JP7039887B2 - Coil device - Google Patents

Description

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

Coil devices are used in various electrical products for various purposes. For example, coil devices are used in EVs (Electric Vehicles), PHVs (Plug-in Hybrid Vehicles), in-vehicle chargers for commuter (vehicles), LLC circuits, etc., and leakage. It is generally used as a transformer such as a transformer.

As the coil device, for example, the coil device shown in Patent Document 1 shown below is known. In the coil device shown in Patent Document 1, the leakage characteristics can be easily adjusted, and it is possible to cope with high frequency while increasing the current.

In the conventional coil device shown in Patent Document 1 and the like, a pair of lead portions corresponding to both ends of a wire constituting the coil are close to each other at a position close to the coil, and when the lead portion is pulled out in a direction away from the coil, the lead portion is formed. It is common to connect to the terminals so that they are separated from each other.

However, it has been found that the leakage characteristics are not stable in such a general lead drawer structure. Particularly in recent years, with the increase in the frequency of the voltage applied to the coil device, the stabilization of leakage characteristics in the high frequency band has become an issue.

Japanese Unexamined Patent Publication No. 2013-254890

The present invention has been made in view of such circumstances, and an object thereof is to provide a coil device having stable leakage characteristics.

In order to achieve the above object, the coil device according to the present invention is
With bobbin
The first wire wound around the outer circumference of the bobbin and
Separately from the first wire, the second wire wound around the outer circumference of the bobbin and
It is a coil device with
The pair of first lead portions composed of both ends of the one wire is
A pair of first rising portions that rise from the outside of the bobbin toward the first pedestal of the bobbin along the winding axis.
A pair of first drawer main bodies arranged from the first rising portion, passing through the first pedestal, and arranged in close proximity to each other at the upper portion along the winding axis of the bobbin.
It is characterized by having.

In the coil device according to the present invention, the pair of first lead portions are raised at the outer periphery of the bobbin along the winding axis at the first rising portion, pass through the first pedestal from the first rising portion, and wind the bobbin. The first drawer main body located at the upper part along the rotation axis is arranged close to each other. That is, in the coil device according to the present invention, the pair of first drawer main bodies are arranged close to each other on the bobbin and are held at a constant distance from each other. The present inventors have found that by adopting such a drawer structure, it is possible to realize a coil device having stable leakage characteristics as compared with a conventional coil device.

According to the experiments conducted by the present inventors, it has been clarified that the leakage characteristics change depending on the distance between the pair of drawer main bodies. Therefore, the leakage characteristics can be optimized by keeping the pair of drawer main bodies close to each other so that the leakage characteristics are good and holding them at a certain distance.

Preferably, it further comprises a case covering the lower portion of the bobbin around which the first and second wires are wound.
The edge of the upper end opening of the case is provided with a proximity holding pedestal that holds the pair of the first drawer main bodies in close proximity to each other.

With this configuration, it becomes easy to hold the pair of first drawer main bodies in close proximity to each other on the bobbin between the first pedestal and the proximity holding pedestal. Further, by providing the proximity holding pedestal in the case, the pair of first drawer main bodies held by the proximity holding pedestal is positioned, which contributes to the stabilization of the leakage characteristics.

In order to secure insulation between the portion where the second wire is wound around the bobbin and the first rising portion, a first insulation is provided on the outer periphery of the bobbin inside the first rising portion. A cover may be attached. With such a configuration, good insulation between the second wire and the first rising portion of the first wire can be ensured.

Preferably, the first insulating cover comprises a pair of passages leading to the first pedestal in close proximity to each other while insulating each other of the pair of first risers. With this configuration, the leakage characteristics can be stabilized.

Preferably, the first pedestal is formed with a drawer passage for keeping the mutual distance between the pair of the first drawer main bodies at the upper part along the winding axis of the bobbin to be constant or less. With such a configuration, it becomes easy to keep the mutual distance between the pair of first drawer main bodies below a certain level, and the leakage characteristics are further stabilized.

The pair of second lead portions formed at both ends of the second wire is
A pair of second risers extending in the direction of the winding axis,
A pair of second drawer main bodies extending in a direction away from the bobbin while maintaining a distance wider than the distance between the pair of the second risers.
A pair of second-direction changes that communicate between the second rising portion and the second drawer main body portion and change the direction of the second rising portion toward the direction of the second drawer main body portion. And may have.

The pair of second lead portions may extend as a second drawer body portion in a direction away from the coil while maintaining a distance narrower than the distance between the second rising portions, but are applied to the second lead portion. If the voltage is high, the reverse is also possible. That is, the pair of second lead portions may extend as the second drawer main body portion in the direction away from the coil while maintaining a distance wider than the distance between the second rising portions.

A second pedestal is formed on the bobbin, and the second lead portion raised at the second rising portion is formed on the second pedestal from the inside to the outside at the position of the second direction changing portion. A pair of locking portions may be formed which are wound around the bobbin and guided in the direction of the second drawer main body portion. With this configuration, each second lead portion is locked to the locking portion without slack, and unwinding of the coil portion formed by the second wire continuous with the second lead portion is prevented. As a result, the leakage characteristics are stabilized.

Preferably, the rising direction of the first rising portion and the rising direction of the second rising portion are the same direction.
The second pedestal is located on the same side of the winding shaft of the coil with respect to the first pedestal formed on the bobbin.

With such a configuration, it becomes easy to position the bottom surface of the bobbin located on the opposite side of the first pedestal and the second pedestal along the winding axis to the cooling side, and the cooling efficiency of the coil and the bobbin can be improved. improves.

Preferably, the first pedestal and the second pedestal are located on opposite sides of the upper outer periphery of the bobbin, and the proximity holding pedestal is located outside the bobbin, the first pedestal and the second pedestal. It is placed between the pedestal and the bobbin. With this configuration, the pair of first lead portions and the pair of second lead portions can be pulled out from two adjacent side surfaces of the case, and the coil device can be installed at the corner of the placement space. Will be easier. Therefore, the coil device can be easily cooled and the arrangement space can be effectively used.

Preferably, on the outer periphery of the bobbin, an intermediate coil portion located between the first coil portion, the second coil portion, and the first coil portion and the second coil portion along the winding axis. And are arranged,
The intermediate coil portion is composed of the first wire.
The first coil portion and the second coil portion are composed of the second wire for continuously forming the first coil portion and the second coil portion.

By having a structure in which the intermediate coil portion is sandwiched between the first coil portion and the second coil portion, the coupling between these coil portions can be enhanced, and it becomes easy to stabilize the leakage characteristics. Further, stable leakage characteristics can be obtained even in the high frequency band.

The first wire may constitute either one of the primary coil and the secondary coil, and the second wire may constitute either the primary coil or the secondary coil.

Preferably, the number of turns of the first wire wound around the bobbin is smaller than the number of turns of the second wire wound around the bobbin. By forming the pair of first lead portions located at both ends of the first wire having a small number of turns into the configuration of the present invention, the effect of the present invention is enhanced.

