Coil device
By designing a gap structure between the spool, winding section, and core in the coil device, combined with the housing connection section and heat dissipation components, the problems of complex core structure and insufficient heat dissipation are solved, and a coil device with efficient cooling and miniaturization is realized.
Patent Information
- Application Number
- CN202510745115.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2024-07-29
- Filing Date
- 2025-06-05
- Publication Date
- 2026-01-30
AI Technical Summary
In the existing technology, the core structure of the coil device is complex and the heat dissipation of the coil is insufficient, making it difficult to achieve efficient heat dissipation.
The structure consists of a spool, first and second winding sections, first and second cores mounted on the spool, a housing, and resin filling. By forming a gap between the outer legs of the cores and utilizing the connecting parts and gaps on the housing to form a cooling airflow path, heat dissipation is improved in conjunction with heat dissipation components.
It achieves high heat dissipation of coil devices with simple structure, improves cooling efficiency, and is suitable for miniaturized coil devices with transformer and inductor functions.
Smart Images
Figure CN121439458A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present disclosure relates to a coil device. BACKGROUND
[0002] As a technique of cooling a coil device, there is disclosed in Patent Literature 1 a technique of forming a through-hole in a core and introducing cooling air to an inner side of the core via the through-hole. By introducing cooling air to the inner side of the core via the through-hole, it is possible to cool the core and the coil and to improve the heat dissipation of the coil device.
[0003] PRIOR ART DOCUMENTS
[0004] PATENT LITERATURE
[0005] Patent Literature 1: Japanese Patent Application Publication No. 2012-156351 SUMMARY
[0006] PROBLEMS TO BE SOLVED BY THE INVENTION
[0007] However, in the case where the through-hole is formed in the core, the structure of the core becomes complicated. In addition, the heat dissipation of the coil cannot be said to be sufficient compared to the heat dissipation of the core.
[0008] The present disclosure provides a coil device having a simple structure and high heat dissipation.
[0009] TECHNICAL SOLUTION FOR SOLVING THE PROBLEM
[0010] The present disclosure provides a coil device having:
[0011] a bobbin;
[0012] a first winding portion disposed on an outer peripheral surface of the bobbin;
[0013] a second winding portion disposed directly or indirectly on an outer peripheral surface of the first winding portion;
[0014] first and second cores mounted on the bobbin;
[0015] a housing that accommodates at least the bobbin; and
[0016] a resin filled into the housing,
[0017] the first core has a first base portion and a pair of first outer leg portions that project from the first base portion and are opposed in a first direction perpendicular to an axial direction of the bobbin,
[0018] the second core has a second base portion and a pair of second outer leg portions that project from the second base portion and are opposed in the first direction,
[0019] In a second direction perpendicular to the axial direction and the first direction, the first outer leg and the second outer leg are separated in such a way that a gap is formed between the first outer leg and the second outer leg. Attached Figure Description
[0020] Figure 1 This is a perspective view of the coil device according to the first embodiment.
[0021] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.
[0022] Figure 3 yes Figure 2 An exploded 3D view of the bobbin shown.
[0023] Figure 4 yes Figure 2 A three-dimensional view of the bobbin and winding section shown.
[0024] Figure 5 It is along Figure 1 The cross-sectional view of the VV line shown.
[0025] Figure 6 It is along Figure 1 The sectional view along line VI-VI is shown.
[0026] Figure 7 It is a top view of a spool with the first, second, and third cores installed.
[0027] Figure 8 From Figure 1 The side view of the housing is omitted from the diagram of the coil assembly.
[0028] Figure 9 From Figure 1 The coil device shown omits a perspective view of its housing.
[0029] Figure 10 yes Figure 1 The diagram shows a three-dimensional view of the shell.
[0030] Figure 11 This is a perspective view of the coil device according to the second embodiment.
[0031] Figure 12 yes Figure 11 A three-dimensional view of the coil assembly shown.
[0032] Figure 13 From Figure 11 The side view of the housing is omitted from the diagram of the coil assembly.
[0033] Figure 14 It is along Figure 11The cross-sectional view of line XIV-XIV shown. Detailed Implementation
[0034] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Furthermore, the illustrations are merely schematic and exemplary representations for the purpose of understanding the present invention, and their appearance and size ratios may differ from the actual product. Additionally, the present invention is not limited to the following embodiments.
[0035] (First Implementation)
[0036] Figure 1 The coil device 1 shown in the first embodiment is a composite coil device that functions as both a transformer and an inductor, and is installed in the power supply circuit of electrical equipment, etc. Figure 2 As shown, the coil device 1 includes at least a bobbin 2, a first winding 3, a second winding 4, a first core 5a-5b, a second core 6a-6b, and a housing 8. Figure 1 ), and resin 9 ( Figure 5 The coil device 1 also has a third core 7a-7b, a first heat dissipation member 10, and a second heat dissipation member 11a-11b, but these structures are not necessary and can be omitted.
[0037] The first core (5a-5b), the second core (6a-6b), and the third core (7a-7b) are all E-type cores, installed on spool 2. Figure 9 The first cores 5a-5b, the second cores 6a-6b, and the third cores 7a-7b have the same shape, but can also have different shapes. The first cores 5a and 5b are combined, the second cores 6a and 6b are combined, and the third cores 7a and 7b are combined. The second core 6a is adjacent to the first core 5a, and the third core 7a is adjacent to the second core 6a. The second core 6b is adjacent to the first core 5b, and the third core 7b is adjacent to the second core 6b.
