Coil device

Abstract

The present invention provides a coil device with excellent heat dissipation, the coil device (10) comprising a winding frame (40) on which a coil (20, 30) is mounted, terminals (91, 92) to which lead portions (22a, 32a) of the coils (20, 30) are connected, and a housing (300) for accommodating the winding frame (40). The terminals (91, 92) comprise a housing cross-piece (120) spanning an upper opening edge (330) of the housing (300), and a lower extension piece (130) connected to the housing cross-piece (120) and extending downward from the housing cross-piece (120) on the outside of the housing (300).

Description

Technical Field

[0001] The present invention relates to a coil device which can also be suitably used as, for example, a transformer. Background Art

[0002] As a coil device for a transformer, for example, there is a known coil device as shown in Patent Document 1. The coil device shown in Patent Document 1 has a housing for accommodating a core and a coil wound around the core (mid-leg portion), and the interior of the housing is filled with a heat dissipation resin. The heat of the core and the coil can be dissipated through the heat dissipation resin.

[0003] However, in the case where a large terminal block is provided above the housing as in the coil device shown in Patent Document 1, it is not suitable to use a high housing, and most of the core and coil contained in the housing are sometimes exposed outside the housing. In this case, the upper part of the core that easily becomes high temperature or the coil with high heat generation cannot be fully immersed in the heat dissipation resin, and high heat dissipation performance cannot be obtained.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-036194 Summary of the invention

[0007] Problems to be solved by the invention

[0008] The present invention has been made in view of such actual conditions, and an object of the present invention is to provide a coil device having excellent heat dissipation performance.

[0009] Technical solutions to solve problems

[0010] In order to achieve the above object, the present invention provides a coil device having:

[0011] a winding frame on which the coil is mounted;

[0012] A terminal to which a lead portion of the coil is connected;

[0013] a housing accommodating the winding frame,

[0014] The terminal includes a housing cross-piece that crosses an upper opening edge of the housing, and a downward extending piece that is connected to the housing cross-piece and extends downward from the housing cross-piece on the outer side of the housing.

[0015] In the coil device of the present invention, the terminal has a shell cross-piece spanning the upper opening edge of the shell, and a lower extension piece connected to the shell cross-piece and extending downward from the shell cross-piece on the outside of the shell. Therefore, the terminal extends to the side of the shell (along the extension direction of the shell cross-piece) but not to the top of the shell, and there is no need to provide a terminal seat for fixing the terminal above the shell. Therefore, a high shell can be used to accommodate most of the coil, etc. inside the shell, and by filling the shell with heat dissipation resin, most of the coil, etc. can be immersed in the heat dissipation resin, and the heat of the coil, etc. can be fully dissipated through the heat dissipation resin.

[0016] Furthermore, in the coil device of the present invention, as described above, since it is not necessary to provide the terminal block above the case, the height of the coil device can be suppressed, and the height of the coil device can be reduced.

[0017] In addition, in the coil device of the present invention, since the terminal is provided with a downward extension piece, it is not necessary to lead the terminal to the lower outside of the housing by, for example, providing a cutout at the bottom of the housing. Therefore, when the heat dissipation resin is filled in the housing, the heat dissipation resin will not leak out from the cutout, etc., and a sufficient amount of heat dissipation resin can be filled in the housing, so that the heat of the coil, etc., can be efficiently dissipated through the heat dissipation resin.

[0018] Preferably, the terminal has an outward protruding piece, the outward protruding piece is connected to the downward extending piece and extends in a direction away from the housing. With such a structure, the outward protruding piece can be used as a user terminal.

[0019] Preferably, an insulating protection portion is further provided, at least a portion of which is interposed between the terminal and the housing to insulate the terminal from the housing. By setting such a structure, a short circuit fault between the terminal and the housing can be prevented via the insulating protection portion, while the terminal is led out to the side of the housing.

[0020] Preferably, the insulating protection portion comprises: a housing cross-over portion, which crosses the upper opening edge of the housing; and an outer extension portion, which is connected to the housing cross-over portion and extends along the outer wall surface of the housing. With such a structure, the terminal can be insulated from the upper opening edge of the housing via the housing cross-over portion, and the terminal can be insulated from the outer wall surface of the housing via the outer extension portion.

[0021] Alternatively, the terminal block may further include a terminal holder for fixing the terminal, and the insulating protection portion may be formed integrally with the terminal holder. By setting such a structure, the step of separately installing the insulating protection portion on the housing may be omitted in the manufacturing process of the coil device, and the manufacturing of the coil device becomes easy.

[0022] Preferably, the insulating protection portion is formed integrally with the terminal. For example, the terminal and the insulating protection portion are integrally formed by insert molding, thereby facilitating the manufacture of the coil device.

[0023] Alternatively, the device may further include a terminal seat for fixing the terminal, and the insulating protection portion may be formed separately from the terminal seat. By adopting such a structure, the structure of the terminal seat or the insulating protection portion may be simplified, and the terminal seat or the insulating protection portion may be easily formed.

[0024] Preferably, the terminal block is formed separately from the winding frame. With such a structure, whenever the specification of the terminal block changes, a terminal block corresponding to the specification can be prepared and installed on the winding frame, so that the specification change can be flexibly responded to. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1A It is a perspective view of the coil device according to the first embodiment of the present invention.

[0026] Figure 1B It is a perspective view of a coil device according to a second embodiment of the present invention.

[0027] Figure 2A It is an exploded perspective view of the coil device shown in FIG. 1 .

[0028] Figure 2B is from Figure 2A The coil device shown is an exploded perspective view with the components mounted on the winding frame removed.

[0029] Figure 2C is from Figure 2B The coil device shown is an exploded perspective view with the components mounted on the winding frame removed.

[0030] Figure 2D Yes means Figure 2B A three-dimensional view of the lead wire portion of the outer coil and its surrounding structure shown.

[0031] Figure 2E is from Figure 2A The coil device shown is an exploded perspective view with the lead lead block mounted on the winding frame removed.

[0032] Figure 3 It is along Figure 1A A cross-sectional view of a coil device of III-III wire is shown.

[0033] Figure 4A Yes means Figure 1A A perspective view of the lead wire portion of the outer coil and its surrounding structure in the coil device shown.

[0034] Figure 4B Yes means Figure 1B A perspective view of the lead wire portion of the outer coil and its surrounding structure in the coil device shown.

[0035] Figure 5A Yes means Figure 1A A three-dimensional view of the insulating protection part shown.

[0036] Figure 5B Yes means Figure 1B A three-dimensional view of the insulating protection part shown. DETAILED DESCRIPTION

[0037] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0038] First embodiment

[0039] like Figure 2A and Figure 2C As shown, Figure 1A The coil device 10 of the first embodiment of the present invention shown in the figure has four cores 12, a bobbin 40, a bobbin cover 50, two core covers 60, a lead wire lead-out cover 70, a heat sink 80, an insulating protection portion 100, an insulating plate 200, and a housing 300. In this embodiment, in the figure, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other, the direction perpendicular to the mounting surface of the coil device 10 is the Z-axis, and the direction in which a pair of lead wire lead-out portions 49 formed on the bobbin 40 are located on opposite sides of each other is the X-axis.

[0040] The housing 300 has an outer side surface 310, an inner side surface 320, an upper opening edge 330, a bottom plate 340, and a concave corner portion 350. The concave corner portion 350 is formed at four corners of the housing 300 and is concave toward the inside of the housing 300. Examples of the material constituting the housing 300 include metals with good thermal conductivity such as aluminum, copper, and stainless steel.