FIG. 1 is a perspective view of a transformer as a coil device according to an embodiment of the present invention. FIG. 2 is an exploded perspective view of the transformer shown in FIG. FIG. 3 is a perspective view of a bobbin and a wire lead portion when the case and the magnetic core are removed from the transformer shown in FIG. FIG. 4 is a cross-sectional view of a main part of the transformer along the line IV-IV shown in FIG. FIG. 5 is a cross-sectional view of a main part of the transformer along the VV line shown in FIG. FIG. 6 is a perspective view of the lead portion of the bobbin and the wire shown in FIG. 3 as viewed from different angles. FIG. 7A is a perspective view showing an example of a common wire and an intermediate wire wound around the bobbin shown in FIG. FIG. 7B is a perspective view of the common wire and the intermediate wire shown in FIG. 7A when viewed from different angles. FIG. 8 is a side view showing the relationship between the common wire and the intermediate wire shown in FIGS. 7A and 7B. FIG. 9 is a circuit diagram showing an equivalent circuit of the transformer shown in FIG.

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

The transformer 10 as a coil device according to the present embodiment shown in FIG. 1 is, for example, an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a vehicle for a commuter (vehicle). It is used for a charger or the like, and is used, for example, to form a part of an LLC circuit.

As shown in FIG. 2, the transformer 10 has a bobbin 20, a core portion (magnetic core) 40 including an upper core 40a and a lower core 40b, and a case 90 in which the lower end portions thereof are housed therein. In the drawings, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other, and the Z-axis corresponds to the height (thickness) of the transformer 10. In the present embodiment, the lower part of the transformer 10 in the Z-axis direction is the installation surface of the transformer. Further, the Y-axis coincides with the longitudinal direction of the base portions 44a and 44b in the cores 40a and 40b. Further, the X-axis is adapted to coincide with the longitudinal direction of the bobbin 20.

In the present embodiment, the case 90 is configured in which the bottom plate 92 is attached to the bottom opening of the case 90 by means such as caulking or gluing, and the upper portion is open. The bottom plate 92 is preferably made of a metal such as aluminum copper or iron having excellent heat dissipation, but may be made of PPS, PET, PBT or the like. Since the bottom plate 92 comes into contact with the lower end surface of the core 40 described later in the Z-axis direction, the bottom plate 92 is preferably made of a material having excellent heat dissipation. A cooling device such as a cooling pipe or a cooling fin may be mounted below the case 90 via the bottom plate 92 or directly.

The case 90 has a square tubular shape as a whole, and a proximity holding pedestal 91 is outside in the Y-axis direction (outside the inside of the case 90) at the edge extending in the X-axis direction of the upper end opening of the case 90. It is equipped to pop out. Fitting holes 91a are formed on the upper surface of the proximity holding pedestal 91 at predetermined intervals in the X-axis direction. A pair of fitting legs 102 formed on both sides of the binding tool 100 in the X-axis direction are inserted into the fitting holes 91a so that they can be engaged with each other. A retaining protrusion 104 is formed at the tip of the fitting leg 102 so that the fitting leg 102 is prevented from coming off after being inserted into the fitting hole 91a.

As shown in FIG. 1, the tips of the first lead portions 37a and 37b are installed on the proximity holding pedestal 91, the binding tool 100 is attached by the pedestal 91, and the tips of the first lead portions 37a and 37b are attached. The parts are kept close to each other. The tips of the first lead portions 37a and 37b are covered with an insulating tube on the core portion 40. Examples of the insulating tube include a silicon tube, a glass tube, and a fluororesin tube.

The case 90 in which the proximity holding pedestal 91 is integrally molded is made of metal, but may be made of synthetic resin or the like. The bottom plate 92 and the case 90 may be integrally molded by die-casting of aluminum or the like. By making the entire case made of metal, heat dissipation is further improved.

The inside of the case 90 may be filled with a heat radiating resin. The heat-dissipating resin is not particularly limited, but for example, a resin having a thermal conductivity of 0.5 to 5, preferably 1 to 3 W / m · K, and having excellent heat dissipation is preferable. Examples of the resin having excellent heat dissipation include silicone-based resin, urethane-based resin, and epoxy-based resin, and among them, silicone resin and urethane resin are preferable. Further, in order to improve heat dissipation, the resin may be filled with a filler having high thermal conductivity.

Further, the heat-dissipating resin of the present embodiment preferably has a shore A hardness of 100 or less, preferably 60 or less. This is because even if the cores 40a and 40b and the bobbin 20 are deformed by heat, the deformation is absorbed and excessive stress is not generated in the cores 40a and 40b. Examples of such a resin include potting resin.

As shown in FIGS. 4 and 5, the coil 300 wound around the bobbin body 21 of the bobbin 20 has a first coil portion 301 and a first coil portion 301 along the winding axis of the coil (substantially parallel to the Z axis). It has two coil portions 302 and an intermediate coil portion 303 located between the first coil portion 301 and the second coil portion 302. That is, in the present embodiment, the intermediate coil portion 303 is sandwiched between the first coil portion 301 and the second coil portion 302 along the winding axis (Z-axis direction) of the coil 300.

The intermediate coil portion 303 is composed of an intermediate wire (first wire) 37, and the first coil portion 301 and the second coil portion 302 are for forming the first coil portion 301 and the second coil portion 302. It is composed of a common wire (second wire) 38.

In this embodiment, the common wire 38 constitutes the primary coil and the intermediate wire 37 constitutes the secondary coil. That is, as shown in FIG. 9, the first coil portion 301 and the second coil portion 302 composed of the common wire 38 are wound on the primary side, and the intermediate coil portion 303 composed of the intermediate wire 37 is wound on the secondary side. By becoming a wire, a transformer is formed between the two. In the present embodiment, a high voltage acts on the primary coil as compared with the secondary coil, and a relatively low voltage acts on the secondary coil. Here, La shown in FIG. 9 is a leakage inductance.

The wires 37 and 38 may each be composed of a single wire, each may be composed of a stranded wire, or one may be a single wire and the other may be a stranded wire. The wires 37 and 38 may be made of the same material or may be different. The outer diameters of the wires 37 and 38 are not particularly limited, but are preferably in the range of 1.0 to 4.0 mm.

In the present embodiment, the outer diameter of the intermediate wire 37 is larger than the outer diameter of the common wire 38 because the current flowing through the secondary coil is large, for example, 3.0 to 4.0 mm is preferable. Further, it is preferable that an insulating film is formed on each of the wires 37 and 38. Further, as shown in FIG. 1, it is preferable that the tip portions of the lead portions 37a, 37b, 38a, 38b of the wires 37 and 38 are further covered with an insulating tube.

The first lead portions 37a and 37b shown in FIG. 1 are both ends of the intermediate wire 37 shown in FIGS. 4 and 5, and the second lead portions 38a and 38b shown in FIG. 1 are common to those shown in FIGS. 4 and 5. Both ends of the wire 38. As shown in FIG. 1, terminals 94 composed of, for example, metal terminals are connected to each end of the first lead portions 37a and 37b and the second lead portions 38a and 38b by soldering or the like, and the respective wires 37 are connected. Both ends of and 38 are electrically connected to the terminal 94.

