 41a and 42a can be pulled out in a short distance from the winding core portion 21 to the terminal block 70, and unnecessary routing of the lead portions 41a and 42a occurs (the wires of the lead portions 41a and 42a length increase), the quality of the coil device 10 can be improved, and the electric resistance can be reduced or resonance of the first wire 41c and the second wire 42c can be suppressed.

Further, as shown in FIG. 6, bobbin hooks 25a and 25b are formed on the flange engaging portions 24a and 24b, so that the lead portions 41a and 42a drawn out along the circumference of the arm portions 72a and 72b are , positional deviation toward the upper ends of the flange engaging portions 24a and 24b can be prevented.

Further, in the present embodiment, as shown in FIG. 1, heat generated in the bobbin 20 or the like can be radiated to the outside through the case 90 and the potting resin 100, and the coil device 10 can be efficiently cooled. It can be carried out. Further, as shown in FIG. 6, through holes 35a and 35b and through holes 36a and 36b are formed in the bobbin 20, so that the potting resin 100 can flow inside and outside the bobbin 20 through these holes. Thus, the potting resin 100 can be spread all over the inside of the case 90 .

Second Embodiment A coil device 110 according to a second embodiment of the present invention is different only in the following points, and the rest of the configuration is the same as that of the first embodiment described above, and has the same effects. . In the drawings, members common to those of the first embodiment are denoted by common reference numerals, and descriptions of overlapping portions are omitted.

As shown in FIG. 11, the coil device 110 has terminal blocks 70_1 and 70_2 and cover portions 80_1 and 80_2. That is, the coil device 110 according to the present embodiment has the terminal block 70_1 and the cover portion 80_1 at positions spaced apart from the outer peripheral surface of the winding core portion 21 in the negative direction of the X axis. 10, but differs from the coil device 10 of the first embodiment in that it also has a terminal block 70_2 and a cover portion 80_2 at a position spaced apart from the outer peripheral surface of the winding core portion 21 in the positive direction of the X axis. ing.

As shown in FIG. 12, the terminal block fixing portions 23a and 23b of the winding core portion 120 are provided with an end portion on the X-axis positive direction side in addition to the end portion on the X-axis negative direction side so that the terminal block 70_2 can be attached. are also formed with flange engaging portions 24a and 24b, bobbin convex portions 30a and 30b, and bobbin stepped portions 31a and 31b. Therefore, the shape of the bobbin 120 on one side of the center in the X-axis direction and the shape of the bobbin 120 on the other side of the center in the X-axis direction are equal (symmetrical).

Also in this embodiment, the same effect as in the first embodiment can be obtained. In addition, in the present embodiment, since the terminal blocks 70_1 and 70_2 are formed on both sides of the winding core 21 in the X-axis direction, the lead portions 41a and/or 41b of the first wire 41c are connected to the terminal block 70_1. Instead of the side where the terminal block 70_2 is arranged, it can be pulled out and fixed to the side where the terminal block 70_2 is arranged. Also, the lead portions 42a and/or 42b of the second wire 42c can be pulled out and fixed to the side where the terminal block 70_2 is arranged instead of the side where the terminal block 70_1 is arranged. Further, for example, when four wires are wound around the outer peripheral surface of the core portion 21, each lead portion of each wire can be connected to each of the eight terminals shown in FIG.

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

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

In each of the above embodiments, each of the cores 50a and 50b is an E-shaped core. may be configured with Alternatively, each of cores 50a and 50b may be composed of a U-shaped core. Alternatively, one of the cores 50a and 50b may be configured with a U-shaped core and the other with an I-shaped core. Alternatively, the core 50a may be configured by combining two U-shaped cores, and the core 50b may be configured by combining two U-shaped cores.

In each of the above embodiments, a plurality of (four) through-holes (through-holes 35a, 35b, 36a, 36b) were formed in the outer peripheral surface of the winding core 21, but the number of through-holes is one. It can be individual. For example, only one through-hole portion may be formed in either the upper portion or the lower portion of the outer peripheral surface of the winding core portion 21 . Also, the number of through holes may be 2 to 3 or 5 or more.

In the first embodiment, the lead portion 41a may be inserted through the notch portion 28a shown in FIG. Further, of the lead portions 41a and 41b, the lead portion 41b may be inserted through the notch portion 28a or the notch portion 29a.

Similarly, the lead portion 42a may be inserted through the notch portion 29b. Further, of the lead portions 42a and 42b, the lead portion 42b may be inserted through the notch portion 28b or the notch portion 29b.

In each of the above-described embodiments, the protruding portions 33 and 34 are formed substantially in the center portion of the winding core portion 21 in the Y-axis direction. may be formed.

In each of the above-described embodiments, two projections (projections 33 and 34) were formed on the winding core 21, but the number of projections may be one, or three or more.

Although two coil portions (the first coil portion 41 and the second coil portion 42) are formed in the winding core portion 21 in each of the above-described embodiments, three or more coil portions may be formed.