[0038] The first cores 5a to 5b each have a base 50, a pair of outer legs 51, and a middle leg 52. The second cores 6a to 6b each have a base 60, a pair of outer legs 61, and a middle leg 62. The third cores 7a to 7b each have a base 70, a pair of outer legs 71, and a middle leg 72.
[0039] Hereinafter, the axis along the direction (first direction) opposite to the pair of legs 51 will be designated as the X-axis. The axis along the direction opposite to the first core 5a and the second core 6a will be designated as the Y-axis. The axis corresponding to the axis of the bobbin 2 will be designated as the Z-axis. The X-axis, Y-axis, and Z-axis are perpendicular to each other.
[0040] In the present disclosure, the positive direction side of the Z-axis is set as "upper", and the negative direction side of the Z-axis is set as "lower". However, the upper side in the Z-axis direction does not necessarily coincide with the upper side in the vertical direction. In addition, the lower side in the Z-axis direction does not necessarily coincide with the lower side in the vertical direction.
[0041] A pair of outer leg portions 51 protrude from the base portion 50 so as to face each other in a direction (X-axis direction) perpendicular to the axial direction of the bobbin 2. The pair of outer leg portions 51 are located at both ends of the base portion 50 in the X-axis direction and extend in a direction (Z-axis direction) perpendicular to the base portion 50.
[0042] However, in the present disclosure, "perpendicular" does not mean only a strict perpendicular concept, and a state in which an error of ±Δθ° (not particularly limited, for example, Δθ = 3) or less occurs with respect to a strict perpendicular is also included in the concept of "perpendicular". In addition, "parallel" does not mean only a strict parallel, and a state in which an error of ±Δθ° (not particularly limited, for example, Δθ = 3) or less occurs with respect to a strict parallel is also included in the concept of "parallel".
[0043] A middle leg portion 52 is located between the pair of outer leg portions 51 and protrudes from the base portion 50. The middle leg portion 52 extends in a direction perpendicular to the base portion 50.
[0044] A pair of outer leg portions 61 protrude from the base portion 60 so as to face each other in the X-axis direction perpendicular to the axial direction of the bobbin 2. The pair of outer leg portions 61 are located at both ends of the base portion 60 in the X-axis direction and extend in a direction (Z-axis direction) perpendicular to the base portion 60. A middle leg portion 62 is located between the pair of outer leg portions 61 and protrudes from the base portion 60. The middle leg portion 62 extends in a direction perpendicular to the base portion 60.
[0045] A pair of outer leg portions 71 protrude from the base portion 70 so as to face each other in the X-axis direction perpendicular to the axial direction of the bobbin 2. The pair of outer leg portions 71 are located at both ends of the base portion 70 in the X-axis direction and extend in a direction (Z-axis direction) perpendicular to the base portion 70. A middle leg portion 72 is located between the pair of outer leg portions 71 and protrudes from the base portion 70. The middle leg portion 72 extends in a direction perpendicular to the base portion 70.
[0046] The outer leg portions 51, 61, and 71 have a rectangular cross section (a cross section perpendicular to the Z-axis), but can have a square shape, another polygonal shape, a circular shape, an elliptical shape, or another shape. In addition, the middle leg portions 52, 62, and 72 have a rectangular cross section, but can have a square shape, another polygonal shape, a circular shape, an elliptical shape, or another shape.
[0047] The first core 5a and 5b can also be composed of a plurality of cores, respectively. For example, the first core 5a and 5b can also be composed by combining a plurality of I-shaped cores into an E-shape. Alternatively, the first core 5a and 5b can also be composed by combining a U-shaped core and an I-shaped core into an E-shape. The same applies to the second core 6a and 6b and the third core 7a and 7b.
[0048] Alternatively, one of the first core 5a and 5b can be an E-shaped core and the other can be an I-shaped core. The same applies to the second core 6a and 6b and the third core 7a and 7b.
[0049] The first core 5a, the second core 6a, and the third core 7a are arranged at intervals along the Y-axis direction. The first core 5b, the second core 6b, and the third core 7b are arranged at intervals along the Y-axis direction.
[0050] In a state where the first core 5a and 5b are attached to the bobbin 2, the front ends of the pair of outer leg portions 51 of the first core 5a can be in contact with the front ends of the pair of outer leg portions 51 of the first core 5b, or can be separated with a gap formed therebetween. In a state where the second core 6a and 6b are attached to the bobbin 2, the front ends of the pair of outer leg portions 61 of the second core 6a can be in contact with the front ends of the pair of outer leg portions 61 of the second core 6b, or can be separated with a gap formed therebetween. In a state where the third core 7a and 7b are attached to the bobbin 2, the front ends of the pair of outer leg portions 71 of the third core 7a can be in contact with the front ends of the pair of outer leg portions 71 of the third core 7b, or can be separated with a gap formed therebetween.
[0051] In a state where the first core 5a and 5b are attached to the bobbin 2, the front ends of the middle leg portions 52 of the first core 5a can be in contact with the front ends of the middle leg portions 52 of the first core 5b, or can be separated with a gap formed therebetween. In a state where the second core 6a and 6b are attached to the bobbin 2, the front ends of the middle leg portions 62 of the second core 6a can be in contact with the front ends of the middle leg portions 62 of the second core 6b, or can be separated with a gap formed therebetween. In a state where the third core 7a and 7b are attached to the bobbin 2, the front ends of the middle leg portions 72 of the third core 7a can be in contact with the front ends of the middle leg portions 72 of the third core 7b, or can be separated with a gap formed therebetween.