In the present embodiment, when the number of turns of the intermediate wire 37 constituting the intermediate coil portion 303 shown in FIGS. 4 and 5 is n2, the total number of turns of the common wire 38 in the first coil portion 301 and the second coil portion 302 is n1. Is preferably 2 times or more, 3 times or more, 5 times or more, and 6 times or more the number of turns n2. In the present embodiment, even when the ratio of the number of turns (n1 / n2) is large, the coupling coefficient can be made relatively large, which contributes to the stabilization of the leakage characteristics.

The total number of turns n1 of the common wire 38 in the first coil portion 301 and the second coil portion 302 is preferably divided into the first coil portion 301 and the second coil portion 302 substantially evenly, but may be slightly different. That is, the number of turns of the common wire 38 in the first coil portion 301 is preferably (0.3 to 0.7) × n1, and the number of turns of the common wire 38 in the second coil portion 302 is (0. It is preferably 7 to 0.3) × n1. This is to improve the coupling coefficient between the primary coil and the secondary coil.

As shown in FIGS. 5 and 8, the common wire 38 has an intercoil connection portion 380 extending between the first coil portion 301 and the second coil portion 302 in the winding axis (Z axis) direction. In the present embodiment, since the first coil portion 301 and the second coil portion 302 are continuously formed by the common wire 38, the common wire 38 is formed between the first coil portion 301 and the second coil portion 302. The coil-to-coil connection portion 380 extending to the winding shaft will be formed.

The coil-to-coil connection portion 380 passes through the inside of the intermediate coil portion 303. Although the details will be described later, in the present embodiment, the common wire 38 is first wound around the bobbin 20 to form the first coil portion 301 and the second coil portion 302, and then the intermediate wire 37 is wound around the bobbin 20. Therefore, the intermediate coil portion 303 is configured.

When the coil is mounted on the bobbin 20 in such an manner, the coil-to-coil connection portion 380 passes through the inside of the intermediate coil portion 303. In this case, as shown in FIG. 5, a second insulating cover 82 is attached to the bobbin 20 in order to insulate the coil-to-coil connection portion 380 from the intermediate coil portion 303. The second insulating cover 82 will be described in detail later.

As shown in FIG. 7A, a pair of second lead portions 38a and 38b are drawn out from the first coil portion 301 and the second coil portion 302. Further, a pair of first lead portions 37a and 37b are drawn out from the intermediate coil portion 303.

More specifically, as shown in FIG. 7A, the first lead portions 37a and 37b formed at both ends of the intermediate wire 37 are the first rising portions 371a and 371b extending in the winding axis (Z axis) direction of the coil. The first drawer main body portions 373a and 373b are provided from the first rising portions 371a and 371b toward the inside of the coil 300 and then toward the outside of the coil 300.

The first rising portions 371a and 371b may be inclined rather than parallel to the Z axis. Further, in the present embodiment, the first drawer main body portions 373a and 373b are inclined straight along the X axis from the first rising portions 371a and 371b toward the inside of the coil 300, and then toward the outside of the coil 300. The coil is configured to tilt straight along the Y-axis, but the shape is not limited. For example, as shown in FIG. 6, the first drawer main body portions 373a and 373b are bent in a substantially arc shape from the first pedestal 22 of the bobbin 20 toward the binding tool 100 at the upper portion of the bobbin 20 in the Z-axis direction. It may be a composite shape of a straight line and a curved line.

In the present embodiment, the first drawer main bodies 373a and 373b are shown in FIG. 6 so that the distance W1 between the first drawer main bodies 373a and 373b shown in FIG. 7A is preferably constant in the range of 0 to 1 mm. The bobbin 20 shown is arranged in close proximity on the bobbin body 21. As shown in FIG. 4, since the core portion 40 is attached to the bobbin 20, the first drawer main body portions 373a and 373b are arranged so that a predetermined gap 106 is maintained at the upper portion of the core portion 40.

The height of the proximity holding pedestal 91 of the case 90 in the Z-axis direction and the notch depth of the drawer passage 221a formed by the notch of the first pedestal 22 of the bobbin 20 are adjusted so that a predetermined gap 106 is formed. .. The predetermined gap 106 is preferably 0 to 10 mm. The predetermined gap 106 may be 0, that is, the first drawer main body portions 373a, 373b of the first lead portions 37a, 37b may be in contact with the upper surface of the core portion 40.

The length of the first drawer main body portions 373a and 373b is preferably 20 to 100 mm. The smaller the clearance W1 is, the smaller the leakage of the secondary coil can be. Further, the length of the first drawer main body portions 373a and 373b is preferably the minimum necessary because the longer the length is, the larger the leakage tends to be.

As shown in FIG. 7A, the second lead portions 38a and 38b formed at both ends of the common wire 38 are paired with the second rising portions 381a and 381b extending in the winding axis (Z axis) direction of the coil. It has a second direction changing portion 382a, 382b toward a direction in which the distance between the two lead portions 38a, 38b is widened, and a second drawer main body portion 383a, 383b extending in a direction away from the coil 300 (X-axis).

The second rising portions 381a and 381b may be inclined rather than parallel to the Z axis. Further, the second drawer main body portions 383a and 383b are not necessarily parallel to the X axis, and may be inclined in the Y axis and / or the Z axis direction. Further, the second direction changing portions 382a and 382b may be linear or curved.

In the present embodiment, the distance between the second drawer main bodies 383a and 383b is configured to be wider than the gap between the second rising portions 381a and 381b. More specifically, the gap gap W2 between the second drawer main bodies 383a and 383b is wider than the gap gap W1 between the drawer main bodies 373a and 373b, and is preferably 1 to 5 mm.

In the present embodiment, it is preferable that the distance between the first drawer main bodies 373a and 373b and the distance between the second drawer main bodies 383a and 383b are constant in each part in the longitudinal direction, but they are different. You may. That is, the first drawer main body portions 373a, 373b or the second drawer main body portions 383a, 383b do not necessarily have to extend in parallel. However, from the viewpoint of improving the leakage characteristics of the transformer 10, it is preferable that the gap spacing W1 between the first drawer main body portions 373a and 373b is small and the gap spacing W1 is constant along the longitudinal direction.

As shown in FIG. 3, the bobbin 20 has a bobbin main body 21 and a first pedestal 22 and a second pedestal 23 integrally molded at both upper ends of the bobbin main body 21 in the X-axis direction. The bobbin 20 is made of plastic such as PPS, PET, PBT, LCP, and nylon, but may be made of other insulating members. However, in the present embodiment, the bobbin 20 is preferably made of, for example, a plastic having a thermal conductivity of 1 W / m · K or more, and is made of, for example, PPS, nylon, or the like.

