Coil device

Abstract

The present invention provides a coil device that can be mounted on a circuit board, which includes: a coil provided with a winding portion and a winding lead wire led out from the winding portion; a terminal block provided with an insulating main body portion and a lead held by the main body portion. Additionally, the lead includes: a bottom-side terminal that protrudes from the bottom surface of the main body portion facing the circuit board and can be connected to the circuit board; a side-side terminal that protrudes from the side surface of the main body portion in a direction different from the protruding direction of the bottom-side terminal and is connected to the end of the winding lead wire. The coil device of the present invention can ensure the insulation distance between the end of the coil connected to the side-side terminal and the circuit board.

Description

Technical Field

[0001] The present invention relates to a coil device. Background Art

[0002] Among coil devices such as reactors or transformers, there are coil devices configured to be directly mountable on a circuit board. In such coil devices, leads such as CP wires (copper-clad steel wires) are used as electrical wirings between the coil device and the circuit board.

[0003] Japanese Patent Application Laid-Open No. 2004-79573 (Japanese Published Patent Gazette) discloses a circuit board-mounted coil device (common mode choke coil) having lead terminals implanted in a bobbin. The end of the winding is wound and soldered to the root of the lead terminal. In addition, the front end portion of the lead terminal can be inserted into a through hole of a printed circuit board and soldered to the printed circuit board. Thus, the coil device can be fixed to and electrically connected to the printed circuit board. Summary of the Invention

[0004] In the common mode choke coil described in Japanese Patent Application Laid-Open No. 2004-79573, the lead terminals are implanted in the bottom surface of the bobbin, and the end of the winding is wound around the lead terminal on the bottom surface side of the bobbin. Therefore, when inserting the lead terminals into the through holes of the printed circuit board to mount the coil device on the printed circuit board, the printed circuit board and the end of the winding are disposed close to each other. Thus, there is a possibility that the insulation distance between the printed circuit board and the winding cannot be ensured and leakage occurs in the wiring from the winding to the printed circuit board.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to provide a coil device capable of ensuring the insulation distance between a circuit board and the end of a coil.

[0006] One embodiment of the present invention provides a coil device mountable on a circuit board, including: a coil having a winding portion and a winding lead wire led out from the winding portion; and a terminal block having an insulating main body portion and a lead held by the main body portion. In addition, the lead has: a bottom surface side terminal protruding from the bottom surface of the main body portion facing the circuit board and capable of being connected to the circuit board; and a side surface side terminal protruding from the side surface of the main body portion in a direction different from the protruding direction of the bottom surface side terminal and connected to the end of the winding lead wire.

[0007] In addition, in one embodiment of the present invention, the side surface side terminal may have a folded-back portion folded back to the side surface, and the end of the winding lead wire is held by the folded-back portion.

[0008] In addition, in one embodiment of the present invention, a gap may be provided between the front end of the folded-back portion of the lead wire and the side surface of the main body portion.

[0009] In addition, in one embodiment of the present invention, the winding lead wire may be a coated wire having a core wire mainly composed of aluminum, and at the end of the winding lead wire, the coating of the winding lead wire is peeled off. In this case, the coil device further includes a covering member that covers the end of the winding lead wire.

[0010] In addition, in one embodiment of the present invention, the connection portion between the end of the winding lead wire and the side surface side terminal may be covered by a covering member.

[0011] In addition, in one embodiment of the present invention, at the connection portion, the end of the winding lead wire may be connected to the side surface side terminal by soldering, and the end of the winding lead wire soldered together is covered by a covering member.

[0012] In addition, in one embodiment of the present invention, the end of the winding lead wire may be hooked by the outer peripheral surface of the side surface side terminal and cross the side surface side terminal in a cross shape.

[0013] In addition, in one embodiment of the present invention, the terminal block may have a plurality of lead wires, and the end of the winding lead wire is connected to the plurality of lead wires.

[0014] In addition, in one embodiment of the present invention, the main body portion and the lead wire may be formed integrally, and the lead wire has a bent portion buried inside the main body portion.

[0015] In addition, in one embodiment of the present invention, the direction in which the bottom surface side terminal protrudes from the bottom surface may be orthogonal to the direction in which the side surface side terminal protrudes from the side surface.

[0016] In addition, in one embodiment of the present invention, the winding portion may be located on the side opposite to the protruding direction of the side surface side terminal of the lead wire with respect to the main body portion, and the winding lead wire is routed from the winding portion to the side surface side terminal through the bottom surface side of the main body portion.

[0017] In addition, in one embodiment of the present invention, a groove parallel to the protruding direction may be provided on the bottom surface of the main body portion, and the winding lead wire is routed through the groove.

[0018] In addition, in one embodiment of the present invention, the depth of the groove may be larger than the outer diameter of the winding lead wire.

[0019] In addition, in one embodiment of the present invention, it is also possible that the portion of the winding lead wire passing through the slot is located on the bottom side rather than the side side terminal in the depth direction of the slot, or at the same height as the side side terminal, and the end of the winding lead wire at the connection portion is located on the opposite side of the bottom side with respect to the side side terminal.

[0020] In addition, in one embodiment of the present invention, it is also possible that the side side terminal is bent toward the opposite side of the bottom side.

[0021] In addition, in one embodiment of the present invention, it is also possible that the winding portion is located on the surface opposite to the bottom surface of the main body portion, and the winding lead wire led out from the winding portion is routed from the winding portion to the side side terminal through the opposite side of the bottom surface side of the main body portion.