[0052] The first cores 5a to 5b are formed from a material comprising magnetic material and resin. The magnetic material constituting the first cores 5a to 5b is not particularly limited, and can be, for example, ferrite (Ni-Zn ferrite, Mn-Zn ferrite, etc.) or metallic magnetic material (Fe-Ni alloy, Fe-Si alloy, Fe-Si-Cr alloy, Fe-Co alloy, Fe-Si-Al alloy, amorphous iron, etc.). The resin constituting the first cores 5a to 5b is not particularly limited, and can be epoxy resin, phenolic resin, polyester resin, polyurethane resin, polyimide resin, etc. The first cores 5a to 5b can also be sintered bodies of metallic magnetic materials. The materials constituting the second cores 6a to 6b and the third cores 7a to 7b are also the same.
[0053] like Figure 4 As shown, the first winding 3 has a winding portion 30 and lead-out portions 31a to 31b extending from the winding portion 30. The winding portion 30 is disposed directly or indirectly on the outer peripheral surface of the first spool 20 constituting the spool 2. The winding portion 30 is formed by spirally winding the first winding 3 around the outer peripheral surface of the first spool 20. The winding direction of the winding portion 30 corresponds to the Z-axis direction. Lead-out portions 31a are one end of the first winding 3, and lead-out portions 31b are the other end of the first winding 3. Terminals are installed on the lead-out portions 31a and 31b.
[0054] The second winding 4 has a winding portion 40 and lead-out portions 41a to 41b extending from the winding portion 40. For example... Figure 2 As shown, at least a portion of the winding portion 40 (in this embodiment, a portion of the winding portion 40) is disposed directly or indirectly on the outer peripheral surface of the winding portion 30. In this embodiment, a portion of the winding portion 40 is disposed directly or indirectly on the outer peripheral surface of the body 250 of the second spool 24 constituting the spool 2. The winding portion 40 is formed by spirally winding the second winding 4 around the outer peripheral surface of the winding portion 30 and the outer peripheral surface of the body 250. The winding direction of the winding portion 40 corresponds to the Z-axis direction. One of the winding portions 30 and 40 functions as a primary coil, and the other functions as a secondary coil.
[0055] like Figure 4 As shown, lead-out portion 41a is one end of the second winding 4, and lead-out portion 41b is the other end of the second winding 4. Terminals are installed on lead-out portions 41a and 41b.
[0056] The first winding 3 and the second winding 4 are, for example, insulated windings. The first winding 3 and the second winding 4 are known windings such as AIW (polyamide-imide copper wire), UEW (polyurethane copper wire), and PEW (polyester copper wire). The first winding 3 and the second winding 4 are round wires, but can also be square wires, stranded wires, stranded wires, braided wires, etc. The material of the core wire constituting the first winding 3 and the second winding 4 is not particularly limited; for example, it can be copper, copper alloy, silver, or nickel. The diameter of the first winding 3 or the second winding 4 is not particularly limited; for example, it can be 10 to 100 μm. The diameter of the first winding 3 is equal to the diameter of the second winding 4, but they can also be different.
[0057] Furthermore, in this disclosure, "equal", "equivalent" or "same" is not only a concept that indicates that the physical quantities of the multiple objects being compared are strictly equal, equivalent or the same, but also includes the state that there is an error of ±Δ% (without particular limitation, for example, Δ = 7, 5 or 3) or less between the physical quantities of the multiple objects being compared.
[0058] like Figure 6 As shown, at least one of the winding portion 30 and the winding portion 40 has a transformer portion 13 that functions as a transformer and an inductor portion 14 that functions as an inductor. The transformer portion 13 includes at least the winding portion 30 and the winding portion 40 that is radially stacked on the winding portion 30. A first core 5a-5b and a second core 6a-6b are disposed in the transformer portion 13. The inductor portion 14 includes at least the winding portion 40. A third core 7a-7b is disposed in the inductor portion 14.
[0059] The winding portion 30 has repeating portions 32 and non-repeating portions 33. The repeating portions 32 overlap with and are covered by the winding portion 40 along the radial direction of the winding portion 30. The non-repeating portions 33 do not overlap with the winding portion 40 along the radial direction of the winding portion 30 and protrude downward from the winding portion 40 along the axial direction of the winding portion 30. The number of layers of the non-repeating portions 33 along the axial direction of the winding portion 30 is two, which is less than the number of layers of the repeating portions 32 along the axial direction of the winding portion 30. However, the number of layers of the non-repeating portions 33 along the axial direction of the winding portion 30 may be equal to or more than the number of layers of the repeating portions 32 along the axial direction of the winding portion 30.
[0060] A portion of the spool 2 (the intermediate flange 213 of the first spool 20) is disposed between the repeating portion 32 and the non-repeating portion 33. Therefore, the repeating portion 32 and the non-repeating portion 33 are separated along the winding direction of the winding portion 30.
[0061] The non-repeating portion 33 is disposed inside the resin 9, which fills the housing 8. In this embodiment, the entire non-repeating portion 33 is disposed inside the resin 9, but a portion of the non-repeating portion 33 (e.g., the upper end of the non-repeating portion 33) may also be exposed from the resin 9.