As shown in FIG. 3, the pedestal 22 has a side wall portion 221. As shown in FIG. 6, on the back surface of the side wall portion 221 (outside of the bobbin 20), rise passages 222a and 222b for guiding the first rising portions 371a and 371b of the first lead portions 37a and 37b are formed. be. These passages 222a and 222b are separated by the separation convex portion 223, and their insulation is secured. A notch-shaped drawer passage 221a is formed in the side wall portion 221. The drawer passage 221a guides the first drawer main body portions 373a and 373b bent at substantially right angles from the first rising portions 371a and 371b to the inside of the bobbin 20 in close proximity to each other, and as shown in FIG. 1, the core The upper street of the bobbin 40 is directed toward the proximity holding pedestal 91.

Further, engaging recesses 224 are formed on both outer surfaces of the side wall portion 221 in the Y-axis direction, and the engaging recesses 224 are formed at both ends of the first pedestal cover 60a shown in FIG. 2 in the Y-axis direction. The provided engaging convex portion 61a is engaged, and the first pedestal cover 60a can be engaged with the first pedestal 22. As shown in FIG. 1, by attaching the first pedestal cover 60a to the first pedestal 22, the first lead portions 37a and 37b are pulled out upward in the Z-axis direction from the first pedestal 22. Further, the first lead portions 37a and 37b are pulled out inside the case 90 on the core portion 40 through the notch-shaped drawer passage 221a of the side wall portion 221 in the first pedestal 22.

The first drawer main body portions 373a, 372b of the first lead portions 37a, 37b, which are pulled out close to the upper part of the core portion 40 through the drawer passage 221a of the first pedestal 22, are bent toward the proximity holding pedestal 91. ing. The proximity holding pedestal 91 is located at substantially the center of the pedestals 22 and 23 located at both ends of the bobbin 20 in the X-axis direction, and is arranged outside the case 90 in the Y-axis direction. A binding tool 100 is attached to the proximity holding pedestal 91, and the first drawer main bodies 373a and 372b of the first lead portions 37a and 37b are held close to each other. That is, the first drawer main body portions 373a and 372b of the first lead portions 37a and 37b are held close to each other between the first pedestal 22 and the proximity holding pedestal on the core portion 40.

As shown in FIG. 3, the second pedestal 23 has a side wall portion 231 and a pair of locking portions 232 formed at both ends in the X-axis direction. The side wall portion 231 is formed so as to surround the peripheral edge of the pedestal 23 except for the side from which the second lead portions 38a and 38b are pulled out. Engagement protrusions 234 are formed on both outer end walls of the side wall portion 231 in the Y-axis direction. The function of the engaging protrusion 234 will be described later.

In the pair of locking portions 232, the second lead portions 38a and 38b raised in the Z-axis direction by the second rising portions 381a and 381b are formed from the inside in the Y-axis direction at the portions of the second direction changing portions 382a and 382b. It is wound around the outside and guided to the outside in the X-axis direction as the second drawer main body portions 383a and 383b with a large gap between them.

By locking the second direction changing portions 382a and 382b of the second lead portions 38a and 38b to the pair of locking portions 232, the second lead portions 38a and 38b are locked to the locking portions 232 without slack. .. As a result, the second coil portion 301 and the second coil portion 302, which are composed of the common wire 38 located between the second lead portions 38a and 38b shown in FIG. 7A, are prevented from being unwound. The lead portions 38a and 38b can be pulled out in a direction away from the coil 300. That is, in the present embodiment, as shown in FIG. 3, the second pedestal 23 is formed with a passage partitioned (or sandwiched) by the side wall portion 231 and the pair of locking portions 232. Through these passages, the second lead portions 38a and 38b can be pulled out in a direction away from the bobbin 20.

As shown in FIG. 2, the second pedestal cover 60b is mounted so as to cover the upper part of the second pedestal 23 in the Z-axis direction. More specifically, holes 61b are formed on the side surfaces of the second pedestal cover 60b at both ends in the Y-axis direction, and the holes 61b are engaged with the engaging protrusions 234 formed on the pedestal 23. , The second pedestal cover 60b can be attached to the second pedestal 23. As a result, it is possible to prevent the second lead portions 38a and 38b shown in FIG. 3 from unnecessarily protruding above the second pedestal 23.

As shown in FIG. 2, the cores 40a and 40b have the same shape in the present embodiment, have an E-shaped cross section in a ZZ cross section, and form a so-called E-shaped core. The mode of the cores 40a and 40b is not limited to the mode shown in FIG. 2, for example, the cores 40a and 40a may be integrally molded, and the cores 40b and 70b may also be integrated. You may have it.

The core 40a arranged on the upper side in the Z-axis direction includes a base portion 44a extending in the Y-axis direction, a pair of side leg portions 48a protruding in the Z-axis direction from both ends of the base portion 44a in the Y-axis direction, and these. It has a middle leg portion 46a protruding in the Z-axis direction from the center in the Y-axis direction between the side leg portions 48a. The core 40b arranged on the lower side in the Z-axis direction includes a base portion 44b extending in the Y-axis direction, a pair of side leg portions 48b protruding in the Z-axis direction from both ends of the base portion 44b in the Y-axis direction, and these. It has a middle leg portion 46b protruding in the Z-axis direction from the center in the Y-axis direction between the side leg portions 48b of the above.

The middle leg portion 46a is inserted into the core leg through hole 21a of the bobbin 20 from above in the Z-axis direction. Similarly, the middle leg portion 46b is inserted into the core leg through hole 21a of the bobbin 20 from below in the Z-axis direction, and inside the core leg through hole 21a, the tips of the middle leg portions 46a and 46b are inserted. As shown in FIG. 5, they may be in contact with each other or may be configured to face each other with a predetermined gap in between. By forming the gap, the leakage characteristic can be adjusted according to the width of the gap G.

The middle leg portion 46a and the middle leg portion 46b have a substantially elliptical column shape so as to match the shape of the inner peripheral surface of the core leg through hole 21a, but the shape is not particularly limited and the core leg is not particularly limited. It may be changed according to the shape of the through hole 21a. Further, as shown in FIG. 2, the side leg portions 48a and 48b have an inner concave curved surface shape that matches the shape of the outer peripheral surface of the bobbin main body 21, and the outer surface thereof has a plane parallel to the XX plane. ing. In the present embodiment, the materials of the cores 40a and 40b include soft magnetic materials such as metal and ferrite, but are not particularly limited.

A cover 50 is arranged between the inner peripheral surfaces of the side legs 48a and 48b and the outer peripheral surface of the bobbin main body 21, respectively. The cover body 52 of the cover 50 has a shape that covers the outer periphery of the bobbin body 21 located between the pedestals 22 and 23 of the bobbin 20. At both ends of the cover body 52 in the Z-axis direction, locking pieces 54 that are bent substantially vertically from the cover body 52 toward the bobbin body 21 are integrally molded. A pair of locking pieces 54 formed on both sides of the cover main body 52 in the Z-axis direction are attached so as to sandwich the upper and lower surfaces of the bobbin main body 21 in the Z-axis direction.

Further, side leg guide pieces 56 extending in the Z-axis direction are integrally molded on the outer surfaces of both ends of the cover main body 52 in the X-axis direction. The inner surfaces of the side legs 48a and 48b come into contact with the outer surface of the cover body 52 located between the pair of side leg guide pieces 56, and the movement of the side legs 48a and 48b in the X-axis direction is caused by the pair of side legs. It is limited by the guide piece 56.