[0022] In addition, in one embodiment of the present invention, it is also possible that the end of the winding lead wire at the connection portion is located on the bottom side with respect to the side side terminal.

[0023] In addition, in one embodiment of the present invention, it is also possible that the side side terminal is bent toward the bottom side.

[0024] In the structure of the embodiment of the present invention, the lead wire has a bottom side terminal and a side side terminal that protrude from the main body portion of the terminal block in different directions. The bottom side terminal is connected to the circuit board, and the side side terminal is connected to the end of the coil. Therefore, when the coil device is mounted on the circuit board, the side side terminal can be arranged at an interval from the circuit board, and the insulation distance between the end of the coil connected to the side side terminal and the circuit board can be ensured. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 is an external perspective view of the coil device according to the first embodiment of the present invention.

[0026] Figure 2 is an external perspective view of the coil device according to the first embodiment of the present invention.

[0027] Figure 3 is an exploded perspective view of the coil device according to the first embodiment of the present invention.

[0028] Figure 4 is a side view of the vicinity of the lead wire of the coil device according to the first embodiment of the present invention.

[0029] Figure 5 is a side view of the vicinity of the lead wire of the coil device according to the first embodiment of the present invention.

[0030] Figure 6 is a diagram showing another example of the bending manner of the lead wire according to the first embodiment of the present invention.

[0031] Figure 7It is a perspective view of the appearance of the coil device according to the second embodiment of the present invention.

[0032] Figure 8 It is an exploded perspective view of the coil device according to the second embodiment of the present invention.

[0033] Figure 9 It is a side view of the vicinity of the lead of the coil device according to the second embodiment of the present invention.

[0034] Figure 10 It is a side view of the vicinity of the lead of the coil device according to the second embodiment of the present invention. Detailed Embodiments

[0035] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, in the following description, the same or corresponding elements are denoted by the same or similar reference numerals, and repeated descriptions are omitted.

[0036] (First Embodiment)

[0037] Figure 1 and Figure 2 It is a perspective view of the appearance of the coil device 1 according to the first embodiment of the present invention. Figure 1 and Figure 2 They are views of observing the same coil device 1 from different perspectives, respectively. Figure 3 It is an exploded perspective view of the coil device 1. In addition, Figure 3 in, the illustration of the covering member 70 described later is omitted. The coil device 1 of the present embodiment is a circuit board-mounted reactor that can be directly mounted on a circuit board.

[0038] In the following description, the direction from the upper right to the lower left in Figure 1 is defined as the X-axis direction, the direction from the upper left to the lower right is defined as the Y-axis direction, and the direction from the bottom to the top is defined as the Z-axis direction. In addition, for the sake of convenience of explanation, the positive direction of the X-axis is called the front, and the negative direction of the X-axis is called the rear. In addition, the Y-axis direction is called the left-right direction. In addition, the positive direction of the Z-axis is called the upper side, and the negative direction of the Z-axis is called the lower side. In addition, the X-axis direction is the axial direction of the coil 10 described later. In addition, when using the coil device 1, the coil device 1 can be arranged in any direction.

[0039] The coil device 1 includes a coil 10, a bobbin 20, a magnetic core 30, and two terminal seats 40. The coil device 1 is mounted on a circuit board disposed on the lower side (Z-axis negative direction side) of the coil device 1.

[0040] The coil 10 of this embodiment is formed by a coated wire 10A such as an enameled wire obtained by covering the outer peripheral surface of a core wire 10A1 with an insulating coating 10A2. In order to reduce weight and cost, a wire material mainly composed of aluminum is used for the core wire 10A1. The coil 10 includes a winding portion 11 formed by winding the coated wire 10A around a bobbin 20 and winding lead wires 12 led out from the winding portion 11. The winding portion 11 is covered with a protective member 13 having an insulating outer peripheral surface. At the end 12A of each winding lead wire 12, the coating 10A2 on the outer peripheral surface is peeled off. The end 12A of each winding lead wire 12 is connected to a lead 50 described later.

[0041] The coil 10 is wound around the outer peripheral surface of a cylindrical bobbin 20. A (center post) 31A of a magnetic core 30 described later is inserted into the hollow portion 21 of the bobbin 20. The bobbin 20 is formed of an insulating material such as phenolic resin, epoxy resin, unsaturated polyester resin, polyurethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), or PBT (Polybutylene Terephthalate).

[0042] As the material of the magnetic core 30, a magnetic material having a high magnetic permeability is used (for example, a powder compact magnetic core, an amorphous magnetic core, a silicon steel sheet, a nanocrystalline magnetic core, a ferrite magnetic core, etc.). As Figure 3 shown, the magnetic core 30 of this embodiment is formed by combining an E-shaped magnetic core 31 and an I-shaped magnetic core 32. The center post 31A of the magnetic core 31 passes through the hollow portion 21 of the bobbin 20, and the portion other than the center post 31A of the magnetic core 31 and the magnetic core 32 are arranged so as to surround the coil 10. In addition, the magnetic core 30 is not limited to Figure 3 the structure of this embodiment shown. For example, the magnetic core 30 may be formed by combining two E-shaped magnetic cores. Alternatively, depending on the type or use of the coil device 1, etc., the coil device 1 may not be provided with the magnetic core 30.