[0062] On the other hand, the repeating portion 32 is disposed outside the resin 9 and protrudes from the resin 9. In this embodiment, the entire repeating portion 32 is exposed from the resin 9, but a portion of the repeating portion 32 (e.g., the lower end of the repeating portion 32) may also be disposed inside the resin 9.
[0063] like Figure 3 As shown, the spool 2 has a first spool 20 and a second spool 24. The spool 2 is made of plastics such as PPS, PET, PBT, LCP, or other insulating components. The spool 2 is composed of two components, the first spool 20 and the second spool 24, but it can also be composed of a single component. The first spool 20 has a body 210, flange portions 211-212, a middle flange portion 213, wall portions 214-219, a protrusion 220, a hook portion 221, guide members 222-223, and a through hole 224.
[0064] The main body 210 is a cylindrical body with a through hole 224. The through hole 224 extends along the axial direction of the main body 210. A flow hole is formed on the main body 210, which extends through the main body 210 from its outer peripheral surface to its inner peripheral surface. When the flow hole is directed to the shell 8 ( Figure 6 When the body 210 is filled with resin 9, the resin 9 flows from the outside to the inside through the flow hole. The top view shape of the body 210 is not particularly limited, but it has an elongated shape in the Y-axis direction.
[0065] A flange portion 211 is formed at the upper end of the body 210 and protrudes from the outer peripheral surface of the body 210 along the radial direction. A flange portion 212 is formed at the lower end of the body 210 and protrudes from the outer peripheral surface of the body 210 along the radial direction. An intermediate flange portion 213 is located between the flange portions 211 and 212 and protrudes from the outer peripheral surface of the body 210 along the radial direction.
[0066] like Figure 4 As shown, a first winding 3 is wound around the outer peripheral surface of the main body 210, forming a wound portion 30. A repeating portion 32 is disposed between the flange portion 211 and the intermediate flange portion 213, and a non-repeating portion 33 is disposed between the intermediate flange portion 213 and the flange portion 212. That is, the intermediate flange portion 213 is located between the repeating portion 32 and the non-repeating portion 33, separating them. Figure 5As shown, in this embodiment, resin 9 is filled into the housing 8 such that the surface (upper surface) of resin 9 is located at the position of the intermediate flange 213. However, the position of the surface of resin 9 may be lower or higher than the position of the intermediate flange 213.
[0067] like Figure 3 As shown, wall portion 214 is located at one end of flange portion 211 in the Y-axis direction and protrudes upward from the upper surface of flange portion 211. Wall portion 215 is located at the other end of flange portion 211 in the Y-axis direction and protrudes upward from the upper surface of flange portion 211. Figure 3 In the example shown, a through hole is formed in the wall portion 215. Figure 7 ).
[0068] The wall portion 216 is located at one end of the flange portion 212 in the Y-axis direction and protrudes downward from the lower surface of the flange portion 212. The wall portion 217 is located at the other end of the flange portion 212 in the Y-axis direction and protrudes downward from the lower surface of the flange portion 212.
[0069] Wall portion 218 is located between wall portions 214 and 215 and protrudes upward from the upper surface of flange portion 211. Wall portion 219 is located between wall portions 216 and 217 and protrudes downward from the lower surface of flange portion 212.
[0070] like Figure 7 and Figure 8 As shown, the base 50 of the first core 5a is disposed between wall portion 214 and wall portion 218. Additionally, the base 60 of the second core 6a is disposed between wall portion 215 and wall portion 218. Furthermore, the base 50 of the first core 5b is disposed between wall portion 216 and wall portion 219. Additionally, the base 60 of the second core 6b is disposed between wall portion 217 and wall portion 219.
[0071] like Figure 3 As shown, a pair of protrusions 220 protrude from the wall portion 214 and extend in a direction away from the second spool 24. A pair of hook portions 221 protrude from the pair of protrusions 220 in a manner close to each other. The hook portions 221 are bent into an L-shape. Lead-out portion 31a ( Figure 7 The lead-out part 31b engages with one hook part 221 and the other hook part 221.
[0072] Guide members 222 and 223 are adjacent to each other and formed on the outer peripheral surface of the main body 210. Guide members 222 and 223 extend along the axial direction of the main body 210. Figure 7 As shown, the lead-out portion 31b is drawn upward from the winding portion 30 while passing between the guide member 222 and the guide member 223. Furthermore, as... Figure 6As shown, the lead-out portion 31b is led out upward from the non-repeating portion 33. On the other hand, the lead-out portion 31a is led out upward from the upper end of the repeating portion 32.
[0073] like Figure 3 As shown, the second spool 24 has a main body 250, flange portions 251-252, a middle flange portion 253, wall portions 254-257, a protrusion 260, a hook portion 261, and a protrusion 265. In a top view, the main body 250 is bent into a C-shape. A flow hole is formed on the main body 250, extending from the outer peripheral surface to the inner peripheral surface of the main body 250. When the flow hole is directed to the housing 8 ( Figure 6 When the body 250 is filled with resin 9, the resin 9 flows from the outside to the inside through the flow hole.