Further, on the inner surface of the cover main body 52, an inward convex portion 58 extending in the longitudinal direction is integrally molded at the central portion in the Z-axis direction. As shown in FIG. 4, the inward convex portion 52 enters between the wound partition walls 26 and 27 from the outside in the radial direction, and extends to the outside of the intermediate wire 37 (intermediate coil portion 303) wound between them. It regulates movement and secures its insulation. These covers 50 are preferably made of an insulating member such as plastic similar to the bobbin 20, but may be made of metal.

As shown in FIGS. 4 and 5, end partition collars 24 and 25 extend outward in the radial direction at both ends of the winding cylinder portion 28 constituting the bobbin main body 21 of the bobbin 20 in the Z-axis direction. , Is integrally molded substantially parallel to the XY plane. On the outer peripheral surface of the winding cylinder portion 28 located between the end partition flanges 24 and 25 in the Z-axis direction, the winding partition flanges 26 and 27 are predetermined in the Z-axis direction so as to project outward in the radial direction. It is formed at intervals. Due to the wound bulkhead collars 26 and 27 formed between these end bulkhead collars 24 and 25, compartments S1 to S3 are formed between these bulkhead collars in order from the bottom in the Z-axis direction. The number of winding bulkhead collars 26 and 27 and the compartments S1 to S3 is not particularly limited.

In the present embodiment, the common wire 38 is continuously wound in the compartments S1 and S3 for several turns to form the first coil portion 301 and the second coil portion 302, and the intermediate wire 37 is provided in the compartment S2. It is wound in one turn to form the third coil portion 303. In the present embodiment, the winding partition flange 26 serves to partition the first coil portion 301 and the intermediate coil portion 303 in the Z-axis direction, and the winding partition flange 27 serves as a second coil portion 302 and the intermediate coil portion 303. It plays a role of partitioning and in the Z-axis direction. The intermediate wire 37 may be wound around the compartment S2 in two or more turns. In that case, it is preferable that the intermediate wire 37 is α-wound around the winding cylinder 28.

As shown in FIG. 4, the section width along the Z axis in the sections S1 and S3 around which the common wire 38 constituting the first coil portion 301 is wound allows one common wire 38 to enter in the Z axis direction. It is set to the width. However, the partition width may be set to a width that allows two or more common wires 38 to enter in the Z-axis direction. Further, in the present embodiment, it is preferable that all the compartment widths are the same, but they may be slightly different.

Further, the section width along the Z-axis in the section S2 around which the intermediate wire 37 constituting the intermediate coil portion 303 is wound is set to a width in which one intermediate wire 37 can be inserted in the Z-axis direction. However, the partition width may be set to a width that allows two or more intermediate wires 37 to enter in the Z-axis direction. Further, in the present embodiment, the section width along the Z axis in the section S2 is preferably different from the section width T1 in accordance with the wire diameter of the common wire 38, but may be the same.

Further, the height of the partition flanges 24 to 27 (the length in the radial direction with respect to the winding axis) is set to a height at which the wire 37 or 38 for one turn or more (one layer or more) can be inserted, and this embodiment is made. Then, preferably, the height is set so that the second wire 38 having 3 to 8 layers can be wound. The heights of the partition walls 24 to 27 are all preferably the same, but may be different.

In the present embodiment, the winding method of the common wire 38 wound around the compartments S1 and S3 is α winding, and the common wire from the coil-to-coil connection portion 380 shown in FIG. 5 to the compartments S1 and S3 shown in FIG. 38 is passed through and started to be wound, and is drawn out to the lead portions 38a and 38b shown in FIG. 7A. The winding method of the intermediate wire 37 wound around the section S2 shown in FIG. 4 is not particularly limited, and may be normal winding or α winding.

Here, the α winding will be described. For example, in order to α-wound the common wire 38 around the bobbin 20 shown in FIG. The compartment S1 and the compartment S3 are communicated with each other through the coil-to-coil connection portion 380. Then, a part of the common wire 38 on the side close to the lead portion 38a is wound in a plurality of layers (6 layers in the present embodiment) inside the section S3, for example, clockwise around the outer circumference of the winding cylinder portion 28. .. At the same time, the other part of the common wire 38 on the side closer to the lead portion 38b is inside the compartment S1 in the direction opposite to (or may be the same direction) as the winding method in the compartment S1. Wind in multiple layers around the outer circumference. In addition, these operations may be performed using an automatic winding machine.

In the intermediate wire 37 wound around the section S2 shown in FIG. 5, after the coil-to-coil connection portion 380 of the common wire 38 is arranged in the portion where the winding partition flange 26 and 27 are partially cut out in the circumferential direction. , The second insulating cover 82 is attached, and then wound in one or more turns between the winding bulkheads 26 and 27.

As shown in FIG. 5, bobbin legs 29 are integrally formed at both ends of the end partition wall flange 25 located at the lowermost part in the Z-axis direction in the X-axis direction. Each bobbin leg 29 is formed so as to project downward in the Z-axis direction from both ends of the end partition wall flange 25 in the X-axis direction. Each bobbin leg 29 accommodates each heat dissipation block 70 shown in FIG. The height of each heat dissipation block 70 in the Z-axis direction is adjusted so that the bottom surface of each heat dissipation block 70 is substantially flush with the bottom surface of the core member 40b when the heat dissipation blocks 70 are housed in the bobbin legs 29. It has been done. That is, the heat dissipation block 70 also has a function as a height adjusting mechanism.

As shown in FIG. 3, notches 264 and 274 are formed on the second pedestal 23 side of the wound bulkhead collars 26 and 27. Further, on the lower surface of the wound partition wall 26 in the Z-axis direction, a counterbore surface 261 that does not penetrate in the Z-axis direction is formed at the circumferential position where the notch 264 is formed. Further, on the upper surface of the wound partition wall 27 in the Z-axis direction, a counterbore surface 271 that does not penetrate in the Z-axis direction is formed at the circumferential position where the notch 274 is formed.

A second insulating cover 82 is attached between the wound bulkhead collars 26 and 27 along the counterbore surfaces 261 and 271 to close the notches 264 and 274. As shown in FIG. 5, the second insulating cover 82 is for insulating the coil-to-coil connection portion 380 from the intermediate coil portion 303.

As shown in FIG. 7A, the second insulating cover 82 includes an intermediate partial cylinder 823 that constitutes a part of a cylinder, and a partial flange 821 formed in parallel at both ends in the Z-axis direction in an XY-axis plane. It has 822 and. A part of the intermediate wire 37 constituting the intermediate coil portion 303 is wound around the intermediate partial cylinder 823 in the circumferential direction. As shown in FIG. 5, the inner peripheral surface of the intermediate portion cylinder 823 faces the outer peripheral surface of the winding cylinder portion 28 of the bobbin 20 with the coil-to-coil connection portion 380 interposed therebetween.