[0041] The housing 300 contains the winding frame 40 and the like, and is filled with heat dissipation resin (not shown). Figure 1A As shown, in this embodiment, the height of the housing 300 in the Z-axis direction is such that most of the bobbin 40 and the core 12 are contained inside the housing 300. Among the parts constituting the housing 300, the bottom plate 340 is integrally formed with these parts.

[0042] like Figure 2A to Figure 2C As shown, four cores 12 are assembled to form a magnetic path for passing magnetic flux generated by a coil described later. These cores 12 have symmetrical shapes and sandwich the bobbin cover 50 and the bobbin 40 in the vertical direction (Z-axis direction in the figure) to connect with each other.

[0043] Each core 12 is a core having a substantially E-shaped longitudinal section (including the cut surface of the Y-axis and the Z-axis). Each core 12 is made of a soft magnetic body such as ferrite or a metal magnetic body, and has a flat base 13 extending in the Y-axis direction, a pair of side legs 16, 16 protruding in the Z-axis direction from both ends of each base 13 in the Y-axis direction, and a center leg 14 protruding in the Z-axis direction from the middle position of each base 13 in the Y-axis direction.

[0044] In the present embodiment, the center leg 14 of each core 12 enters the first through hole 44a formed in the first hollow cylinder 44 of the bobbin 40. A gap is formed between the cores 12 and 12 adjacent to each other in the X-axis direction by the separating protrusion 44b formed on the inner peripheral wall of the first hollow cylinder 44. A heat dissipation resin such as a potting resin described later enters the gap, thereby improving the heat dissipation of the heat generated inside the coil device 10.

[0045] The gap formed by the separation convex portion 44b corresponds to the thickness of the separation convex portion 44b in the X-axis direction. The separation convex portion 44b is formed inside the through hole 44a, in the center of the X-axis direction, and on both sides of the Y-axis direction along the Z-axis. The thickness of the separation convex portion 44b in the X-axis direction is not particularly limited, but is preferably 0.05 to 5 mm, and more preferably 0.1 to 3 mm.

[0046] The bobbin 40 has a substantially elliptical flat-plate bobbin base plate 42 at its lower end in the Z-axis direction. Legs 42a are formed at each end of the bobbin base plate 42 in the X-axis direction, and a first hollow cylinder 44 is integrally formed at a substantially central portion of the bobbin base plate 42 so as to extend upward in the Z-axis direction.

[0047] A bobbin upper flange 48 is integrally formed on the Z-axis upper portion of the first hollow cylinder 44 so as to protrude radially from the first hollow cylinder 44 in the Y-X plane. Lead wire lead-out portions 49 are provided at both ends of the bobbin upper flange 48 in the X-axis direction.

[0048] like Figure 2E As shown, the lead lead portion 49 is composed of a lead lead block (terminal base) 490 and a lead lead base 491, and the lead lead block 490 is provided with terminals 91 and 92. The terminals 91 and 92 are fixed (integrated) by being embedded in the lead lead block 490 by insert molding or the like.

[0049] like Figure 4A and Figure 5A As shown, the terminals 91 and 92 have lead connection pieces 91a and 92a. Figure 2CThe lead wire portions 22a, 22a of the inner coil 20 (first winding 22) or the lead wire portions 32a, 32a of the outer coil 30 (second winding 32) are shown. The lead wire connecting pieces 91a, 92a have a substantially C-shape, as shown in FIG. Figure 2E As shown, the lead portions 22a, 22a or the lead portions 32a, 32a led outward in the Y-axis direction are clamped.

[0050] like Figure 4A and Figure 5A As shown in FIG. 1 , the end portions of the lead connecting pieces 91a and 92a in the X-axis direction are integrally connected with the side extension pieces 91b and 92b. When viewed from the lead connecting pieces 91a and 92a, the side extension pieces 91b and 92b extend outward in the Y-axis direction (away from the winding frame 40). Figure 2E As shown, its extension direction is substantially consistent with the extension direction of the lead portions 22a, 22a or the lead portions 32a, 32a.

[0051] like Figure 4A and Figure 5A As shown, the ends of the side extension pieces 91b and 92b on the inner side in the Y-axis direction (the opposite side to the side where the lead connection pieces 91a and 92a are arranged) are integrally connected with the upper extension pieces 91c and 92c. The upper extension pieces 91c and 92c extend upward in the Z-axis direction and extend to Figure 2A That is, a portion of the upper extension pieces 91c and 92c extends upward from the upper opening edge 330, and the upper extension pieces 91c and 92c extend above and below the upper opening edge 330 of the housing 300 along the Z-axis direction.

[0052] The housing cross-pieces 91d and 92d are integrally connected to the upper ends of the upper extension pieces 91c and 92c in the Z-axis direction. The housing cross-pieces 91d and 92d extend toward the center of the winding frame 40 along the X-axis direction. A step corresponding to the height of the upper extension pieces 91c and 92c is formed between the housing cross-pieces 91d and 92d and the side extension pieces 91b and 92b. Figure 3 As shown, the housing cross-pieces 91d and 92d extend across the inside and outside of the housing 300 along the Y-axis direction, and span (across or cross) the upper opening edge 330 of the housing 300, and extend from the outside (inside) toward the inside (outside) of the housing 300 above the upper opening edge 330. The housing cross-pieces 91d and 92d have a flat plate shape parallel to the X-Y plane, but may also have a curved structure, for example.

[0053] like Figure 4A and Figure 5AAs shown in FIG. 1 , the outer ends of the housing cross pieces 91d and 92d in the X-axis direction are integrally connected with the lower extension pieces 91e and 92e. The lower extension pieces 91e and 92e have a flat plate shape parallel to the Y-Z plane and extend downward in the Z-axis direction. The lower extension pieces 91e and 92e have a shape that is longer than the upper extension pieces 91c and 92c in the Z-axis direction, as shown in FIG. Figure 3 As shown, the housing cross pieces 91d and 92d extend downward from the outer side of the housing 300.

[0054] The lower extension pieces 91e and 92e are arranged along Figure 2A The outer side surface 310 of the housing 300 shown is extended and extends along the Z-axis direction across the upper opening edge 330 of the housing 300 .

[0055] like Figure 4A and Figure 5B As shown, the outer protruding pieces 91f and 92f are integrally connected to the lower ends of the lower extension pieces 91e and 92e in the Z-axis direction, that is, the inner sides in the Y-axis direction. The outer protruding pieces 91f and 92f have a flat plate shape parallel to the X-Z plane and extend in the X-axis direction. Figure 3 As shown, the outer protruding pieces 91f and 92f extend in a direction away from the outer side surface 310 of the housing 300. The height of the outer protruding pieces 91f and 92f relative to the bottom plate 340 of the housing 300 is determined by the length of the lower extending pieces 91e and 92e in the Z-axis direction, but the height is not limited to the example shown in the figure and can be lower.

[0056] like Figure 2E As shown, the lead-out seat 491 is formed integrally with the winding frame 40 and is arranged at each end of the winding frame upper flange portion 48 of the winding frame 40 in the X-axis direction. An insulating wall 491e is formed between the lead-out seat 491 and the winding frame upper flange portion 48. The insulating wall 491e has a flat plate shape parallel to the Y-Z plane and abuts against the insulating plate portion 66 of the core cover 60. The position of the upper end of the insulating wall 491e is roughly consistent with the position of the upper end of the insulating plate portion 66. The insulating wall 491e is to Figure 2A When the core 12 shown is mounted on the bobbin 40 , the core 12 and the lead wire portion 32 a of the outer coil 30 are insulated from each other.