[0074] A flange portion 251 is formed at the upper end of the body 250, protruding from the outer peripheral surface of the body 250 along the radial direction. A flange portion 252 is formed at the lower end of the body 250, protruding from the outer peripheral surface of the body 250 along the radial direction. An intermediate flange portion 253 is located between the flange portions 251 and 252, protruding from the outer peripheral surface of the body 250 along the radial direction. Figure 4 As shown, the intermediate flange portion 253 and the intermediate flange portion 213 are combined. (As shown...) Figure 6 As shown, in this embodiment, resin 9 is filled into the housing 8 such that the surface (upper surface) of resin 9 is located at the position of the intermediate flange 253. However, the position of the surface of resin 9 may be lower or higher than the position of the intermediate flange 253.
[0075] like Figure 2 and Figure 4 As shown, when the second spool 24 and the first spool 20 are combined, the second winding 4 can be wound around the outer peripheral surface of the main body 250 and the outer peripheral surface of the winding portion 30. Thus, a winding portion 40 is formed on the outer peripheral surface of the main body 250 and the outer peripheral surface of the winding portion 30. The winding portion 40 is disposed between the flange portion 251 and the intermediate flange portion 253, but not between the intermediate flange portion 253 and the flange portion 252.
[0076] like Figure 3 As shown, wall portion 254 is located at one end of flange portion 251 in the Y-axis direction and protrudes upward from the upper surface of flange portion 251. Wall portion 255 is located at the other end of flange portion 251 in the Y-axis direction and protrudes upward from the upper surface of flange portion 251.
[0077] Wall portion 256 is located at one end of flange portion 252 in the Y-axis direction and protrudes downward from the lower surface of flange portion 252. Wall portion 257 is located at the other end of flange portion 252 in the Y-axis direction and protrudes downward from the lower surface of flange portion 252. Figure 4As shown, wall portion 254 is combined with wall portion 215, and wall portion 256 is combined with wall portion 217.
[0078] like Figure 8 As shown, the base 70 of the third core 7a is disposed between wall portion 254 and wall portion 255. Additionally, the base 70 of the third core 7b is disposed between wall portion 256 and wall portion 257.
[0079] like Figure 3 As shown, a pair of protrusions 260 protrude from the wall portion 255 and extend in a direction away from the first spool 20. A pair of hook portions 261 protrude from the pair of protrusions 260 in a manner close to each other. The hook portions 261 are bent into an L-shape. Lead-out portion 41a ( Figure 7 The lead-out portion 41b engages with one hook portion 261 and the other hook portion 261. Furthermore, the lead-out portions 41a and 41b are drawn out from the upper end of the winding portion 40 and upward between the flange portion 251 and the intermediate flange portion 253.
[0080] Multiple protrusions 265 are formed on the outer peripheral surface of the body 250, extending axially along the body 250 between the flange portion 251 and the intermediate flange portion 253. The multiple protrusions 265 protrude radially from the outer peripheral surface of the body 250. Because multiple protrusions 265 are formed on the outer peripheral surface of the body 250, the winding portion 40 ( Figure 4 It is disposed on the outer peripheral surface of the main body 250 via multiple protrusions 265.
[0081] like Figure 2 As shown, the first heat dissipation member 10 is composed of a flat, plate-like component. The material constituting the first heat dissipation member 10 is not particularly limited, and can be, for example, metals such as aluminum, copper, or silver. Undifferences 100 are formed on the surface (upper surface) of the first heat dissipation member 10. The irregularities 100 are formed in a slit shape. The irregularities 100 have multiple protrusions extending along the Y-axis direction and multiple recesses extending along the Y-axis direction. The multiple protrusions and multiple recesses are arranged along the X-axis direction.
[0082] like Figure 1 As shown, the first heat dissipation member 10 is disposed at the base 50 of the first core 5a, the base 60 of the second core 6a, and the base 70 of the third core 7a. The first heat dissipation member 10 is at least directly disposed at the base 50 and the base 60, but may also be disposed indirectly at the base 50 and the base 60. The first heat dissipation member 10 is mounted to the base 50, the base 60, and the base 70, for example, using an adhesive.
[0083] like Figure 2As shown, the second heat dissipation components 11a and 11b are formed in an E-shape. The materials constituting the second heat dissipation components 11a and 11b are not particularly limited, and can be metals such as aluminum, copper, or silver. The second heat dissipation components 11a and 11b have the same shape, but can also have different shapes. The second heat dissipation components 11a and 11b are combined. The second heat dissipation components 11a and 11b each have a base 110, a pair of outer legs 111, and a middle leg 112.
[0084] A pair of outer legs 111 protrude from the base 110 and are opposite each other in the X-axis direction. The pair of outer legs 111 are located at both ends of the base 110 in the X-axis direction and extend in a direction perpendicular to the base 110 (Z-axis direction). A middle leg 112 is located between the pair of outer legs 111 and protrudes from the base 110. The middle leg 112 extends in a direction perpendicular to the base 110.
[0085] The front ends of one pair of legs 111 of the second heat dissipation member 11a may be connected to the front ends of one pair of legs 111 of the second heat dissipation member 11b, or they may be separated by forming a gap between them. The front end of the middle leg 112 of the second heat dissipation member 11a may be connected to the front end of the middle leg 112 of the second heat dissipation member 11b, or they may be separated by forming a gap between them.
[0086] The end faces of the second heat dissipation members 11a and 11b in the Y-axis direction are formed with concave and convex shapes 113. The concave and convex shapes 113 are formed in the shape of slits. The concave and convex shapes 113 have a plurality of protrusions extending in the Z-axis direction and a plurality of concave shapes extending in the Z-axis direction. The plurality of protrusions and the plurality of concave shapes are arranged in the X-axis direction.