In the second insulating cover 82, one partial flange 821 (see FIG. 7A) is in contact with the counterbore surface 261 (see FIG. 3) of the wound partition wall portion 26, and the other partial flange 822 (see FIG. 7A) is in contact with the wound partition wall. It abuts on the counterbore surface 271 (see FIG. 3) of the portion 27 and is fixed to the bobbin 20 so that it can be slid and inserted. As shown in FIG. 8, in the present embodiment, the coil-to-coil connection portion 380 passes inside the intermediate coil portion 303, but as shown in FIG. 5, the coil-to-coil connection portion 380 and the intermediate coil portion 303 are intermediate. Insulated via a partial cylinder 823.

As shown in FIG. 5, a notch is formed on the first pedestal 22 side of the end partition flange 24 and the wound partition flange 26 so that the first insulating cover 81 shown in FIG. 7B can be attached. As shown in FIG. 7B, the first insulating cover 81 insulates the first rising portions 371a and 371b of the first lead portions 37a and 37b from the first coil portion 301 (common wire 38 which is the second wire). belongs to.

As shown in FIG. 7B, the first insulating cover 81 has partial collars 811 and 812 formed in parallel at both ends in the Z-axis direction in an XY-axis plane, a wall portion 813, and a pair of side portions 814. And have. A convex portion 815 is formed on the outer surface of the wall portion 813 in the X-axis direction, and a rising passage 816 is formed on both sides of the convex portion 815 in the Y-axis direction. In the rise passage 816, the first rising portions 371a and 371b of the first lead portions 37a and 37b are guided along the Z-axis direction. As shown in FIG. 5, in the first insulating cover 81, one partial flange 811 is fitted into a groove formed in the end partition wall portion 24, and the other partial flange 812 is applied to the counterbore surface of the wound partition wall portion 26. It is fixed to the bobbin 20 by being brought into contact with the slide and inserted.

As shown in FIGS. 7A and 7B, the first rising portions 371a and 371b of the first lead portions 37a and 37b and the first coil portion 301 are well insulated via the first insulating cover 81. As shown in FIG. 7B, since the winding partition wall 27 has an overhanging portion extending outward in the X-axis direction (direction away from the winding axis of the bobbin 20), the intermediate between FIGS. 7AB and 7B. The insulation between the wire 37 and its first lead portions 37a and 37b and the second coil portion 302 is also well maintained.

These insulating covers 81 and 82 are made of an insulating member such as plastic which is similar to or different from the bobbin 20. The insulating covers 81 and 82 are formed separately from the bobbin 20 and attached to a part of the bobbin 20 in the circumferential direction.

The transformer 10 according to the present embodiment is manufactured by assembling each member shown in FIG. 2 and winding an intermediate wire 37 and a common wire 38 around the bobbin 20. Hereinafter, an example of a method for manufacturing the transformer 10 will be described with reference to FIG. In the production of the transformer 10, the bobbin 20 is first prepared. The material of the bobbin 20 is not particularly limited, but the bobbin 20 is formed of an insulating material such as resin.

Next, the common wire 38 is wound around the outer circumference of the winding cylinder portion 28 of the bobbin 20 by α winding to form the first coil portion 301 and the second coil portion 302. The common wire 38 used for forming the first coil portion 301 and the second coil portion 302 is not particularly limited, but a litz wire or the like is preferably used. Further, the second lead portions 38a and 38b, which are the end portions of the common wire 38 when forming the first coil portion 301 and the second coil portion 302, are soldered and connected to, for example, the terminal 94.

Next, the second insulating cover 82 and the first insulating cover 81 are attached to the bobbin 20 around which the common wire 38 is wound. The first insulating cover 81 may be attached to the bobbin 20 later, and at least the second insulating cover 82 may be attached to the bobbin 20.

Next, the intermediate wire 37 is wound around the outer circumference of the winding cylinder portion 28 of the bobbin 20 to form the intermediate coil portion 303. The intermediate wire 38 used for forming the intermediate coil portion 303 may be the same as or different from the common wire 38. Further, the first lead portions 37a and 37b, which are the end portions of the intermediate wire 37 when forming the intermediate coil portion 303, are soldered to, for example, the terminal 94 and connected.

Next, the first lead portions 37a and 37b are pulled out from the intermediate coil portion 303 upward on the Z axis, passed through the rise passage 816 of the first insulating cover 81 shown in FIG. 7B, and then the first pedestal 22 shown in FIG. It leads to the first pedestal 22 through the start-up passages 222a and 222b. In that state, the first pedestal cover 60a shown in FIG. 2 is attached to the pedestal 22, and the first lead portions 37a and 37b are temporarily fixed to the pedestal 22.

Further, as shown in FIG. 7A, the second lead portions 38a and 38b are pulled out from the first coil portion 301 and the second coil portion 302 upward on the Z axis, and are locked to the locking portion 232 as shown in FIG. While pulling it away from the coil. Then, the second pedestal cover 60b is attached to the pedestal 23.

Next, the covers 50 shown in FIG. 2 are attached to both sides of the bobbin 20 in the Y-axis direction, and then the cores 40a and 40b are attached from the vertical direction in the Z-axis direction. That is, the tips of the side legs 48a and 48b are joined to each other while having a gap between the tips of the middle legs 46a and 46b of the cores 40a and 40b. Examples of the material of the cores 40a and 40b include soft magnetic materials such as metal and ferrite, but the material is not particularly limited. The gap may be 0.

After that, the first lead portions 37a and 37b are guided onto the bobbin main body 21 through the notch-shaped drawer passage 221a of the first pedestal 22, and as shown in FIG. 1, the first lead portions 37a and 37b are mutually guided over the core portion 40. It is guided to the proximity holding pedestal 91 of the case 90 in close proximity to. In the proximity holding pedestal 91, the binding tool 100 is attached, and the tip portions of the first lead portions 37a and 37b are held in close proximity to the pedestal 91.

Before and after that, the heat dissipation block 70 is housed inside the bobbin leg 29. The bobbin leg 29 may be provided with a heat dissipation block 70 in advance. After that, the bottom plate 92 is adhered to the bottom opening of the case 90, the assembly is housed in the case 90 whose upper part is open, and the inside of the case 90 is filled with heat-dissipating resin. By the above steps, the transformer 10 according to the present embodiment can be manufactured.

The transformer 10 according to the present embodiment has a structure (sandwich structure) in which the intermediate coil portion 303 is sandwiched between the first coil portion 301 and the second coil portion 302. Therefore, the coupling between these coil portions can be increased, and it becomes easy to stabilize the leakage characteristics. Further, even in the high frequency band, it is possible to realize a highly coupled transformer 10 capable of obtaining stable leakage characteristics.

Further, the first coil portion 301 and the second coil portion 302 are continuously formed by the common wire 38. With such a configuration, it is possible to prevent the current from flowing unevenly to either the first coil portion 301 or the second coil portion 302. Since the current is prevented from flowing unevenly, it is possible to prevent one of the coil portions 301 or 302 from abnormally generating heat. Further, the wire length of the common wire 38 constituting the first coil portion 301 and the second coil portion 302 is shortened as compared with the case where the first coil portion 301 and the second coil portion 302 are composed of separate wires. Is possible, and copper loss can be reduced. If the copper loss can be reduced, the efficiency can be improved and the heat generation can be reduced.