[0043] Each terminal block 40 (40A, 40B) has a main body portion 41 (41A, 41B) and a plurality of leads 50 (50A, 50B) held by the main body portion 41. Each lead 50 is integrally formed with the main body portion 41 by injection molding. The two terminal blocks 40A and 40B are arranged in the front-rear direction in front of and behind the bobbin 20, respectively.

[0044] As the material of the main body portion 41, an insulating material is used. The material of the main body portion 41 is, for example, phenolic resin, epoxy resin, unsaturated polyester resin, urethane resin, BMC, PPS, or PBT. In this embodiment, in order to reduce the number of parts of the coil device 1, the two main body portions 41A and 41B are integrally formed with the bobbin 20.

[0045] Each lead 50 (50A, 50B) has a core wire made of a metal such as iron wire, steel wire, or copper wire. Tin or an alloy containing tin is plated on the outer peripheral surface of the core wire so that solder containing tin in its composition can easily adhere. Each lead 50 uses, for example, a copper-clad steel wire (CP wire).

[0046] Figure 4 and Figure 5 It is a side view showing the vicinity of the terminal block 40A disposed in the front (positive X-axis direction side) in the coil device 1. Figure 4 It shows the state before the terminal 53A of the lead 50A described later is bent, Figure 5 It shows the state after the terminal 53A is bent.

[0047] Each lead 50A of the terminal block 40A has a bent portion 51A buried in the main body portion 41A and a pair of terminals (bottom surface side terminal 52A, side surface side terminal 53A) protruding from the main body portion 41A. The bent portion 51A is bent 90 degrees so that both ends face downward and forward respectively. The bottom surface side terminal 52A (bottom surface, denoted as "terminal 52A") is one end portion (lower end portion) of the lead 50A protruding downward from the bottom surface 42A of the main body portion 41A. The bottom surface 42A becomes the surface facing the circuit board disposed on the lower side (negative Z-axis direction side) of the main body portion 41A. The side surface side terminal 53A (bottom surface, denoted as "terminal 53A") is the other end portion (front end portion) of the lead 50A protruding forward from the side surface 43A in the front (positive X-axis direction side) of the main body portion 41A. The protruding direction of the terminal 52A is orthogonal to the protruding direction of the terminal 53A.

[0048] Each lead 50B of the terminal block 40B has a bent portion (not shown) buried in the main body portion 41B and a pair of terminals 52B and 53B protruding from the main body portion 41B. The bent portion of the lead 50B is bent 90 degrees so that both ends face downward and rearward respectively. The terminal 52B is one end portion (lower end portion) of the lead 50B protruding downward from the bottom surface 42B on the lower side (negative Z-axis direction side) of the main body portion 41B. The terminal 53B is the other end portion (rear end portion) of the lead 50B protruding rearward from the side surface 43B in the rear (negative X-axis direction side) of the main body portion 41B. The protruding direction of the terminal 52B is orthogonal to the protruding direction of the terminal 53B.

[0049] In the present embodiment, the bottom surface 42A of the main body portion 41A is parallel to the XY plane, and the side surface 43A is parallel to the YZ plane. In addition, the bottom surface 42B of the main body portion 41B is parallel to the XY plane, and the side surface 43B is parallel to the YZ plane.

[0050] Of the pair of terminals 52A and 53A, the terminal 52A on the bottom surface 42A side is inserted into a cutout or a through hole provided in a circuit board (not shown) and soldered thereto. Thus, the coil device 1 is fixed to the circuit board, and each lead 50A is connected to the wiring on the circuit board. Among the leads 50A, the terminal 53A on the side surface 43A side is connected to the end portion 12A of the winding lead-out wire 12.

[0051] A plurality of leads 50A and a plurality of leads 50B are respectively arranged at intervals in the left-right direction (Y-axis direction). In order to hold the plurality of leads 50A and 50B, each main body portion 41A, 41B has a shape that is long in the left-right direction. On the bottom surfaces 42A, 42B of the main body portions 41A, 41B, grooves 44A, 44B extending in the front-rear direction (X-axis direction) are provided between adjacent leads 50A, 50B. The grooves 44A, 44B are formed such that the dimension (width) C1 in the Y-axis direction (see Figure 2 ) and the dimension (depth) C2 in the Z-axis direction (see Figure 4 ) are larger than the outer diameter D of the winding lead-out wire 12.

[0052] In the front terminal block 40A, each winding lead-out wire 12 led out from the winding portion 11 passes through one of the grooves 44A. Then, each winding lead-out wire 12 passing through the groove 44A is led out to the front of the main body portion 41A. At this time, the portion of the winding lead-out wire 12 led out to the front from the groove 44A is disposed below the terminal 53A. In addition, the portion of the winding lead-out wire 12 led out to the front from the groove 44A may be disposed at substantially the same height as the terminal 53A. Then, the winding lead-out wire 12 is bent upward, and then the winding lead-out wire 12 is bent in the left-right direction at a position above the terminal 53A. At this time, when viewed with a line of sight parallel to the Z-axis, the winding lead-out wire 12 intersects the terminal 53A in a cross shape. At least the portion of the winding lead-out wire 12 from the portion intersecting the terminal 53A to the front end is the end portion 12A from which the covering 10A2 is peeled off.

[0053] After the winding lead-out wire 12 is bent and intersects the terminal 53A, as Figure 5 shown, the terminal 53A is folded back rearward in a manner of grasping the end portion 12A of the winding lead-out wire 12. Thus, the winding lead-out wire 12 can be held in a state of being grasped by the terminal 53A. In addition, at the end portion 12A of the winding lead-out wire 12, since the covering 10A2 on the outer peripheral surface is peeled off, the terminal 53A grasps the end portion 12A, so that the lead 50A and the winding lead-out wire 12 (i.e., the coil 10) are conductively connected.