[0087] like Figure 9 As shown, the second heat dissipation member 11a is disposed on the end face of the third core 7a in the Y-axis direction. The second heat dissipation member 11a is directly disposed on the end face of the third core 7a in the Y-axis direction, but it can also be disposed indirectly on the end face of the third core 7a in the Y-axis direction. Additionally, the second heat dissipation member 11b is disposed on the end face of the third core 7b in the Y-axis direction. The second heat dissipation member 11b is directly disposed on the end face of the third core 7b in the Y-axis direction, but it can also be disposed indirectly on the end face of the third core 7b in the Y-axis direction. The second heat dissipation members 11a and 11b are mounted to the third cores 7a and 7b, for example, using adhesive.
[0088] like Figure 10 As shown, the housing 8 has a base plate 80, side plates 81a to 81d, and a connecting portion 82. The housing 8 is made of a metal with excellent cooling properties, such as aluminum. At least one spool 2 is accommodated in the housing 8.
[0089] Side plates 81a to 81d extend from the outer periphery of the base plate 80 in a direction perpendicular to (above) the base plate 80. Side plates 81a and 81b are opposite each other in the Y-axis direction and bulge outward toward the outer side of the housing 8 according to the shape of the spool 2. Side plates 81c and 81d are opposite each other in the X-axis direction.
[0090] The connecting portion 82 is formed in the shape of a slit and extends elongatedly along the X-axis when viewed from the Y-axis direction. The connecting portion 82 connects the housing 8 in the Y-axis direction from the outer surface to the inner surface of the side plate 81a or 81b. In this embodiment, the connecting portion 82 is a through hole penetrating the side plate 81a or 81b. However, the connecting portion 82 is not limited to a through hole; it may also be a cut that cuts into the outer periphery of the side plate 81a or 81b. Alternatively, the connecting portion 82 may also be a recessed portion from the outer periphery of the side plate 81a or 81b.
[0091] exist Figure 10 In the example shown, two connecting portions 82 are arranged vertically on side plate 81a. Similarly, two connecting portions 82 are arranged vertically on side plate 81b. The shape of the connecting portions 82, viewed from a direction perpendicular to side plate 81a or 81b, is actually elliptical or rectangular, but can also be circular, square, other polygonal, or other shapes. Furthermore, the number of connecting portions 82 on side plate 81a or 81b is not limited to two; it can be one or more. For example, viewed from a direction perpendicular to side plate 81a or 81b, multiple circular connecting portions 82 are arranged along the X-axis.
[0092] like Figure 6 As shown, the connecting portion 82 is located at a position separate from the surface (upper surface) of the resin 9 filling the housing 8 in the direction toward the opening of the housing 8 (above). The resin 9 is filled in the housing 8 to the same position as the connecting portion 82, but it may also be filled to a position lower than the position of the connecting portion 82. Furthermore, the resin 9 is not particularly limited, and may be made of, for example, silicone resin, polyurethane resin, or epoxy resin.
[0093] At least a portion of the outer peripheral surface of the winding portion 40 passes through the connecting portion 82 and faces the outside of the housing 8. Furthermore, the connecting portion 82 is located such that the outer peripheral surface of the winding portion 40 can be observed from the outside of the housing 8 through the connecting portion 82. Therefore, when cooling air flows towards the coil assembly 1 along the Y-axis direction, at least a portion of the cooling air flows into the inside of the housing 8 via the connecting portion 82. Then, at least a portion of the cooling air blows onto the winding portion 40, thereby cooling the winding portion 40.
[0094] like Figure 8As shown, in this embodiment, in the Y-axis direction, the outer leg portion 51 of the first core 5a is separated from the outer leg portion 61 of the second core 6a. Furthermore, in the Y-axis direction, the outer leg portion 51 of the first core 5b is separated from the outer leg portion 61 of the second core 6b. Therefore, a gap 12 is formed between the outer leg portions 51 and 61. The width of the gap 12 in the Y-axis direction is equal to or greater than the width of the wall portion 218 of the first spool 20 in the Y-axis direction. For example, the width of the gap 12 in the Y-axis direction is more than half the diameter of the first winding 3 or the second winding 4. In addition to being formed between the outer leg portions 51 and 61, the gap 12 is also formed between the base 50 and the base 60.
[0095] As described above, at least a portion of the cooling air flows into the inner side of the housing 8 via the connecting portion 82. At least a portion of the cooling air flows out to the outer side of the cores 5a and 5b through the gap 12 between the outer legs 51 and 61. Thus, in this embodiment, the connecting portion 82 functions as an inlet for introducing cooling air into the interior of the housing 8, while the gap 12 functions as an outlet for discharging cooling air to the outer side of the cores 5a and 5b. Therefore, a cooling air flow path is formed from the connecting portion 82 to the gap 12, passing around the outer peripheral surface of the winding portion 40.
[0096] Furthermore, in this embodiment, in the Y-axis direction, the outer legs 61 of the second cores 6a and 6b are separated from the outer legs 71 of the third cores 7a and 7b. Therefore, a gap that functions as a flow path for cooling air is also formed between the outer legs 61 and the outer legs 71.