Further, in the present embodiment, since the coupling coefficient between the primary coil and the secondary coil is high, the leakage characteristics are stabilized even when the number of turns of the primary coil and the number of turns of the secondary coil are significantly different. Is easy. That is, according to the present embodiment, the effect is large even when the turns ratio of the number of turns of the common wire 38 in the first coil portion 301 and the second coil portion 302 to the number of turns of the intermediate wire 37 in the intermediate coil portion 303 is large. Specifically, even when the turns ratio n1 / n2 between the total number of turns n1 of the common wire 38 and the number of turns n2 of the intermediate wire 37 is 2 or more and 3 or more or 5 or more, a more remarkable effect can be obtained.

Further, in the present embodiment, the common wire 38 is α-wound around the bobbin 20. With such a configuration, the first coil portion 301 and the second coil portion 302 arranged apart from each other along the winding axis can be easily formed by using a single common wire 38. .. Further, it is easy to make the number of coil turns the same in the first coil portion 301 and the second coil portion 302, and it is also easy to change the number of turns.

Further, as shown in FIG. 4, in each of the first coil portion 301 and the second coil portion 302, the distance between the flange portions 24 to 27 of the bobbin 20 is such that only a single wire 38 is present along the winding axis. By adjusting the above, it becomes easy to prevent variations in the number of turns of the wires 37 and 38 per layer, which contributes to stabilization of the leakage characteristics. That is, it becomes easy to strictly control the coupling coefficient between the primary coil and the secondary coil.

Further, the α winding can reduce the number of layers in the winding axis direction even if the number of windings is increased, which contributes to lowering the height and miniaturization of the transformer 10. Further, by making the winding α, the wire is not pulled out from the center of the winding, so that the wires do not overlap, which contributes to lowering the height of the transformer 10.

In particular, in the present embodiment, as shown in FIG. 7A, the pair of first lead portions 37a and 37b are pulled out from the intermediate coil portion 303, and as shown in FIG. 6, the winding shafts are formed at the first rising portions 371a and 371b. It is started up around the outer circumference of the bobbin 20 along the (Z axis). The pair of first lead portions 37a and 37b pass through the first pedestal 22 from the first rising portions 371a and 371b, and in the first drawer main body portions 373a and 373b located above along the 20-turn axis of the bobbin. They are placed close to each other. That is, in the transformer 10 according to the present embodiment, the pair of first drawer main body portions 373a and 373b are arranged close to each other on the bobbin 20 and are held at a constant distance W1 (see FIG. 7A). With such a drawer structure, it is possible to realize a coil device having stable leakage characteristics as compared with a conventional transformer.

According to the experiments conducted by the present inventors, it has been clarified that the leakage characteristics change depending on the distance between the pair of drawer main bodies 373a and 373b. Therefore, the leakage characteristics can be optimized by keeping the pair of drawer main bodies 373a and 3732b close to each other so that the leakage characteristics are good and holding them at a certain distance W1.

According to the experiments of the present inventors, it has been clarified that the leakage can be reduced to 3/4 or less as compared with the conventional coil device only by changing the drawer structure of the pair of first lead portions 37a and 37b. In particular, it was confirmed that it is particularly effective when the ratio of the number of turns between the primary coil and the secondary coil is large.

Further, in the present embodiment, as shown in FIG. 1, the edge portion of the upper end opening of the case 90 is provided with a proximity holding pedestal 91 that holds a pair of first drawer main body portions 373a and 373b in close proximity to each other. There is. With this configuration, it is easy to hold the pair of first drawer main body portions 373a and 373b in close proximity to each other on the core portion 40 between the first pedestal 22 and the proximity holding pedestal 91. Become. Further, by providing the proximity holding pedestal 91 in the case 90, the pair of first drawer main body portions 373a and 373b held by the proximity holding pedestal 91 are positioned, which contributes to the stabilization of the leakage characteristics.

Further, in the transformer 10 of the present embodiment, as shown in FIG. 7A, the first insulating cover 81 is attached. With this configuration, good insulation between the common wire 38 and the first rising portions 371a and 371b of the intermediate wire 337 can be ensured.

Further, the first insulating cover 81 includes a pair of rising passages 816 and 813 that lead the pair of first rising portions 371a and 371b to the first pedestal 22 while insulating them from each other. With this configuration, the leakage characteristics can be stabilized.

Further, the first pedestal 22 is formed with drawer passages 222a and 222b for keeping the mutual distance between the pair of first drawer main body portions 373a and 373b at the upper part along the winding axis of the bobbin at a certain level or less. .. With such a configuration, it becomes easy to keep the mutual distance between the pair of first drawer main body portions 373a and 373b below a certain level, and the leakage characteristics are further stabilized.

Further, in the present embodiment, as shown in FIG. 7A, the pair of second lead portions 38a and 38b are away from the coil portion 300 while maintaining a distance wider than the distance between the second rising portions 381a and 381b. It extends as the second drawer main body portions 383a and 383b. With such a configuration, good insulation can be maintained even when the voltage applied to the second lead portions 38a and 38b is high. However, the reverse is also possible. That is, the pair of second lead portions 38a and 38b extend as the second drawer main body portions 383a and 383b in the direction away from the coil 300 while maintaining a distance narrower than the distance between the second rising portions 381a and 381b. May be good.

Further, in the present embodiment, as shown in FIG. 3, a second pedestal 23 is formed on the bobbin 20, and a second pedestal 23 is erected by the second rising portions 381a and 381b on the second pedestal 23. A pair of locking portions (locking convex portions) 232 in which the lead portions 38a and 38b are wound from the inside to the outside at the positions of the second direction changing portions 382a and 382b and are guided in the direction of the second drawer main body portions 383a and 383b. It has been formed. With this configuration, the second lead portions 38a and 38b are locked to the locking portions 232 without slack, and the coils 301 and 302 formed by the common wire 38 continuous with the second lead portions 38a and 38b. Unwinding is prevented. As a result, the leakage characteristics are stabilized.

Further, in the present embodiment, as shown in FIG. 7A, the rising directions of the first rising portions 371a and 371b and the rising directions of the second rising portions 381a and 381b are the same along the Z axis. The second pedestal 23, like the first pedestal 22, is located on the same side of the bobbin 20 in the Z-axis direction. With such a configuration, it becomes easy to position the bottom surface of the bobbin 20 located on the opposite side of the first pedestal 22 and the second pedestal 23 along the Z axis to the cooling side, and the coil portion shown in FIG. 7A. The cooling efficiency of the bobbin 20 and the core portion 40 shown in the 300 and FIG. 2 is improved.