[0057] The insulating wall 491e is formed with a fixing recess 491f that is recessed toward the center of the bobbin 40. The fixing recess 491f is disposed between a pair of insulating plate portions 66 of the core cover 60 and is disposed substantially flush with the insulating plate portions 66.

[0058] A base center portion 491a and two base side portions 491b, 491b are formed at each end of the winding frame upper flange portion 48 in the X-axis direction. The base center portion 491a and the base side portion 491b have a shape that extends the winding frame upper flange portion 48 outward in the X-axis direction and have a substantially flat plate shape parallel to the X-Y plane. The base center portion 491a is arranged between the two base side portions 491b, 491b.

[0059] A base lead-out groove 491c is formed between one base side portion 491b and the base center portion 491a. Similarly, a base lead-out groove 491c is formed between another base side portion 491b and the base center portion 491a. The lead portion 32a of the outer coil 30 can be inserted through the base lead-out groove 491c. The base lead-out groove 491c extends along the X-axis direction.

[0060] A side thin plate portion 491d is formed at the outer end of the base side portion 491b in the Y-axis direction. The side thin plate portion 491d extends along the X-axis direction, and the thickness of the side thin plate portion 491d is thinner than the thickness of the base side portion 491b. The groove 490i of the lead lead block 490 described later is engaged with the side thin plate portion 491d.

[0061] The lead block 490 has a function as a terminal seat for fixing the terminals 91 and 92, and is formed separately from the bobbin 40 (lead seat 491). Examples of the material constituting the lead block 490 include resin materials such as PET, PBK, or PPS.

[0062] like Figure 5A As shown, the lead block 490 has a base 490a, and an engaging protrusion 490g is formed substantially at the center of the base 490a in the Y-axis direction. The engaging protrusion 490g protrudes from the inner end of the base 490a in the X-axis direction toward the center of the winding frame 40.

[0063] Two front wall portions 490b, 490b are formed on the inner end surface of the base 490a in the X-axis direction so as to sandwich the engaging protrusion 490g therebetween. One front wall portion 490b is arranged on one side of the base 490a in the Y-axis direction, and the other front wall portion 490b is arranged on the other side of the base 490a in the Y-axis direction. The front wall portion 490b has a wall surface parallel to the Y-Z plane, such as Figure 2E As shown, the front surface of the front wall portion 490b abuts against the insulating wall 491e.

[0064] A fixing convex portion 490h is formed on the inner end surface of the front wall portion 490b. The fixing convex portion 490h is located on the side of the inner end surface of the front wall portion 490b where the engaging convex portion 490g is disposed. The inner end surface of each fixing convex portion 490h formed on each front wall portion 490b abuts against each end of the fixing concave portion 491f formed on the insulating wall 491e of the lead lead seat 491 in the Y-axis direction. Thus, when the lead lead block 490 is mounted on the lead lead seat 491, the lead lead block 490 can be prevented from being misaligned in the Y-axis direction relative to the lead lead seat 491.

[0065] A vertical lead-out groove 490e is formed between the engaging protrusion 490g and one front wall portion 490b. Similarly, a vertical lead-out groove 490e is formed between the engaging protrusion 490g and another front wall portion 490b. The vertical lead-out groove 490e extends in the Z-axis direction, and the lead portion 32a of the outer coil 30 can be inserted along the vertical lead-out groove 490e. The lead portion 32a is led out toward the upper part of the Z-axis direction inside the vertical lead-out groove 490e. That is, the vertical lead-out groove 490e plays the role of a guide groove that guides the lead portion 32a toward the upper part of the Z-axis direction.

[0066] A rear wall portion 490c extending from one side in the Y-axis direction to the other side is formed at the rear end of the base 490a in the X-axis direction. Figure 5A As shown in FIG. 1 , two terminal holes 490j are formed in the rear wall portion 490c at a predetermined interval in the Y-axis direction. The housing cross-pieces 91d and 92d of the terminals 91 and 92 are led out through the terminal holes 490j.

[0067] A horizontal lead-out groove 490f is formed between the rear wall portion 490c and the front wall portion 490b. The horizontal lead-out groove 490f extends toward the outside in the Y-axis direction, and the lead portion 32a of the outer coil 30 can be inserted along the horizontal lead-out groove 490f. In more detail, the lead portion 32a led toward the upper side in the Z-axis direction along the vertical lead-out groove 490e is bent toward the Y-axis direction, and is led toward the outside in the Y-axis direction along the horizontal lead-out groove 490f. That is, the horizontal lead-out groove 490f plays the role of a guide groove that guides the lead portion 32a to the outside in the Y-axis direction.

[0068] A side wall portion 490d is formed at each end of the base 490a in the Y-axis direction. The side wall portion 490d has a wall surface parallel to the XZ plane and extends downward in the Z-axis direction. The terminal hole 490j is connected to the side wall portion 490d, and the side extension pieces 91b and 92b of the terminals 91 and 92 are led out through the terminal hole 490j.

[0069] A groove 490i is formed in the side wall portion 490d. The groove 490i is formed on the inner side of the side wall portion 490d in the Y-axis direction and extends along the X-axis direction. Figure 2E ) is inserted into the groove 490i while sliding, and the groove 490i and the side thin plate portion 491d are engaged. In this way, the lead lead seat 491 can be engaged with the lead lead block 490, and the lead lead block 490 can be fixed to the lead lead seat 491. In addition, the side wall portion 490d can also be made of a resin with a high thermal conductivity than the resin filled in the housing 300 ( Figure 3 In this case, the lead lead block 490 is in contact with the high thermal conductivity resin filled in the housing 300 to dissipate heat.

[0070] The insulating protection part 100 has an inner extension part 110, a housing cross part 120, and an outer extension part 130. The insulating protection part 100 is interposed between the terminals 91, 92 and the housing 300 to insulate the terminals 91, 92 from the housing 300 (see Figure 3 In this embodiment, the insulating protection portion 100 and the lead-out block 490 are formed separately, and are kept in a freely detachable state with respect to the housing 300.

[0071] The insulating protection part 100 is made of an insulating material. As the material constituting the insulating protection part 100, polyimide resin, silicone resin, epoxy resin, acrylic resin, polyetheretherketone resin, polyethersulfone resin, polyacetal resin or aromatic polyamide resin can be used. In addition, resins having heat resistance or elasticity in addition to insulation can also be used.

[0072] The insulating protection part 100 has a thin plate (flat plate) shape and is formed in a substantially C-shape. Figure 1A As shown, the insulating protection part 100 is installed on the housing 300 in a manner spanning the outer side surface 310, the inner side surface 320, and the upper opening edge 330 of the housing 300. The thickness of the insulating protection part 100 is preferably 0.5 to 1.0 mm. Among them, the thickness of the insulating protection part 100 is not limited to the above thickness, and can be appropriately determined within a range that can effectively ensure the insulation between the terminals 91 and 92 arranged on its surface and the housing 300 arranged on its back. The width of the insulating protection part 100 in the Y-axis direction is larger than the interval between the terminals 91 and 92 in the Y-axis direction.