DESCRIPTION OF SYMBOLS 10, 110... Coil device 20, 120... Bobbin 21... Core part 211... Through hole 22a, 22b... Collar part 220a, 220b... Collar part main body 23a, 23b... Terminal block fixing part 230a, 230b... fixed main body 24a, 24b... collar engaging part 25a, 25b... bobbin hook part 26a, 26b... partition part 27a, 27b... extended collar part 28a, 28b, 29a, 29b... notch part 30a , 30b... bobbin convex portion, 31a, 31b... bobbin stepped portion, 310a, 310b... step lower surface, 32a, 32b... placement portion, 33, 34... projecting portion, 35a, 35b, 36a, 36b... through hole portion, 37a , 37b... Recessed bottom part 41... First coil part 42... Second coil part 41a, 41b... First lead part 41c... First wire 42a, 42b... Second lead part 42c... Second wire, 43 contact area 44, 45 non-contact area 50a, 50b core 51a, 51b base portion 510a, 510b outer surface 511a, 511b inner surface 512a, 512b upper surface 513a, 513b lower surface, 52a, 52b... Outer legs 520a, 520b... Inner side of outer legs 53a, 53b... Middle legs 54a, 54b... Upper concave portion 540a, 540b... Upper bottom surface 541a, 541b... Upper tapered surface 55a, 55b ... Lower concave portion 550a, 550b ... Lower bottom surface 550a, 551b ... Lower tapered surface 56a, 56b ... Thick portion 61_1, 61_2, 62_1, 62_2 ... Terminal 610_1, 610_2, 620_1, 620_2 ... External connection portion , 611_1, 611_2, 621_1, 621_2 ... connection part 612_1, 612_2, 622_1, 622_2 ... connection wire bottom part 613_1, 613_2, 623_1, 623_2 ... connection wire folding part 70, 70_1, 70_2 ... terminal block, 71 ... terminal block Base portion 72a, 72b Arm portion 73a, 73b Terminal block hook portion 74a, 74b Terminal block step portion 740a, 740b Step lower surface 75a, 75b Terminal block concave portion 76a, 76b Lead insertion groove , 77a_1, 77a_2, 77b_1, 77b_2 ... terminal fixing portion 770a_1, 770a_2, 770b_1, 770b_2 ... terminal insertion groove 78 ... cover mounting portion 79 ... bottom fixing portion 80, 80_1, 80_2 ... cover portion 81 ... cover bottom portion , 82... Insulating part 820... Insulating concave part 83a, 83b... Cover side part 84... Gripping part 841... Upper arm 842... Lower arm 90... Case Base, 91... Case bottom, 92... Case side, 93... Joining part, 100... Resin.

Claims (11)

a bobbin having a winding core around which a wire is wound, and a flange formed at an axial end of the winding core;
a terminal block formed separately from the bobbin and attached to the bobbin;
In the coil device, the terminal block is arranged at a position spaced apart from an outer peripheral surface of the core in a direction orthogonal to an axial direction of the core. The terminal block is connected to one axial end of the winding core and the other axial end of the winding core, and is substantially parallel to the axial direction of the winding core. 2. The coil device according to claim 1, wherein the coil device is arranged in the . The terminal block has an arm portion protruding toward the bobbin and having a hook-shaped first hook formed at the tip thereof,
3. The coil device according to claim 1, wherein the flange portion is formed with a flange engaging portion that extends in a direction substantially perpendicular to the arm portion and engages with the first hook portion. A second hook portion having a hook shape is formed at the tip portion of the collar engaging portion,
4. The coil device according to claim 3, wherein the lead portion of the wire is pulled out along the periphery of the arm portion toward the terminal block while the first hook portion is engaged with the flange engaging portion. A terminal block fixing portion to which the terminal block is fixed is formed at an axial end of the bobbin,
The terminal block fixing portion has a first stepped portion,
The terminal block has a second stepped portion,
5. The first stepped portion and the second stepped portion are engaged in a state in which the first stepped lower surface of the first stepped portion and the second stepped lower surface of the second stepped portion are in contact with each other. The coil device according to any one of 1. A terminal block fixing portion to which the terminal block is fixed is formed at an axial end of the bobbin,
The terminal block fixing portion has a projection projecting toward the terminal block,
The coil device according to any one of claims 1 to 5, wherein the terminal block has a concave portion that engages with the convex portion. The flange portion is formed along the circumferential direction of the winding core portion,
The coil device according to any one of claims 1 to 6, wherein the flange portion is formed with a notch portion through which the lead-out portion of the wire is inserted. one lead-out portion of the wire passes through the notch portion and is drawn out from the outside of the collar portion toward the terminal block;
8. The coil device according to claim 7, wherein the other lead-out portion of the wire is pulled out from the inside of the collar portion toward the terminal block without passing through the notch portion. further comprising a cover portion arranged around the terminal block,
The wire is composed of a plurality of wires,
A plurality of terminals to which lead portions of the plurality of wires are respectively connected are attached to the terminal block along an axial direction of the winding core portion,
9. The cover part according to any one of claims 1 to 8, wherein the cover part has a grip part that grips the terminal block, a bottom part that is arranged below the plurality of terminals, and a side part that rises from a side edge of the bottom part. The coil device according to 1. The coil device according to any one of claims 1 to 9, wherein the axial direction of the winding core portion is substantially parallel to the mounting surface. further comprising a case in which the bobbin is accommodated,
The case can be filled with a potting resin,
The coil device according to any one of claims 1 to 10, wherein at least one through-hole is formed in the outer peripheral surface of the winding core.

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