Further, as shown in FIG. 1, the first pedestal 22 and the second pedestal 23 are located on opposite sides of each other on the upper outer periphery of the bobbin 20, and the proximity holding pedestal 91 is located at the outer position of the bobbin 20 and is the first. It is arranged between the pedestal 22 and the second pedestal 23. With this configuration, the pair of first lead portions 37a and 37b and the pair of second lead portions 38a and 38b can be pulled out from two adjacent side surfaces of the case 90, and the transformer 10 can be arranged in a space. It becomes easy to install in the corner of. Therefore, the transformer 10 can be easily cooled and the arrangement space can be effectively used.

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

For example, as another embodiment in which the coil is mounted on the outer periphery of the bobbin 20, the intermediate wire 37 is first wound around the bobbin 20 to form the intermediate coil portion 303, and then the common wire 38 is wound around the bobbin 20. A mode in which one coil portion 301 and the second coil portion 302 are configured is also conceivable. When the coil is mounted on the bobbin 20 in such an manner, the coil-to-coil connection portion 380 passes outside the intermediate coil portion 303.

Further, the relationship between the primary coil and the secondary coil described above may be reversed. That is, the common wire 38 may form a secondary coil, and the intermediate wire 37 may form a primary coil. Further, in that case, the magnitude relationship of the outer diameter of each wire may be the opposite of the above-mentioned example. Alternatively, the outer diameters of these wires may be the same.

10 ... Transformer 20 ... Bobbin 21 ... Bobbin body 21a ... Core leg through hole 22 ... First pedestal 221 ... Side wall 221a ... Drawer passage 222a, 222b ... Rise passage 223 ... Separation convex part 224 ... Engagement recess 23 ... 2 pedestal 231 ... Side wall part 232 ... Locking part 234 ... Engagement protrusion 24, 25 ... End partition bobbin 244 ... Notch 26, 27 ... Winding partition bar 261,271 ... Counterbore surface 272 ... Lead locking groove 264 , 274 ... Notch 28 ... Winding cylinder 29 ... Bobbin leg 300 ... Coil 301 ... First coil 302 ... Second coil 303 ... Intermediate coil 37 ... Intermediate wire 37a, 37b ... First lead 371a, 371b ... 1st rising part 373a, 373b ... 1st drawer main body part 38 ... Common wire 38a, 38b ... 2nd lead part 381a, 381b ... 2nd rising part 382a, 382b ... 2nd direction changing part 383a, 383b ... 2nd Drawer body 380 ... Coil connection 40 ... Magnetic core (core)
40a ... Upper core 40b ... Lower core 44a, 44b ... Base part 46a, 46b ... Middle leg part 48a, 48b ... Side leg part 50 ... Cover 52 ... Cover body part 54 ... Locking piece 56 ... Side leg guide piece 58 ... Inside Directional convex part 60a ... 1st pedestal cover 60b ... 2nd pedestal cover 70 ... Heat dissipation block 81 ... 1st insulating cover 811, 812 ... Partial collar 813 ... Wall part 814 ... Side part 815 ... Convex part 816 ... Passage 82 ... 2nd Insulation cover 821, 822 ... Partial collar 823 ... Intermediate part cylinder 90 ... Case 91 ... Proximity holding pedestal 91a ... Fitting hole 92 ... Bottom plate 94 ... Terminal 100 ... Bundling tool 102 ... Fitting leg 104 ... Retaining protrusion 106 ... Gap

Claims (11)

With bobbin
The first wire wound around the outer circumference of the bobbin and
Separately from the first wire, the second wire wound around the outer circumference of the bobbin and
It is a coil device with
The pair of first lead portions formed at both ends of the first wire is
A pair of first rising portions that rise from the outside of the bobbin toward the first pedestal of the bobbin along the winding axis.
A pair of first drawer main bodies, which are located on the upper side of the bobbin from the first rising portion, pass through the first pedestal, and are arranged in close proximity to each other. Have and
Further having a case covering the lower portion of the bobbin around which the first wire and the second wire are wound.
A coil device comprising a proximity holding pedestal that holds a pair of the first drawer main bodies in close proximity to each other at the edge of the upper end opening of the case. With bobbin
The first wire wound around the outer circumference of the bobbin and
Separately from the first wire, the second wire wound around the outer circumference of the bobbin and
It is a coil device with
The pair of first lead portions formed at both ends of the first wire is
A pair of first rising portions that rise from the outside of the bobbin toward the first pedestal of the bobbin along the winding axis.
A pair of first drawer main bodies, which are located on the upper side of the bobbin from the first rising portion, pass through the first pedestal, and are arranged in close proximity to each other. Have and
The pair of second lead portions formed at both ends of the second wire is
A pair of second risers extending in the direction of the winding axis,
A pair of second drawer main bodies extending in a direction away from the bobbin while maintaining a distance wider than the distance between the pair of the second risers.
A pair of second-direction changes that communicate between the second rising portion and the second drawer main body portion and change the direction of the second rising portion toward the direction of the second drawer main body portion. A coil device characterized by having a portion and a portion. A second pedestal is formed on the bobbin, and the second lead portion raised at the second rising portion is formed on the second pedestal from the inside to the outside at the position of the second direction changing portion. The coil device according to claim 2, wherein a pair of locking portions that are wound around the coil device and guided in the direction of the second drawer main body portion are formed. The rising direction of the first rising portion and the rising direction of the second rising portion are the same direction.
The coil device according to claim 3 , wherein the second pedestal is located on the same side of the winding shaft of the first wire with respect to the first pedestal formed on the bobbin. Further having a case covering the lower portion of the bobbin around which the first wire and the second wire are wound.
The edge of the upper end opening of the case is provided with a proximity holding pedestal that holds the pair of the first drawer main bodies in close proximity to each other.
The first pedestal and the second pedestal are located on opposite sides of each other on the upper outer periphery of the bobbin, and the proximity holding pedestal is located on the outer side of the bobbin, with the first pedestal and the second pedestal. The coil device according to claim 3 or 4 , which is arranged between them. In order to secure insulation between the portion where the second wire is wound around the bobbin and the first rising portion, a first insulation is provided on the outer periphery of the bobbin inside the first rising portion. The coil device according to any one of claims 1 to 5, wherein a cover is attached. The coil device according to claim 6 , wherein the first insulating cover includes a pair of passages leading to the first pedestal by bringing the pair of the first rising portions close to each other while insulating each other. Claims 1 to 7 are formed in the first pedestal with a drawer passage for keeping a mutual distance between a pair of the first drawer main bodies at an upper portion along the winding axis of the bobbin at a certain level or less. The coil device according to any one of. On the outer periphery of the bobbin, a first coil portion, a second coil portion, and an intermediate coil portion located between the first coil portion and the second coil portion are arranged along the winding axis. And
The intermediate coil portion is composed of the first wire.
Claim 1 is characterized in that the first coil portion and the second coil portion are composed of the second wire for continuously forming the first coil portion and the second coil portion. 8. The coil device according to any one of 8. Claimed, wherein the first wire constitutes either one of a primary coil and a secondary coil, and the second wire constitutes either one of a primary coil or a secondary coil. The coil device according to any one of 1 to 9. The coil device according to any one of claims 1 to 10, wherein the number of turns of the first wire wound around the bobbin is smaller than the number of turns of the second wire wound around the bobbin.

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