[0073] like Figure 3 and Figure 5AAs shown, the inner extension portion 110 has a flat plate shape parallel to the Y-Z plane and extends along the inner side surface 320 of the housing 300. The inner extension portion 110 abuts against the inner side surface 320 of the housing 300. The length of the inner extension portion 110 in the Z-axis direction is appropriately determined within a range that enables the insulating protection portion 100 to be reliably held (hooked) on the upper opening edge 330 of the housing 300. The inner extension portion 110 is preferably formed on the resin surface ( Figure 3 The double-dotted line portion) is formed in a manner extending toward the lower side.

[0074] The housing cross-section 120 is integrally connected to the upper end of the inner extension portion 110 in the Z-axis direction. The housing cross-section 120 extends in the X-axis direction in a direction away from the winding frame 40 (outside the winding frame 40). The housing cross-section 120 extends in the X-axis direction in a manner spanning the inside and outside of the housing 300, and spans (spans or crosses) the upper opening edge 330 of the housing 300, and at the same time extends from the inside of the housing 300 to the outside on the upper surface of the upper opening edge 330.

[0075] The housing cross-section 120 has a flat plate shape parallel to the X-Y plane and abuts against the upper opening edge 330 of the housing 300. The housing cross-section 120 and the housing cross-section pieces 91d and 92d of the terminals 91 and 92 are opposite. The length of the housing cross-section 120 in the X-axis direction is substantially equal to the length of the upper opening edge 330 of the housing 300 in the X-axis direction. Figure 3 In the illustrated example, a predetermined gap is formed between the case spanning portion 120 and the case spanning pieces 91 d and 92 d of the terminals 91 and 92 , but the case spanning pieces 91 d and 92 d may be in contact with each other.

[0076] The outer extension portion 130 is integrally connected to the outer end of the housing cross-section 120 in the X-axis direction. The outer extension portion 130 has a flat plate shape parallel to the Y-Z plane and extends downward in the Z-axis direction. The outer extension portion 130 abuts against the outer side surface 310 of the housing 300. The outer extension portion 130 has a shape longer than the inner extension portion 110 in the Z-axis direction and extends downward from the housing cross-section 120 along the outer side surface 310 of the housing 300.

[0077] The outer extension portion 130 is opposed to the lower extension pieces 91e and 92e of the terminals 91 and 92. Figure 3 In the illustrated example, a predetermined gap is formed between the outer extending portion 130 and the lower extending pieces 91 e and 92 e , but they may be in contact with each other.

[0078] like Figure 1AAs shown, the lower end of the outer extension 130 in the Z-axis direction is arranged at a position lower than the lower end of the lower extension pieces 91e and 92e in the Z-axis direction of the terminals 91 and 92. Thus, the insulation between the lower extension pieces 91e and 92e and the outer side surface 310 of the housing 300 can be reliably achieved via the outer extension 130.

[0079] In this embodiment, the terminals 91 and 92 are covered by the housing spanning portion 120 and the outer extending portion 130 at the upper portion of the housing 300 exposed from the lead lead portion 49 (lead lead block 490 ), thereby forming an insulating region in this portion.

[0080] like Figure 3 As shown, a first winding portion 45 is formed on the outer periphery of the first hollow cylinder 44 located between the bobbin upper flange portion 48 and the bobbin base plate 42. In the first winding portion 45, a plurality of winding partition flanges 46 that separate the winding winding portions adjacent to each other along the winding axis (Z axis) of the inner coil 20 are formed integrally with the first hollow cylinder 44 at predetermined intervals along the winding axis and approximately parallel to the bobbin base plate 42 (and the bobbin upper flange portion 48). Details of the winding partition flanges 46 and the winding method of the first winding 22 will be described later.

[0081] In this embodiment, the elliptical ring-shaped winding partition flange 46 is formed on a plane substantially parallel to the XY axis so that the winding regions 47 with a predetermined interval are formed along the Z axis direction. Figure 2B The outer periphery of the first hollow cylinder 44 of the substantially elliptical cylinder shape shown. In this embodiment, a plurality of winding bulkhead flanges 46 are formed substantially parallel to each other at predetermined intervals along the Z-axis direction, but the number is not particularly limited. The region where the winding bulkhead flanges 46 are formed is the first winding portion 45.

[0082] The winding area width along the winding axis (Z axis) in each winding area 47 separated by the winding partition flange 46 is set to a width that only one winding wire 22 can enter. That is, the winding area width w1 is preferably d1<w1<(2×d1) relative to the wire diameter d1 of the winding wire 22, and more preferably d1<w1<(1.2×d1). If the winding area width w1 is too wide relative to the wire diameter d1, winding disorder is likely to occur, and the compactness requirement of the coil device is violated.

[0083] In addition, in each winding area 47, the winding area width is preferably the same, but may be slightly different. In addition, the winding area width between the winding frame upper flange portion 48 and the winding adjacent flange 46 at the uppermost position may be larger than the winding area width between the winding adjacent flanges 46. In addition, similarly, the winding area width between the winding frame base plate 42 and the winding adjacent flange 46 at the lowermost position may be larger than the winding area width between the winding adjacent flanges 46. In this embodiment, the predetermined total number of windings wound in each winding area 47 is not particularly limited.

[0084] like Figure 2C As shown, in this embodiment, a positioning protrusion 46d for contacting and positioning with the inner peripheral surface of the bobbin cover 50 is formed in a part of the circumference of any winding partition wall flange 46. In the portion other than the positioning protrusion 46d, a flow gap 46e is formed between the outer peripheral surface of the winding partition wall flange 46 and the inner peripheral surface of the bobbin cover 50, through which a heat dissipating resin can flow.

[0085] Preferably, the positioning protrusion 46d protrudes from the outer peripheral surface of the winding partition flange 46 at a position in contact with the inner side of the split connection portion 53 of the bobbin cover 50. The protruding height (radial height) of the positioning protrusion 46d determines the radial width of the flow gap 46e, and is preferably about 0.5 to 1 mm. This is to facilitate the flow of the heat dissipating resin and to achieve good coupling between the coils 20 and 30.

[0086] A step portion 48a is formed on the upper surface of the winding frame upper flange portion 48, which is lower than other portions along the Z axis. A positioning recess 48b is formed on the step portion 48a, which is recessed toward the center of the winding frame 40. An engaging convex portion 48c is formed inside the positioning recess 48b, which can be engaged with an opening 64b formed on the mounting edge 64 of the winding frame cover 60 described later.

[0087] The bobbin base plate 42 , the first hollow cylinder portion 44 , the bobbin upper flange portion 48 , the lead wire lead-out seat 491 , and the winding partition flange 46 on the bobbin 40 are preferably integrally formed by injection molding or the like.

[0088] like Figure 2B As shown, a first through hole 44 a penetrating in the Z-axis direction is formed inside the first hollow cylinder 44 on the bobbin base plate 42 . Figure 2A The center leg 14 on the core 12 shown enters the first through hole 44a from the top and bottom in the Z-axis direction, and the front end of the center leg 14 is close to (against) the first through hole 44a in the approximate center of the through hole 44a in the Z-axis direction. In addition, in the approximate center of the through hole 44a in the Z-axis direction, the front end of the center leg 14 inserted from the top and bottom in the Z-axis can also form a gap at a predetermined interval without contacting.

[0089] like Figure 2C As shown, the bobbin cover 50 is composed of a pair of half bodies 50a and 50b that can be divided into two in the X-axis direction, and is combined by a split connection portion 53 parallel to the winding axis (Z axis). In the combined state, the second winding portion 55 is formed on the outer periphery of the cover 50. The bobbin cover 50 is wound around the first winding portion 45 (see FIG. 4 ) of the bobbin 40. Figure 3 ) to form the inner coil 20, it is installed on the outer periphery of the winding frame 40 and combined by dividing the connecting part 53.