[0054] In addition, in the present embodiment, as Figure 1 and Figure 2As shown, each winding lead wire 12 passes through a slot 44A disposed more outward in the left-right direction than the terminal 53A to which it is connected. Therefore, the two winding lead wires 12 are bent from the outside to the inside at a position above the terminal 53A with their front ends facing each other. However, the present invention is not limited to this structure. As long as the winding lead wire 12 is arranged in a manner that it is held by the terminal 53A. For example, when each winding lead wire 12 passes through a slot 44A near the center in the left-right direction among a plurality of slots 44A, and the connected terminal 53A is arranged more outward than the slot 44A through which the winding lead wire 12 passes, each winding lead wire 12 is bent from the inside to the outside at a position above the terminal 53A. Even in this case, since the winding lead wire 12 and the terminal 53A cross in a cross shape, the terminal 53A is folded back, so that the end portion 12A of the winding lead wire 12 can be held by the terminal 53A.

[0055] In a state where the end portion 12A of the winding lead wire 12 is held by the terminal 53A, the connection portion 60 between the winding lead wire 12 and the terminal 53A is brazed together. When brazing, in a state where the front side (positive X-axis direction side) of the coil device 1 faces vertically downward, the connection portion 60 is immersed in the molten solder. Thereby, at the connection portion 60, the gap between the winding lead wire 12 and the terminal 53A can be filled with solder. In addition, it is also possible that the connection portion 60 is not immersed in the solder, and soldering is performed using a soldering iron.

[0056] After brazing the connection portion 60, it is covered with a covering member 70. The covering member 70 is closely attached to the winding lead wire 12 in a manner that at least covers the entire end portion 12A of the winding lead wire 12. The covering member 70 is applied to the connection portion 60 in a liquid state, for example, and then a material for curing (so-called adhesive) is used. Thereby, the covering member 70 can be closely attached to the connection portion 60.

[0057] The covering member 70 is provided to prevent electrolytic corrosion from occurring at a portion where the covering 10A2 of the coated wire 10A is peeled off when current flows through the coil 10. It is considered that electrolytic corrosion is caused by energization in a state where moisture adheres to the conductor. Therefore, it is desirable that the material of the covering member 70 has insulation and waterproof properties. In addition, it is desirable that the material of the covering member 70 is a material with less deterioration due to heat. Thereby, it is possible to prevent cracks (cracks) from occurring in the covering member 70 due to the heat generated when current flows through the coil 10, and to prevent electrolytic corrosion from being caused by moisture entering the cracks. The covering member 70 can be made of, for example, epoxy resin, silicone resin, urethane resin, etc.

[0058] In addition, it is desirable that the covering member 70 covers not only the end portion 12A of the winding lead wire 12 but also the portion of the terminal 53A that holds the end portion 12A. Thereby, it is possible to prevent leakage current from occurring due to contact between the terminal 53A and external components. Further, the terminal 53A is disposed between the left and right ends of the main body portion 41A in the lateral direction. In addition, when the coil device 1 is mounted on the circuit board, the main body portion 41A is disposed behind the terminal 53A, and the circuit board is disposed below the terminal 53A. Therefore, it is difficult for external components to come into contact with the terminal 53A from the left and right directions, the rear, and the bottom. Accordingly, the covering member 70 may not cover the terminal 53A on the left and right, rear, and bottom sides.

[0059] According to the present embodiment, the pair of terminals 52A and 53A of the lead wire 50A project in different directions (downward and forward) from the main body portion 41A. Therefore, a structure can be achieved in which the terminal 53A in the front does not interfere with the circuit board, and the terminal 52A below is connected to the circuit board. Thereby, the insulation distance between the end portion 12A of the winding lead wire 12 held by the terminal 53A and the circuit board can be ensured, and leakage current from the coil 10 to the circuit board can be prevented. Further, in the present embodiment, since the terminal 53A projects forward in parallel with the circuit board, the insulation distance between the end portion 12A of the winding lead wire 12 held by the terminal 53A and the circuit board can be more reliably ensured regardless of the length of the terminal 53A in the front-rear direction.

[0060] In addition, according to the present embodiment, the pair of terminals 52A and 53A of the lead wire 50A project from surfaces (bottom surface 42A and side surface 43A) of the main body portion 41A in different directions from each other. Therefore, when the main body portion 41A is disposed with the bottom surface 42A facing the circuit board in order to mount the coil device 1 on the circuit board, the side surface 43A is disposed at an interval from the circuit board. Accordingly, the terminal 53A projecting from the side surface 43A can be disposed at an interval from the circuit board. Thereby, the insulation distance between the end portion 12A of the winding lead wire 12 held by the terminal 53A and the circuit board can be more reliably ensured.

[0061] In addition, in the present embodiment, since the terminal 53A of the lead wire 50A projects from the front side surface 43A of the main body portion 41A, the size of the terminal block 40A in the up-down direction (Z-axis direction) can be reduced, and the coil device 1 can be easily made thinner. Further, the side surface 43A may not be parallel to the YZ plane. The side surface 43A may be provided as long as the terminal 53A can project forward, and may be inclined from the YZ plane in the Y-axis direction or the Z-axis direction.