[0097] Next, the manufacturing method of coil device 1 will be described. First, in Figure 3 The first winding 3 is wound around the outer circumferential surface of the main body 210 of the first spool 20 shown. Figure 4 ), forming a winding portion 30. Then, by passing through the hook portion 221, the lead-out portions 31a and 31b ( Figure 4 It is drawn out from the winding section 30. Then, as... Figure 4 As shown, the second spool 24 is combined with the first spool 20 on which the first winding 3 is wound. Next, the second winding 4 is wound onto the outer peripheral surface of the winding portion 30 and the outer peripheral surface of the main body 250 of the second spool 24, forming... Figure 2 The winding portion 40 is shown. Then, the lead-out portions 41a and 41b are led out from the winding portion 40 by passing through the hook portion 261.
[0098] Next, as Figure 9As shown, the first cores 5a-5b, the second cores 6a-6b, and the third cores 7a-7b are assembled with the spool 2 (an assembly of the first spool 20 and the second spool 24). Next, the first heat dissipation member 10 is installed on the base 50, base 60, and base 70. Additionally, the second heat dissipation members 11a-11b are installed on the second cores 7a and 7b. Then, as... Figure 1 As shown, the spool 2 and other components are housed in the housing 8, as follows: Figure 5 Resin 9 is filled into the interior of the housing 8 as shown. As described above, the coil device 1 can be manufactured.
[0099] like Figure 1 As shown, in the coil device 1 of this embodiment, the outer legs 51 and 61 are separated in a manner with a gap 12 formed between them, in the Y-axis direction perpendicular to the axial direction (Z-axis direction) of the spool 2 and the direction opposite to the pair of outer legs 51 (X-axis direction). Therefore, at least a portion of the cooling air supplied toward the winding section 40 flows along the outer peripheral surface of the winding section 40, passes through the gap 12 between the outer legs 51 and 61, and flows outward from the inside of the first core 5a and the second core 6a. As a result, the winding section 40 is cooled, and the heat dissipation of the coil device 1 is improved. Furthermore, it is not necessary to process the first core 5a and the second core 6a to ensure the flow path of the cooling air, thus improving the heat dissipation of the coil device 1 with a simple structure.
[0100] In addition, such as Figure 5 As shown, the winding portion 30 has a repeating portion 32 that overlaps with the winding portion 40 along the radial direction of the winding portion 30, and a non-repeating portion 33 that does not overlap with the winding portion 40 along the radial direction of the winding portion 30. Moreover, the non-repeating portion 33 is disposed inside the resin 9. Therefore, the heat of the winding portion 30 is transmitted to the resin 9 through the non-repeating portion 33, and the winding portion 30 can be effectively cooled.
[0101] Furthermore, the repeating section 32 is exposed from the resin 9. Therefore, the cooling air supplied toward the winding section 40 can easily reach the repeating section 32, effectively cooling the winding section 30.
[0102] In addition, such as Figure 1 As shown, the housing 8 has a connecting portion 82 that connects the housing 8 from its outer surface to its inner surface in the Y-axis direction. Therefore, when cooling air flows in the Y-axis direction, the cooling air flows through the connecting portion 82 into the inside of the housing 8. As a result, the cooling air can easily reach the winding portion 40 and effectively cool the winding portion 40.
[0103] In addition, such as Figure 6As shown, the connecting portion 82 is located at a position separated from the surface of the resin 9 in the direction of the opening toward the housing 8. Therefore, the cooling air flowing into the inside of the housing 8 through the connecting portion 82 can easily reach the winding portion 40, effectively cooling the winding portion 40.
[0104] In addition, such as Figure 1 As shown, the coil device 1 has a first heat dissipation member 10 with protrusions and depressions 100. Furthermore, the first heat dissipation member 10 is disposed directly or indirectly on the base 50 and the base 60. Therefore, the first heat dissipation member 10 enables heat dissipation from the first core 5a and the second core 6a.
[0105] In addition, such as Figure 6 As shown, at least one of the winding portion 30 and the winding portion 40 has a transformer portion 13 that functions as a transformer and an inductor portion 14 that functions as an inductor. Therefore, both the functions of a transformer and an inductor are provided in a single coil device 1. This contributes to the miniaturization of electronic devices compared to the case where the transformer and inductor are installed separately.
[0106] In addition, such as Figure 9 As shown, the coil device 1 has a third core 7a adjacent to either the first core 5a or the second core 6a (in this embodiment, the second core 6a) along the Y-axis direction, and a second heat dissipation member 11a with protrusions and recesses 113. Furthermore, the third core 7a is disposed in the inductor section 14, and the second heat dissipation member 11a is disposed directly or indirectly on the end face of the third core 7a in the Y-axis direction. Therefore, the second heat dissipation member 11a enables heat dissipation from the third core 7a, which is more difficult to cool than the first core 5a and the second core 6a.
[0107] (Second Implementation)
[0108] Figure 11 The coil device 1A of the second embodiment shown has the same structure as the coil device 1 of the first embodiment, except for the points shown below. The same reference numerals are used for parts that are repeated in the coil device 1 of the first embodiment, and detailed descriptions thereof are omitted.
[0109] like Figure 12 As shown, the coil device 1A has a bobbin 2A. The bobbin 2A is composed of a single bobbin. The bobbin 2A has a structure in which a second bobbin 24 is attached to the first bobbin 20 in the first embodiment, with a protrusion 260 and a hook 261. A pair of protrusions 260 protrude from the wall portion 215 and extend in a direction away from the center of the bobbin 2A. A pair of hooks 261 protrude from the pair of protrusions 260 in a manner that they approach each other.