[0090] The bobbin cover 50 has a second winding portion 55 that covers the inner coil 20 from the outside, and a cover lower flange portion 52 and a cover upper flange portion 58 are formed along the circumferential direction at a predetermined interval in the Z-axis direction on the outer periphery of the second winding portion 55. The lower flange portion 52 and the upper flange portion 58 are arranged parallel to the plane of the X-Y axis and extend parallel to the installation surface.

[0091] Between the lower flange portion 52 and the upper flange portion 58 is a second winding portion 55, in which the second winding wire 32 constituting the outer coil 30, for example, which is a secondary coil, is arranged and wound (or α-wound). Arrangement winding refers to a common winding method of winding the winding wire from one end of the winding shaft toward the other end. α-winding will be described later.

[0092] At the split connection portion 53 of the bobbin cover 50 , the outer connection piece 53 b of the other half 50 b is inserted radially outward of the inner connection piece 53 a of the half 50 a , and the half parts 50 a and 50 b are connected to form the bobbin cover 50 .

[0093] The cover upper flange portion 58 of the connection portion 53a located in the half body 50a is formed with a stepped connection upper flange portion 58a which is higher than other portions along the Z axis. In addition, the cover upper flange portion 58 of the connection portion 53b located in the other half body 50b is formed with a connection upper flange portion 58b which is located below the connection upper flange portion 58a along the Z axis and can be inserted under the connection upper flange portion 58a for connection.

[0094] In addition, a stopper protrusion 58i is formed on the cover upper flange portion 58 of the connection portion 53b located in the other half body 50b, with which the connection front end of the connection upper flange portion 58a can abut. The stopper protrusion 58i protrudes upward along the Z axis relative to the upper surface of most of the cover upper flange portion 58. The protrusion height of the stopper protrusion 58i relative to the upper surface of most of the cover upper flange portion 58 is preferably substantially the same as the protrusion height of the connection upper flange portion 58a along the Z axis. The upper surface of these stopper protrusions 58i and the upper surface of the connection upper flange portion 58a are in contact with the lower surface of the winding frame upper flange portion 48 of the winding frame 40, and an air outlet gap is formed between the upper surface of most of the cover upper flange portion 58 other than the divided connection portion 53 and the lower surface of the winding frame upper flange portion 48.

[0095] The cover upper flange portion 58 on the opposite side of the connecting upper flange portion 58a along the X-axis of the half body 50a is provided with an engaging protrusion 58c protruding from the upper side of the cover upper flange portion 58 along the Z-axis. An engaging surface 58e is formed on the upper surface of the engaging protrusion 58c, and the protruding height of the engaging surface 58e relative to the upper surface of the cover upper flange portion 58 along the Z-axis is the same as the step height of the connecting flange portion 58a. The engaging surface 58e contacts the lower surface of the base central portion 491a and the base side portion 491b of the lead lead-out seat 491. The lower surface of the base central portion 491a and the base side portion 491b is at a height substantially the same as the lower surface of the winding frame upper flange portion 48 along the Z-axis. In addition, the engaging protrusion 58c is formed with cutouts corresponding to the two base lead-out grooves 491c, 491c formed on the lead lead-out seat 491.

[0096] The cover upper flange portion 58 on the other half body 50b, which is on the opposite side of the connecting upper flange portion 58b along the X-axis, is provided with an engaging protrusion 58d protruding upward from the upper surface of the cover upper flange portion 58 along the Z-axis. An engaging surface 58f is formed on the upper surface of the engaging protrusion 58d, and the protruding height of the engaging surface 58f relative to the upper surface of the cover upper flange portion 58 along the Z-axis is the same as the protruding height of the stopper protrusion 58i. The engaging surface 58f contacts the lower surface of the base central portion 491a and the base side portion 491b of the lead wire lead-out seat 491. The lower surface of the base central portion 491a and the base side portion 491b is at a height substantially the same as the lower surface of the winding frame upper flange portion 48 along the Z-axis.

[0097] like Figure 2A and Figure 2B As shown, in the second winding portion 55 (refer to Figure 2C ) is provided with a pair of core covers 60 from both sides in the Y-axis direction. The core cover 60 is made of an insulating member such as a synthetic resin, and has a cover body 62, whose outer peripheral surface is a guide surface for the side legs 16 on the guide core 12, and the outer coil 30 is located on its inner peripheral surface.

[0098] Mounting flanges 64, 64 are integrally formed at both ends of the cover body 62 in the Z-axis direction. A protruding piece 64a protruding toward the center of the winding frame 40 is formed on the mounting flange 64, and an opening 64b is formed inside the protruding piece 64a. The engaging protrusion 48c of the flange portion 48 on the winding frame (see Figure 2C ) is engaged with the opening 64b, and the protruding piece 64a is engaged with the positioning recess 48b (refer to Figure 2C ) combination, whereby the mounting edge 64 engages with the upper surface of the winding frame upper flange portion 48, and the core cover 60 is mounted on the winding frame 40. In addition, although detailed illustration is omitted, the mounting edge 64 on the lower side of the Z axis engages with the lower surface of the winding frame substrate 42.

[0099] The cover body 62 has an inner peripheral surface shape corresponding to the outer peripheral surface shape of the core cover 60, and an insulating plate portion 66 is integrally formed at both ends thereof in the X-axis direction. Figure 1A As shown, the insulating plate portion 66 of the core cover 60 increases the lead portion 32a of the core 12 and the outer coil 30 (see Figure 2B The inner surface of the insulating plate portion 66 (the center side of the coil device 10 ) may be in contact with the core 12 , or may have a shape that matches the outer shape of the core 12 .

[0100] exist Figure 1A In the embodiment shown, the lead wire lead cover 70 is installed to cover the upper and side portions of the lead wire lead block 490. Figure 2B As shown, the lead wire lead cover 70 includes a top plate portion 71 , side wall portions 72 , a rear wall portion 73 , and a recessed portion 74 .

[0101] The top plate portion 71 has a flat plate shape that is long in the Y-axis direction, and a recessed portion 74 is formed at the outer end portion in the X-axis direction. Figure 2E The insulating wall 491e of the lead lead seat 491 shown in FIG. 4 and the rear wall 490c of the lead lead block 490 (see FIG. 4A ). Figure 1A ), protecting the lead-out block 490 from above. The recess 74 is recessed toward the center side of the winding frame 40 and has a predetermined width in the Y-axis direction.

[0102] A side wall portion 72 is formed at each end of the top plate portion 71 in the Y-axis direction. The side wall portion 72 has a flat plate shape parallel to the XZ plane and is substantially square. The side wall portion 72 is disposed on the side of the lead lead block 490 to protect the lead lead block 490 from the side in the Y-axis direction.

[0103] Two rear wall portions 73, 73 are formed at the outer end of the top plate portion 71 in the X-axis direction. The rear wall portion 73 has a flat plate shape parallel to the Y-Z plane and is formed in a substantially square shape. One rear wall portion 73 is arranged on one side of the top plate portion 71 in the Y-axis direction and is connected to the adjacent side wall portion 72. The other rear wall portion 73 is arranged on the other side of the top plate portion 71 in the Y-axis direction and is connected to the adjacent side wall portion 72. The rear wall portion 73 is arranged on the outer side of the lead lead block 490 in the X-axis direction to protect the lead lead block 490 from the rear.