[0062] In addition, in the present embodiment, the lead wire 50A has a bent portion 51A embedded inside the main body portion 41A. With this structure, it is possible to prevent the lead wire 50A from coming off the main body portion 41A. In addition, the bending angle of the bent portion 51A is not limited to 90 degrees. The bent portion 51A only needs to be bent in such a way that the terminal 52A protrudes from the bottom surface 42A and the terminal 53A protrudes from the side surface 43A. When the bending angle of the bent portion 51A is less than 90 degrees, the protruding angle and length of the terminal 53A are adjusted so that the terminal 53A does not interfere with the circuit board when the coil device 1 is mounted on the circuit board.

[0063] In addition, in the present embodiment, each winding lead wire 12 is held by two lead wires 50A. As a result, the number of lead wires 50A through which current flows increases and the contact area between the winding lead wire 12 and the lead wire 50A becomes larger, so a larger current can flow through the coil 10. In addition, the number of lead wires 50A holding each winding lead wire 12 is not limited to two. For example, the winding lead wire 12 can be held by one lead wire 50A, or can be held by three or more lead wires 50A. By holding the winding lead wire 12 with multiple lead wires 50A, the winding lead wire 12 can be held more stably.

[0064] In addition, in the present embodiment, a gap G with a specified interval is provided between the side surface 43A of the main body portion 41A and the front end of the bent terminal 53A. By providing this gap G, the end portion 12A of the winding lead wire 12 is arranged at a position spaced apart from the side surface 43A of the main body portion 41. As a result, when the connection portion 60 is immersed in solder, a gap can be ensured between the side surface 43A of the main body portion 41A and the liquid surface of the molten solder. Since the main body portion 41A uses a resin material, a gap can be ensured between the main body portion 41A and the liquid surface of the solder, so that the main body portion 41A can be prevented from melting due to the heat of the solder.

[0065] In addition, in the present embodiment, since the entire connection portion 60 can be immersed in solder without bringing the main body portion 41A into contact with the solder, the lead wire 50A and the winding lead wire 12 of the connection portion 60 can be reliably connected together using solder.

[0066] In addition, in the present embodiment, since the end portion 12A of the winding lead wire 12 is held at a position spaced apart from the side surface 43A of the main body portion 41, even when the end portion 12A of the winding lead wire 12 is connected to the terminal 53A by soldering or welding using a soldering iron, the main body portion 41A can be prevented from melting due to the heat generated by the soldering iron or welding.

[0067] In addition, in the present embodiment, the terminal 53A of the lead wire 50A is bent such that the length L in the X-axis direction of the folded portion 53A1 is the same as or longer than the outer diameter D of the winding lead wire 12. As a result, the contact area between the winding lead wire 12 and the lead wire 50A becomes larger, and the winding lead wire 12 can be firmly held. In addition, since this contact area becomes larger, the contact resistance between the winding lead wire 12 and the lead wire 50A becomes smaller, and the current that can flow through the winding lead wire 12 (i.e., the coil 10) can be increased.

[0068] In addition, the gap G between the side surface 43A of the main body portion 41A and the front end of the terminal 53A is set such that, for example, it is equal to or greater than the outer diameter D of the winding lead wire 12 (when the coil 10 is formed of the coated wire 10A having a diameter of 3.2 mm, the outer diameter D is 3.2 mm or more). As a result, the terminal 53A of the lead wire 50 can be folded back without interfering with the side surface 43A. In addition, the solder attached to the connection portion 60 is less likely to contact the main body portion 41A through the terminal 53A, and melting of the main body portion 41A can be prevented.

[0069] In addition, in the present embodiment, as Figure 4 , Figure 5 shown, the terminal 53A of the lead wire 50A is bent upward (i.e., bent to the side opposite to the bottom surface 42A side). With this structure, when the coil device 1 is mounted on the circuit board such that the bottom surface 42 faces the circuit board, interference between the terminal 53A of the lead wire 50A and the circuit board can be prevented. In addition, with this structure, the terminal 53A of the lead wire 50A can protrude forward from a lower position of the main body portion 41A. As a result, the size of the main body portion 41A in the up-down direction (Z-axis direction) can be reduced, and the entire coil device 1 can be made thinner. In addition, with the structure in which the terminal 53A is bent upward, the insulation distance between the terminal 53A and the circuit board can be ensured.

[0070] In addition, in the present embodiment, in the core wire 10A1 of the coated wire 10A forming the coil 10, a material mainly composed of aluminum is used instead of a material mainly composed of copper. Since aluminum is a material cheaper than copper, according to the present embodiment, the coil device 1 can be manufactured relatively inexpensively. In addition, aluminum is lighter than copper, and thus, by using the core wire 10A1 mainly composed of aluminum, the coil device 1 can be made lighter.

[0071] In addition, in existing coil devices, there are two methods of connecting one terminal to a circuit board and connecting one terminal to the lead-out wire of the coil winding. Since the shape of the terminal needs to be maintained as a rod shape to be inserted into the through-hole of the circuit board, in existing coil devices, in order to connect the terminal and the coil, the coil needs to be wound around the terminal. In contrast, in the present embodiment, the terminal 52A on the bottom surface side connected to the circuit board and the terminal 53A on the side surface side connected to the end portion 12A of the winding lead-out wire 12 are provided separately. Therefore, it is not necessary to wind the winding lead-out wire 12 around the terminal 52A of the lead 50, and the terminal 53A with higher rigidity than the winding lead-out wire 12 is folded back and grasps the winding lead-out wire 12, so that the terminal 53A and the coil 10 can be more reliably connected with less man-hours. In addition, the shape of the winding lead-out wire 12 at the connection portion 60 becomes simple, and the operation of covering the end portion 12A of the winding lead-out wire 12 from which the covering 10A2 has been peeled off with the covering member 70 becomes easy.