[0110] like Figure 13As shown, the coil device 1A has first cores 5a to 5b and second cores 6a to 6b. However, unlike the coil device 1 of the first embodiment, it does not have third cores 7a to 7b. In the coil device 1A of this embodiment, the inductor section 14 is omitted from the coil device 1 of the first embodiment. Figure 6 The coil device 1A actually functions as a transformer.
[0111] like Figure 13 As shown, in this embodiment, in the Y-axis direction, the outer leg 51 is also separated from the outer leg 61 by forming a gap 12 between the outer leg 51 and the outer leg 61. Therefore, the same effect as in the first embodiment can be obtained.
[0112] In addition, such as Figure 14 As shown, the housing 8 has a connecting portion 82 that connects the housing 8 from its outer surface to its inner surface in the Y-axis direction. Therefore, when cooling air flows in the Y-axis direction, the cooling air flows through the connecting portion 82 into the inside of the housing 8. As a result, the cooling air can easily reach the winding portion 40 and effectively cool the winding portion 40.
[0113] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the present invention.
[0114] like Figure 5 As shown, in the above embodiments, the winding portion 40 is stacked on the winding portion 30 along the radial direction of the winding portion 30, but the winding portion 40 and the winding portion 30 may also be arranged vertically along the winding axis direction of the winding portion 30.
[0115] Alternatively, a portion of the winding portion 40 (e.g., the lower end) may be disposed inside the resin 9.
[0116] Explanation of reference numerals in the attached figures
[0117] 1. 1A…coil device
[0118] 2, 2A… spool
[0119] 20…First spool
[0120] 210…Main Body
[0121] 211, 212...Flange portion
[0122] 213…Intermediate flange portion
[0123] 214~219…wall section
[0124] 220…protrusion
[0125] 221…Hook section
[0126] 222, 223… guide components
[0127] 224… Through hole
[0128] 24…Second spool
[0129] 250…main body
[0130] 251, 252...Flanges
[0131] 253…Intermediate flange portion
[0132] 254~257…wall section
[0133] 260…protrusion
[0134] 261…Hook
[0135] 265…convex part
[0136] 3…First winding
[0137] 30… Winding section
[0138] 31a, 31b... Introduction
[0139] 32…repeated section
[0140] 33…Non-repeating part
[0141] 4…Second winding
[0142] 40… Winding section
[0143] 41a, 41b... Introduction
[0144] 5a, 5b... First chip
[0145] 50…base
[0146] 51…outer foot
[0147] 52…Midfoot
[0148] 6a, 6b... second core
[0149] 60…base
[0150] 61…outer foot
[0151] 62…Midfoot
[0152] 7a, 7b... Third core
[0153] 70…base
[0154] 71…Outer foot
[0155] 72…Midfoot
[0156] 8…shell
[0157] 80…base plate
[0158] 81a~81d…side plates
[0159] 82…connecting parts
[0160] 9…resin
[0161] 10…First heat dissipation component
[0162] 100…concave-convex
[0163] 11a, 11b... Second heat dissipation components
[0164] 110…base
[0165] 111…Outer foot
[0166] 112…Midfoot
[0167] 113…concave-convex
[0168] 12…gap
[0169] 13…Transformer Department
[0170] 14…Inductor Section
Claims
1. A coil device, wherein a bobbin is provided; a first winding portion is provided on an outer circumferential surface of the bobbin; a second winding portion is provided on an outer circumferential surface of the first winding portion directly or indirectly; a first core and a second core are provided on the bobbin; a housing accommodates at least the bobbin; and a resin is filled in the housing, the first core has a first base portion and a pair of first outer leg portions protruding from the first base portion and facing each other in a first direction perpendicular to an axial direction of the bobbin, the second core has a second base portion and a pair of second outer leg portions protruding from the second base portion and facing each other in the first direction, the first outer leg portions and the second outer leg portions are separated from each other in a second direction perpendicular to the axial direction and the first direction, with a gap formed between the first outer leg portions and the second outer leg portions.
2. The coil device according to claim 1, wherein the first winding portion has a repeated portion overlapping the second winding portion in a radial direction of the first winding portion, and a non-repeated portion not overlapping the second winding portion in the radial direction of the first winding portion, the non-repeated portion is provided inside the resin.
3. The coil device according to claim 2, wherein the repeated portion is exposed from the resin.
4. The coil device according to any one of claims 1 to 3, wherein the housing has a communication portion communicating the housing in the second direction from an outer surface to an inner surface of the housing.
5. The coil device according to claim 4, wherein the communication portion is located at a position separated from a surface of the resin in a direction toward an opening of the housing.
6. The coil device according to any one of claims 1 to 3, wherein a first heat dissipation member having a concave-convex is further provided, the first heat dissipation member is provided directly or indirectly on the first base portion and the second base portion.
7. The coil device according to any one of claims 1 to 3, wherein at least one of the first winding portion and the second winding portion has a transformer portion functioning as a transformer and an inductor portion functioning as an inductor.
8. The coil device according to claim 7, wherein a third core is further provided adjacent to the first core or the second core in the second direction; and a second heat dissipation member having a concave-convex is further provided, the third core is provided on the inductor portion, the second heat dissipation member is provided directly or indirectly on an end surface of the third core in the second direction.
Citation Information
Patent Citations
Magnetic core
JP2012156351A