[0104] Figure 2C The first winding 22 shown can be made of a single wire or a twisted wire, preferably an insulated coated wire. The outer diameter d1 of the first winding 22 is not particularly limited, but in the case of a large current, for example, it is preferably The second winding 32 may be the same as the first winding 22 , or may be different.

[0105] In this embodiment, Figure 2C The inner coil 20 formed by the first winding 22 shown constitutes the primary coil of the transformer, and the outer coil 30 formed by the second winding 32 wound around the bobbin cover 50 constitutes the secondary coil. Alternatively, the inner coil 20 may constitute the secondary coil, and the outer coil 30 may constitute the primary coil.

[0106] In this embodiment, the first winding 22 is, for example, wound from the first winding portion 45 (see Figure 3 ) is α-wound in the central part of the Z-axis direction. Therefore, in this embodiment, the wire diameter of the second winding 32 constituting the outer coil 30 is larger than the wire diameter of the first winding 22, but the wire diameter is not particularly limited, and the wire diameters can be the same or different. In addition, the materials of the first winding 22 and the second winding 32 can be the same or different.

[0107] The lead wire portion 22a from the lower winding portion of the first winding wire 22 after α winding is lifted upward in the Z-axis direction and inserted through Figure 2E The lead wire lead-out seat 491 shown in the figure leads to the interior of the base lead-out groove 491 c, and then guides to the vertical lead-out groove 490 e of the lead-out block 490 .

[0108] like Figure 2D As shown, in this embodiment, the insulating plate 200 is mounted on one end side of the winding frame 40 in the X-axis direction so that the lead portion 22a led upward in the Z-axis direction does not contact the outer coil 30. In addition, the insulating plate 200 is not mounted on the other end side of the winding frame 40 in the X-axis direction.

[0109] like Figure 2C and Figure 2DAs shown, the insulating plate 200 has a plate body 210, a plate top plate 220, a plate outer protrusion 230, and a lead passage 240. The plate body 210 has a flat plate shape parallel to the YZ plane, and a plate top plate 220 is formed at its upper end. The plate top plate 220 extends toward the inner side in the X-axis direction and is fixed to the lower surface of the base center portion 491a and the base side portion 491b of the lead lead-out seat 491.

[0110] Two plate outer protrusions 230, 230 are formed on the surface of the plate body 210 and protrude outward in the X-axis direction of the winding frame 40. The two plate outer protrusions 230, 230 are respectively arranged at a predetermined interval along the Y-axis direction and extend along the Z-axis direction. The interval between the two plate outer protrusions 230, 230 is approximately equal to or larger than the diameter of the first winding 22.

[0111] A lead wire passage 240 extending in the Z-axis direction is formed between the two plate outer protrusions 230, 230. The lead wire portion 22a (the lead wire portion 22a from the lower winding portion of the first winding 22) leading upward in the Z-axis direction can be inserted into the lead wire passage 240. Since the lead wire portion 22a is inserted into the lead wire passage 240 and led upward in the Z-axis direction, a short circuit failure between the lead wire portion 22a and the outer coil 30 can be prevented.

[0112] The lead wire portion 22a from the upper winding portion of the first winding 22 after α winding is directly guided to the base lead-out groove 491c of the lead lead-out seat 491 and the vertical lead-out groove 490e of the lead lead-out block 490, inserted into the interior of the horizontal lead-out groove 490f, and led out toward the outside of the Y-axis direction. In addition, a pair of lead wire portions 22a of the inner coil 20 are respectively led out along the horizontal lead-out groove 490f toward the opposite side of the Y-axis direction.

[0113] In contrast, Figure 2B and Figure 2C As shown, in the bobbin cover 50, the second winding 32 constituting the outer coil 30 that becomes the secondary coil is wound in a row on the second winding portion 55. The row winding refers to a winding method in which the winding 32 is sequentially wound from one end toward the other end in the Z-axis direction relative to the outer peripheral surface of the winding portion 55. In the present embodiment, only one layer of row winding is performed. Assuming that two layers are wound in a row, in the case of the row winding, after the first layer is completely wound, the second layer is wound thereon.

[0114] Next, use Figure 2A to Figure 2C , Figure 2E An example of a method for manufacturing the coil device 10 will be described below. In manufacturing the coil device 10, first, the winding frame 40 is prepared. The material of the winding frame 40 is not particularly limited, but the winding frame 40 is formed of an insulating material such as resin.

[0115] Next, the first winding wire 22 is wound around the outer periphery of the first hollow cylinder 44 of the bobbin 40 to form the inner coil 20. The first winding wire 22 for forming the inner coil 20 is not particularly limited, but a litz wire or the like is preferably used.

[0116] Next, the bobbin cover 50 is attached to the bobbin 40 on which the inner coil 20 is formed. The second winding 32 constituting the outer coil 30 is wound around the outer periphery of the second winding portion 55 on the bobbin cover 50 .

[0117] Next, the lead block 490 with the terminals 91 and 92 mounted thereon is slid toward the lead seat 491 , and the side thin plate portion 491 d of the lead seat 491 is engaged with the groove 490 i of the lead block 490 , whereby the lead block 490 is mounted on the lead seat 491 .

[0118] Next, the insulating plate 200 is mounted on one end side of the winding frame 40 in the X-axis direction, and the lead wire portion 22a from the lower winding portion of the inner coil 20 is inserted through the lead wire passage 240 of the insulating plate 200 and led out in the Z-axis direction. Furthermore, the lead wire portion 22a is inserted through a vertical lead-out groove 490e of the lead wire lead-out block 490 and led out in the Z-axis direction, and is inserted through a horizontal lead-out groove 490f and led out to the outside in the Y-axis direction.

[0119] In addition, the lead wire portion 22a from the upper winding portion of the inner coil 20 is directly inserted through the inside of another vertical lead-out groove 490e of the lead lead-out block 490 and led out in the upper direction of the Z axis, and is simultaneously inserted through the inside of another horizontal lead-out groove 490f and led out in the outer direction of the Y axis. In addition, the pair of lead wire portions 32a, 32a of the outer coil 30 are both directly inserted through the inside of each vertical lead-out groove 490e of the lead lead-out block 490 and led out in the upper direction of the Z axis, and are simultaneously inserted through the inside of each horizontal lead-out groove 490f and led out in the outer direction of the Y axis.

[0120] Next, the lead connection pieces 91a and 92a of the terminals 91 and 92 sandwich the pair of lead parts 22a and 22a, respectively, and connect them. Similarly, the lead connection pieces 91a and 92a of the terminals 91 and 92 sandwich the pair of lead parts 32a and 32a, respectively, and connect them.

[0121] Next, the lead wire lead-out cover 70 is mounted on the lead wire lead-out block 490 to cover the lead wire lead-out block 490. After that, the core cover 60 is mounted on both sides of the bobbin cover 50 in the Y-axis direction, and then the core 12 is mounted from the upper and lower directions in the Z-axis direction. That is, the front ends of the middle legs 14, 14 of the core 12 and the front ends of the side legs 16, 16 are brought close to each other. In addition, a gap may be provided between the front ends of the middle legs 14, 14.

[0122] The material of each core 12 may be a soft magnetic material such as metal or ferrite, but is not particularly limited. The core 12 is fixed to the bobbin cover 50 and the bobbin 40 by bonding with an adhesive or winding a strip-shaped member around the outer periphery. A heat sink 80 is mounted above the core 12 in the Z-axis direction.