[0072] In addition, in the present embodiment, the terminal 53A of the lead 50A is provided on the opposite side of the winding portion 11 with respect to the terminal block 40A. With this structure, when the operator performs the operation of connecting the winding lead-out wire 12 to the terminal 53A, it is possible to prevent the winding portion 11 from interfering with the operation, and the workability when manufacturing the coil device 1 is improved. In addition, the winding lead-out wire 12 is routed from the winding portion 11 to the terminal 53A through the lower side (bottom surface 42A side) of the terminal block 40A. With this structure, it is possible to prevent the winding lead-out wire 12 from interfering with the magnetic core 30. In addition, with this structure, when the coil device 1 is mounted on the circuit board, the winding lead-out wire 12 is disposed in the region sandwiched between the terminal block 40A and the circuit board. Therefore, it is possible to prevent the covering 10A2 of the winding lead-out wire 12 from being peeled off due to contact between the winding lead-out wire 12 and external components, resulting in leakage.

[0073] In addition, in the present embodiment, the winding lead-out wire 12 passes through the groove 44A of the terminal block 40A. Therefore, the groove 44A serves as a guide for the winding lead-out wire 12, and the routing operation of the winding lead-out wire 12 becomes easy. In addition, the winding lead-out wire 12 disposed in the groove 44A is protected by the terminal block 40A. Therefore, it is possible to more reliably prevent the winding lead-out wire 12 from contacting external components.

[0074] In addition, in the present embodiment, when the winding lead wire 12 passing through the slot 44A is bent upward in front of the terminal block 40A, a force is applied upward. By using this upward force, the winding lead wire 12 is stretched upward in the slot 44A, and the winding lead wire 12 is arranged so as to be close to the bottom of the slot 44A. Since the vertical dimension C2 (depth) of the slot 44A is larger than the outer diameter D of the winding lead wire 12, a gap is provided between the upwardly stretched winding lead wire 12 and the bottom surface 42A of the terminal block 40A. When the coil device 1 is mounted on the circuit board in this state, a gap is provided between the winding lead wire 12 arranged close to the bottom of the slot 44A and the circuit board, and the insulation distance between the winding lead wire 12 and the circuit board can be ensured.

[0075] In addition, in the present embodiment, the winding lead wire 12 is hooked by the outer peripheral surface of the terminal 53A of the lead wire 50A. Thereby, the winding lead wire 12 can be stably held, and thus the connection operation between the winding lead wire 12 and the lead wire 50A becomes easy.

[0076] In addition, in the present embodiment, the winding lead wire 12 is bent in the left-right direction while being hooked by the lead wire 50A, whereby the end portion 12A of the winding lead wire 12 crosses the terminal 53A of the lead wire 50A in a cross shape. Therefore, the lead wire 50A can be held by the folded-back terminal 53A.

[0077] In addition, Figure 5 In the structure shown, the terminal 53A of the lead wire 50A is bent in a U shape, but the structure of the present embodiment is not limited thereto. Figure 6 Another example of the bending method of the terminal 53A of the lead wire 50A is shown. As Figure 6 shown, the terminal 53A of the lead wire 50A may also be bent in a manner of winding around the winding lead wire 12 (i.e., at an angle of 180° or more). Thereby, the winding lead wire 12 can be held more stably, and the winding lead wire 12 and the lead wire 50A can be conductively connected more reliably.

[0078] In addition, in the present embodiment, as long as the winding lead wire 12 and the lead wire 50A are conductively connected, the connection method is not limited to soldering. For example, the winding lead wire 12 and the lead wire 50A may be welded while the lead wire 50A holds the winding lead wire 12.

[0079] (Second Embodiment)

[0080] Next, the coil device of the second embodiment of the present invention will be described. Figure 7 is an external perspective view of the coil device 101 of the second embodiment of the present invention. Figure 8 is an exploded perspective view of the coil device 101. In addition, Figure 8 in, the illustration of the covering member 170 described later is omitted.

[0081] The coil device 101 of the second embodiment includes a coil 110, a bobbin 120, a magnetic core 130, and two terminal seats 140 (140A, 140B). The direction of the axis of the coil of the coil device 101 of the second embodiment is different from that of the coil device 1 of the first embodiment.

[0082] The coil 110 is formed of the same coated wire 10A as the coil 10 of the first embodiment. The coil 110 has a winding portion 111 disposed with its axis oriented in the vertical direction (Z-axis direction), and two winding lead wires 112 led out from both ends of the winding portion 111. The outer peripheral surface of the winding portion 111 is covered with an insulating protective member 113. In addition, in the present embodiment, the winding lead wires 112 are led out from the upper part of the winding portion 111.

[0083] The bobbin 120 is cylindrical. The coil 110 is wound around the outer peripheral surface of the bobbin 120. The hollow portion 121 of the bobbin 120 penetrates in the vertical direction. A part of the magnetic core 130 is inserted into the hollow portion 121.