[0123] Next, the assembly formed by assembling the above-mentioned components is housed in the housing 300 filled with heat dissipation resin. The resin is filled before the coil device 10 is housed in the housing 300. As the housing 300, it is preferable to use a housing having a height such that the inner coil 20 and the outer coil 30 are entirely contained inside. The heat dissipation resin is not particularly limited, but a resin having excellent heat dissipation properties, for example, with a thermal conductivity of 0.5 to 5, preferably 1 to 3 W / m·K, is preferable.

[0124] As resins with excellent heat dissipation, for example, there are silicone resins, polyurethane resins, epoxy resins, etc., but silicone resins (organic silicone resins) and polyurethane resins are preferred. In addition, in order to improve heat dissipation, fillers with high thermal conductivity can also be filled into the resin.

[0125] In addition, the heat dissipating resin of this embodiment preferably has a Shore A hardness of 100 or less, preferably 60 or less. This is to absorb the deformation even if the core 12 is deformed by heat, so that excessive stress is not generated in the core 12. As such a resin, a potting resin is exemplified.

[0126] As for the amount of heat dissipation resin filled inside the shell 300, it is preferred that the inner coil 20 arranged around the winding frame 40 and the outer coil 30 arranged around the winding frame cover 50 are impregnated with the heat dissipation resin as a whole (the upper end portions of the inner coil 20 and the outer coil 30 or the lower surface of the flange portion 48 on the winding frame are impregnated).

[0127] The insulating protection part 100 is pre-installed on each wall surface located on both sides of the housing 300 in the X-axis direction so as to straddle the outer side surface 310, the inner side surface 320 and the upper opening edge 330. In addition, the insulating protection part 100 may be fixed to the housing 300 by adhesive or the like as needed.

[0128] A cooling device such as a cooling pipe or cooling fin may be installed below the housing 300 via a metal plate or the like, or may be directly installed.

[0129] In the present embodiment, after a series of assembly steps, the coil device 10 may be subjected to varnish immersion treatment. The coil device 10 of the present embodiment can be manufactured through the above steps.

[0130] In the coil device 10 of the present embodiment, the terminals 91 and 92 have shell cross-pieces 91d and 92d and downward extension pieces 91e and 92e. Therefore, the terminals 91 and 92 extend to the side of the shell 300 (along the extension direction of the shell cross-pieces 91d and 92d) instead of extending to the top of the shell 300, and there is no need to provide a terminal seat (lead lead block 490) for fixing the terminals 91 and 92 to the top of the shell 300. Therefore, a high shell 300 can be used to accommodate most of the coils 20, 30 and the core 12 inside the shell 300. By filling the shell 300 with heat dissipation resin, most of the coils 20, 30 and the core 12 can be immersed in the heat dissipation resin, and the heat of the coils 20, 30 and the core 12 can be fully dissipated through the heat dissipation resin.

[0131] In addition, in the coil device 10 of the present embodiment, as described above, since the terminal block (lead lead block 490) does not need to be provided above the housing 300, the height of the coil device 10 can be suppressed, and the height of the coil device 10 can be reduced.

[0132] In addition, in the coil device 10 of the present embodiment, since the terminals 91 and 92 are provided with the downward extending pieces 91e and 92e, it is not necessary to lead the terminals 91 and 92 to the lower outside of the housing 300 by providing a cutout or the like, for example, at the lower part of the housing 300. Therefore, when the heat dissipation resin is filled in the housing 300, the heat dissipation resin does not leak out from the cutout or the like, and a sufficient amount of the heat dissipation resin can be filled in the housing 300, so that the heat of the coils 20 and 30 and the core 12 can be efficiently dissipated through the heat dissipation resin.

[0133] In addition, in this embodiment, the terminals 91 and 92 have the outward protruding pieces 91f and 92f. Therefore, the outward protruding pieces 91f and 92f can be used as user terminals.

[0134] In addition, the coil device 10 of the present embodiment includes the insulating protection portion 100 . Therefore, the terminals 91 and 92 can be led out to the side of the housing 300 while preventing a short circuit failure between the terminals 91 and 92 and the housing 300 via the insulating protection portion 100 .

[0135] In addition, in this embodiment, the insulating protection part 100 has the housing cross-section 120 and the outer extension part 130. Therefore, the terminals 91 and 92 can be insulated from the upper opening edge 330 of the housing 300 via the housing cross-section 120, and the terminals 91 and 92 can be insulated from the outer side surface 310 of the housing 300 via the outer extension part 130.

[0136] In addition, in this embodiment, the lead block 490 is provided, and the insulating protection part 100 is formed separately from the lead block 490. Therefore, the structure of the lead block 490 or the insulating protection part 100 can be simplified, and the lead block 490 or the insulating protection part 100 can be easily formed.

[0137] In this embodiment, the lead block 490 is formed separately from the winding frame 40. Therefore, whenever the specification of the lead block 490 changes, the lead block 490 corresponding to the specification can be prepared and installed on the winding frame 40, which can flexibly cope with the specification change.

[0138] Second embodiment

[0139] In addition to the points shown below, Figure 1B and Figure 5B The coil device 10A of the second embodiment shown has the same structure as the coil device 10 of the first embodiment, and exhibits the same operation and effects. Figure 1B and Figure 5B In the following description, the same reference numerals are used to denote the same components as those in the coil device 10 according to the first embodiment, and part of the description thereof will be omitted.

[0140] The coil device 10A of the present embodiment includes an insulating protection portion 100A. Figure 5A and Figure 5B By comparison, it can be seen that the insulating protection part 100A of this embodiment is different from the insulating protection part 100 of the first embodiment in that it is formed integrally with the lead-out block 490. The insulating protection part 100A and the lead-out block 490 are integrally formed by injection molding or the like.

[0141] The insulating protection part 100A has a housing cross-section 120A and an outer extension 130A, and has a substantially L-shaped shape. On the other hand, the insulating protection part 100A does not have a structure corresponding to the inner extension 110 of the first embodiment. In this embodiment, the insulating protection part 100A is integrated with the lead lead block 490, and the rear wall 490c of the lead lead block 490 plays the same role as the above-mentioned inner extension 110.

[0142] The housing cross-section 120A is formed thicker than the housing cross-section 120 of the first embodiment, and the housing cross-section pieces 91d and 92d of the terminals 91 and 92 are accommodated inside. That is, in this embodiment, the housing cross-section pieces 91d and 92d are embedded inside the housing cross-section 120A and are not exposed outside. The inner end of the housing cross-section 120A in the X-axis direction is integrally connected to the upper end of the rear wall 490c of the lead lead-out block 490 in the Z-axis direction. The lower surface of the housing cross-section 120A abuts against the upper opening edge 330 of the housing 300.

[0143] The outer extension portion 130A is formed thicker than the outer extension portion 130A of the first embodiment, and the lower extension pieces 91e and 92e of the terminals 91 and 92 are accommodated inside. That is, in this embodiment, the lower extension pieces 91e and 92e are embedded in the interior of the outer extension portion 130A and are not exposed to the outside. On the outer end surface of the outer extension portion 130A in the X-axis direction, two terminal holes 131 and 131 are formed at a predetermined interval along the Y-axis direction. The outer protruding pieces 91f and 92f of the terminals 91 and 92 are led out through the terminal holes 131 and 131. The inner end surface of the outer extension portion 130A in the X-axis direction abuts against the outer side surface 310 of the housing 300.

[0144] The insulating protection portion 100A is attached to the housing 300 by sandwiching the upper end portion of the housing 300 with the outer extension portion 130A and the rear wall portion 490 c of the lead-out block 490 .

[0145] In this embodiment, the same effect as in the first embodiment can be obtained. Moreover, in this embodiment, the insulating protection portion 100A is formed integrally with the lead wire lead-out block 490. Therefore, in the manufacturing process of the coil device 10A, the process of separately installing the insulating protection portion 100A (as a single body) on the housing 300 can be omitted, and the manufacture of the coil device 10A becomes easy.

[0146] In the present embodiment, the insulating protection portion 100A is formed integrally with the terminals 91 and 92. For example, by integrally forming the terminals 91 and 92 and the insulating protection portion 100A by insert molding or the like, the coil device 10A can be easily manufactured.

[0147] The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the present invention.

[0148] For example, the first winding 22 does not need to be α-winding, but may be arranged winding. Even if it is arranged winding, the effect of the present invention can be expected. Moreover, the specific shape of the winding frame 40 or the specific shape of the core 12 is not limited to the above-mentioned embodiment, and various changes can be made. In addition, the coil device of the present invention can also be used for reactors and the like as a purpose other than transformers.

[0149] In the above-mentioned embodiments, the shape of the insulating protection part 100, 100A may be appropriately changed. Figure 5A In the embodiment, the inner extension portion 100 may be omitted from the insulating protection portion 100 to form the insulating protection portion 100 composed of the housing cross portion 110 and the outer extension portion 130. Figure 5B In the embodiment, the insulating protection portion 100A and the lead wire lead-out block 490 may be separated.

[0150] In the above embodiments, the coil device 10, 10A may include two insulating protection parts 100, 100A, one insulating protection part 100, 100A insulates the terminal 91 from the housing 300, and the other insulating protection part 100, 100A insulates the terminal 92 from the housing 300.

[0151] In this case, the shape of the insulating protection portion 100 , 100A may be substantially identical to the shape of the housing cross-sections 91 d , 92 d and the downward extending sections 91 e , 92 e of the terminals 91 , 92 .

[0152] Description of Reference Numerals

[0153] 10, 10A... coil device

[0154] 12... cores

[0155] 13...base

[0156] 14…Mid-foot

[0157] 16... Side foot

[0158] 20...Inner coil

[0159] 22...First winding (ワイヤ)

[0160] 22a……Lead wire part

[0161] 30...Outer coil

[0162] 32... Second winding

[0163] 32a……lead part

[0164] 40... Winding rack

[0165] 42... Winding frame substrate

[0166] 42a……Feet

[0167] 44……First hollow cylinder

[0168] 44a...first through hole

[0169] 44b: Separation convex portion

[0170] 45...First winding section

[0171] 46...Wrapping the flange of the next wall

[0172] 46d……positioning convex part

[0173] 46e... circulation gap

[0174] 47... Winding area

[0175] 48... Flange on winding frame

[0176] 48a……Steps

[0177] 48b... Positioning recess

[0178] 48c......Engagement convex part

[0179] 49...lead lead-out section

[0180] 490...Lead lead block (terminal block)

[0181] 490a……base

[0182] 490b...front wall

[0183] 490c...Rear wall

[0184] 490d...side wall

[0185] 490e...vertical outlet slot

[0186] 490f...Horizontal lead-out slot

[0187] 490g... snap-fit ​​convex part

[0188] 490h...fixing convex part

[0189] 490i... Groove

[0190] 490j……Terminal hole

[0191] 491...lead lead socket

[0192] 491a……Central part of the base

[0193] 491b……side of base

[0194] 491c……Base lead-out slot

[0195] 491d... side thin plate

[0196] 491e...Insulation wall

[0197] 491f...fixing recess

[0198] 50...Bobbin cover

[0199] 50a, 50b...half body

[0200] 52... flange portion under the hood

[0201] 52a ... support part

[0202] 53...Dividing the connection

[0203] 53a...Inner connecting piece

[0204] 53b...Outer connecting piece

[0205] 55... Second winding section

[0206] 58... flange portion on the cover

[0207] 58a ... connected to the upper flange

[0208] 58b ... Connecting lower flange

[0209] 58c, 58d...engaging part

[0210] 58e, 58f...Interlocking surface

[0211] 58g, 58h... step surface

[0212] 58i……Stop convex part

[0213] 60... Core cover

[0214] 62……Hood body

[0215] 62a……Segment

[0216] 64...Installation edge

[0217] 64a...protruding piece

[0218] 64b... opening

[0219] 66...Insulation board

[0220] 70...Lead lead cover

[0221] 71……Top plate

[0222] 72……Side wall

[0223] 73... Rear wall

[0224] 74…concave

[0225] 80...Heat Radiator

[0226] 91, 92... terminals

[0227] 91a, 92a...lead connection piece

[0228] 91b, 92b...Side extensions

[0229] 91c, 92c...upper extension piece

[0230] 91d, 92d... Shell span piece

[0231] 91e, 92e... lower extension piece

[0232] 91f, 92f...External protrusion

[0233] 100, 100A...Insulation protection part

[0234] 110...Inner extension

[0235] 120, 120A... Shell cross section

[0236] 130, 130A...External extension

[0237] 131……Terminal hole

[0238] 200...Insulation board

[0239] 210……board body

[0240] 220……Top plate

[0241] 230……Outer protrusion of the plate

[0242] 240... Lead Path

[0243] 300……Shell

[0244] 310...Outer side

[0245] 320...Inside

[0246] 330... Upper opening edge

[0247] 340...base plate

[0248] 350...concave corner.

Claims

1. A coil device, comprising: A winding frame capable of mounting the coil; A terminal capable of connecting a lead portion of the coil; A housing capable of accommodating the winding rack; a terminal holder capable of fixing the terminal, The terminal comprises a housing cross-piece spanning the upper opening edge of the housing, a lower extension piece connected to the housing cross-piece and extending downward from the housing cross-piece on the outer side of the housing, and a lead connection piece connected to the lead portion. The lateral extension piece of the terminal is led out through the lateral terminal hole formed in the terminal seat. The lead connection piece is formed on the front end side of the led-out lateral extension piece. The terminal seat is provided with a horizontal lead-out groove through which the lead portion passes, and the side terminal hole is formed below the horizontal lead-out groove. The terminal seat provided with the lead connection piece is arranged inside the upper opening edge of the housing. The housing is filled with heat dissipation resin. Most of the coil and the core are impregnated in the heat dissipation resin.

2. The coil device according to claim 1, characterized in that The terminal has an outer protruding piece, and the outer protruding piece is connected to the lower extending piece and extends in a direction away from the housing.

3. The coil device according to claim 1, characterized in that The invention further comprises an insulating protection part, at least a part of which is interposed between the terminal and the housing to insulate the terminal from the housing.

4. The coil device according to claim 3, characterized in that The insulating protection part has: a shell spanning portion spanning an upper opening edge of the shell; and The outer extension portion is connected to the shell cross portion and extends along the outer wall surface of the shell.

5. The coil device according to claim 3, characterized in that The insulating protection portion is formed integrally with the terminal base.

6. The coil device according to claim 5, characterized in that The insulating protection portion is formed integrally with the terminal.

7. The coil device according to claim 3, characterized in that The insulating protection portion is formed separately from the terminal seat.

8. The coil device according to any one of claims 5 to 7, characterized in that: The terminal seat and the winding frame are formed separately.

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