[0084] The magnetic core 130 is formed by combining an E-shaped magnetic core 131 and an I-shaped magnetic core 132. The central column 131A of the magnetic core 131 is disposed so as to pass through the hollow portion 121 of the bobbin 120, and the portion other than the central column 131A of the magnetic core 131 and the magnetic core 132 are disposed so as to surround the coil 110.

[0085] Each terminal seat 140 (140A, 140B) has a resin main body portion 141 (141A, 141B) and a plurality of lead wires 150 (150A, 150B). Each lead wire 150 is integrally formed with the main body portion 141 by injection molding. The two terminal seats 140A and 140B are respectively disposed in front of and behind the bobbin 120 in the front-rear direction (X-axis direction). In addition, in the present embodiment, the terminal seats 140A and 140B are integrally formed with the bobbin 120.

[0086] Figure 9 A side view showing the vicinity of the terminal seat 140A disposed on the front side (positive X-axis side) in the coil device 101. Figure 9 Showing the state before the terminal 153A of the lead wire 150A is bent, Figure 10 Showing the state after the terminal 153A of the lead wire 150A is bent.

[0087] Each lead wire 150A of the terminal block 140A has a bent portion 151A buried in the main body portion 141 and a pair of terminals (bottom-side terminal 152A, side-side terminal 153A) protruding from the main body portion 141A. The bent portion 151A is bent 90 degrees so that both ends face downward and forward, respectively. The bottom-side terminal 152A (bottom surface, denoted as "terminal 152A") is one end portion (lower end portion) of the lead wire 150A protruding downward from the bottom surface 142A on the lower side (negative Z-axis direction side) of the main body portion 141A. The side-side terminal 153A (bottom surface, denoted as "terminal 153A") is the other end portion (front end portion) of the lead wire 150A protruding forward from the side surface 143A on the front side (positive X-axis direction side) of the main body portion 141A.

[0088] The lead-out wires 112 of each winding of the coil 110 are led out from the upper part of the winding portion 111 and stretched downward. Then, the end portion 112A of the lead-out wire 112 is hooked by the terminal 153A and bent in the left-right direction. Thus, the end portion 112A of the lead-out wire 112 and the terminal 153A cross in a cross shape. In this state, the terminal 153A is folded back rearward in a manner of gripping the end portion 112A of the lead-out wire 112. Thus, the end portion 112A of the lead-out wire 112 can be held in a state of being gripped by the terminal 153A.

[0089] In a state where the end portion 112A of the lead-out wire 112 is gripped by the terminal 153A, the connection portion 160 between the end portion 112A and the terminal 153A is brazed together. Further, after brazing the connection portion 160, the connection portion 160 is covered with a covering member 170. The covering member 170 is in close contact with the lead-out wire 112 in a manner of covering at least the entire portion where the covering 10A2 of the covered wire 10A is peeled off (that is, the end portion 112A of the lead-out wire 112).

[0090] In the present embodiment, the bending direction of the terminal 153A is different from the bending direction of the terminal 53A in the first embodiment. In the present embodiment, the end portion 112A of the lead-out wire 112 is arranged below the terminal 153A in a manner of crossing the terminal 153A. Therefore, in order to grip the end portion 112A of the lead-out wire 112, the terminal 153A is bent downward (that is, toward the bottom surface 142A) and then folded back rearward.

[0091] In this embodiment, the coil 110 is arranged to be placed on the upper surface of the terminal block 140. Therefore, the winding lead wire 112 is led out from the upper part of the winding portion 111, so that interference between the winding lead wire 112 and the terminal block 140 can be prevented. In addition, when the winding lead wire 112 is led out from the lower part of the winding portion 111, since the distance from the winding portion 111 to the terminal 153A is short, the length of the winding lead wire 112 becomes short, and it may be difficult to route the winding lead wire 112. However, in this embodiment, since the winding lead wire 112 is led out from the upper part of the winding portion 111, the length of the winding lead wire 112 can be ensured, and the routing of the winding lead wire 112 becomes easy.

[0092] The above is the description of the exemplary embodiments of the present invention. The embodiments of the present invention are not limited to the above description, and various modifications can be made within the scope of the technical idea of the present invention. For example, a structure in which the embodiments explicitly exemplified in the specification or self-evident embodiments are appropriately combined is also included in the embodiments of the present invention.

[0093] (Variant example)

[0094] For example, in the above embodiment, the coil devices 1 and 101 are described as reactors, but the coil devices in the embodiments of the present invention are not limited to reactors. The coil device may also be a device having a coil such as a transformer or a choke coil, for example.

[0095] In addition, in the above first and second embodiments, both of the two winding lead wires 12 and 112 are respectively connected to the lead wires 50A and 150A of the front terminal blocks 40A and 140A, but the embodiments of the present invention are not limited to this structure. Depending on the coil devices 1 and 101 or the wiring of the circuit board on which the coil devices 1 and 101 are mounted, etc., it can be changed which of the front and rear lead wires 50 and 150 each winding lead wire 12 and 112 is connected to.

[0096] For example, in the first embodiment, the two winding lead wires 12 are led out from the front lower end of the winding portion 11. However, depending on the structure of the coil 10, sometimes one winding lead wire 12 is led out from the front lower end of the winding portion 11, and the other is led out from the rear lower end of the winding portion 11. In this case, one winding lead wire 12 is connected to the front lead wire 50A, and the other winding lead wire 12 is connected to the rear lead wire 50B, so that the routing distance of the winding lead wire 12 can be shortened.

[0097] In addition, when the coil devices 1 and 101 have multiple coils, the number of winding lead-out wires increases as the number of coils increases. In this case, when all the winding lead-out wires are connected to any one of the front and rear lead wires 50 and 150, the winding lead-out wires may interfere with each other. Therefore, when the coil devices 1 and 101 have multiple coils, the multiple winding lead-out wires are divided into the winding lead-out wires led out forward and the winding lead-out wires led out backward, so as to prevent the winding lead-out wires from interfering with each other.

[0098] In addition, in the above-described embodiments, the coil devices 1 and 101 are provided with the lead wires 50A and 150A having terminals protruding forward and the lead wires 50B and 150B having terminals protruding backward, but the embodiments of the present invention are not limited to this structure. For example, in the above-described first and second embodiments, the winding lead-out wires 12 and 112 are respectively connected to the front lead wires 50A and 150A, so the rear lead wires 50B and 150B may not have terminals protruding backward. Alternatively, the coil devices 1 and 101 may not have the rear lead wires 50B and 150B. In addition, all the lead wires 50A and 150A provided in the front terminal blocks 40A and 140A may not have the terminals 53A and 153A protruding forward. Only the lead wires 50A and 150A connected to the winding lead-out wires 12 and 112 may have the terminals 53A and 153A, and the other lead wires 50A and 150A may only have the terminals 52A and 152A connected to the circuit board.

[0099] In addition, the terminal 53A of the lead wire 50A in the first embodiment is bent upward, and the terminal 153A of the lead wire 150A in the second embodiment is bent downward, but the embodiments of the present invention are not limited to this structure. For example, the terminals 53A and 153A may be bent in the left and right directions. In this structure, the winding lead-out wires 12 and 112 can also be held by the terminals 53A and 153A.

[0100] In addition, the coil devices 1 and 101 may be provided with lead wires having terminals protruding in the left and right directions from the main body portions 41 and 141.

Claims

1. A coil device capable of being installed on a circuit board, characterized in that, Comprising: A coil having a winding portion and winding leads extending from the winding portion; And A terminal block having an insulating main body portion and a plurality of leads held by the main body portion, The plurality of leads include: A plurality of bottom-side terminals protruding from the bottom surface of the main body portion opposite to the circuit board and capable of being connected to the circuit board; And A plurality of side-side terminals protruding from the side surface of the main body portion in a direction different from the protruding direction of the bottom-side terminals and connected to the ends of the winding leads, The plurality of side-side terminals have a folded-back portion that folds back toward the side surface, In such a manner that the ends of the winding leads cross each of the plurality of side-side terminals in a cross shape while being hooked by the outer peripheral surfaces of the plurality of side-side terminals, the ends of the winding leads are held by the folded-back portions of the plurality of side-side terminals, whereby the ends of the winding leads are connected to the plurality of leads.

2. The coil device according to claim 1, wherein: A gap is provided between the front end of the folded-back portion of the lead and the side surface of the main body portion.

3. The coil device according to claim 1, wherein: The winding lead is a coated wire having a core wire mainly composed of aluminum, At the end of the winding lead, the coating of the winding lead is peeled off, The coil device further includes a covering member covering the end of the winding lead.

4. The coil device according to claim 3, wherein: The connection portions of the ends of the winding leads and the plurality of side-side terminals are covered by the covering member.

5. The coil device according to claim 4, wherein: At the connection portions, the ends of the winding leads are connected to the plurality of side-side terminals by soldering, The ends of the winding leads being soldered are covered by the covering member.

6. The coil device according to claim 1, wherein: The main body portion and the plurality of leads are integrally formed, The plurality of leads have bent portions buried inside the main body portion.

7. The coil device according to claim 1, wherein: The direction in which the plurality of bottom-side terminals protrude from the bottom surface is orthogonal to the direction in which the plurality of side-side terminals protrude from the side surface.

8. The coil device according to any one of claims 1 to 7, wherein: The winding portion is located on the side opposite to the protruding direction of the side-side terminals of the plurality of leads with respect to the main body portion, The winding leads are routed from the winding portion to the plurality of side-side terminals through the bottom surface side of the main body portion.

9. The coil device according to claim 8, wherein: A groove parallel to the protruding direction is provided on the bottom surface of the main body portion, The winding leads are routed through the groove.

10. The coil device according to claim 9, wherein: The depth of the groove is greater than the outer diameter of the winding lead.

11. The coil device according to claim 9, wherein: The portion of the winding lead wire passing through the slot is located closer to the bottom surface side than the plurality of side surface side terminals in the depth direction of the slot, or is located at the same height as the side surface side terminals. The end portion of the winding lead wire at the connection portion of the end portion of the winding lead wire and the plurality of side surface side terminals is located on the opposite side of the bottom surface side with respect to the plurality of side surface side terminals.

12. The coil device according to claim 10, wherein: The plurality of side surface side terminals are bent toward the opposite side of the bottom surface side.

13. The coil device according to any one of claims 1 to 7, wherein: The winding portion is located on the surface opposite to the bottom surface of the main body portion. The winding lead wire led out from the winding portion is routed from the winding portion to the plurality of side surface side terminals through the opposite side of the bottom surface side of the main body portion.

14. The coil device according to claim 13, wherein: The end portion of the winding lead wire at the connection portion of the end portion of the winding lead wire and the plurality of side surface side terminals is located on the bottom surface side with respect to the plurality of side surface side terminals.

15. The coil device according to claim 14, wherein: The plurality of side surface side terminals are bent toward the bottom surface side.

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