Coil device

Abstract

The present invention provides a coil device with good insulation between terminals and easy space saving. The coil device (10) comprises: a bobbin (20) for winding a first wire (37) constituting a first coil part (35) and a second wire (38) constituting a second coil part (36); a terminal block (80) to which a pair of first lead parts (37a, 37b) of the first wire (37) and a pair of second lead parts (38a, 38b) of the second wire (38) are drawn. A fixing part (64α, 64β) of the fixed terminal (60a-60d) is formed by insert molding in the terminal block (80). Each terminal (60a-60d) comprises: an external connection part (69) protruding from the terminal block (80) in the X-axis; and a wire connection part (68α, 68β) protruding from the terminal block (80) along the X-axis and integrally formed with the external connection part (69), respectively clamping the lead parts (37a, 37b, 38a, 38b) and connecting them.

Description

Technical Field

[0001] The present invention relates to a coil device suitable for use as a transformer or the like. Background Art

[0002] Patent Document 1 discloses a coil device having a terminal block with a pair of lead wires from which a conducting wire is drawn. However, conventional coil devices have the following problems: it is difficult to arrange a plurality of terminals in close proximity in an insulated state, and it is difficult to achieve space saving in order to ensure insulation.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2015-65431 Summary of the invention

[0006] Problems to be solved by the invention

[0007] The present invention has been developed in view of such actual situation, and an object of the present invention is to provide a coil device having excellent insulation between terminals and easily realizing space saving.

[0008] Technical solutions to solve problems

[0009] In order to achieve the above-mentioned purpose, the present invention provides a coil device, which comprises: a bobbin for winding a wire; a conductive terminal connected to a lead portion of the wire; and an insulating terminal seat for mounting the terminal. In the coil device, the terminal comprises: a fixed portion fixed to the terminal seat; an external connection portion formed integrally with the fixed portion at a front end position protruding from the terminal seat along a first axis; and a wire connection portion, which protrudes from the terminal seat at a position between the fixed portion and the external connection portion along the first axis, is formed integrally with the external connection portion, and is connected to the lead portion by clamping it.

[0010] In the coil device of the present invention, a fixed portion and an external connection portion of the terminal are arranged along the first axis, and a wire connection portion is formed between them. Therefore, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent and space can be saved. In addition, it also contributes to the miniaturization of the coil device.

[0011] Preferably, the fixing portion and the external connection portion are integrally connected at a connection portion exposed from the terminal block, and the wire connection portion is integrally formed at the connection portion. By adopting such a structure, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent, and space can be saved. In addition, it also contributes to the miniaturization of the coil device.

[0012] Furthermore, it is preferable that the fixing portion and the connecting portion are continuously formed as a part of a base plate, and the lead connecting portion is formed by being bent back from a side edge of the connecting portion so as to sandwich the lead portion.

[0013] More preferably, the external connection portion includes an insertion piece formed by being bent at a predetermined angle from the connection portion.

[0014] By adopting such a structure, the terminal can be easily formed by pressing a conductive plate such as a metal plate. Moreover, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent and space can be saved. In addition, it also contributes to the miniaturization of the coil device.

[0015] Preferably, the insertion piece has an insertion edge that can be inserted into the external substrate along a third axis parallel to the winding axis of the lead wire. By adopting such a structure, connection of the terminal to the external substrate becomes extremely easy.

[0016] The coil device of the present invention may also include a cover member, on which a contact portion capable of contacting the reverse insertion edge of the insertion piece on the side opposite to the insertion edge is formed. By adopting such a structure, the cover member bears the reaction force when the insertion piece is inserted into the receiving side terminal of the external circuit, and the connection of the terminal to the external substrate becomes easier. In addition, no excessive force is applied to the terminal.

[0017] A notch may be formed at the front end of the connection portion and the bent intersection of the insertion piece. By adopting such a structure, the strain and deformation of the insertion piece can be effectively prevented, and the insertion piece can be easily inserted into the receiving-side terminal of the external substrate.

[0018] The external connection part and the wire connection part may be offset from each other on a second axis intersecting the first axis. By adopting such a structure, the lead part of the wire and the wire connection part can be easily connected by welding or fusion.

[0019] Alternatively, the terminal seat and the bobbin may be separately formed and installed on the terminal seat connection portion of the bobbin. By adopting such a structure, when the specification of the terminal seat changes, it is sufficient to replace the terminal seat installed on the bobbin with a terminal seat corresponding to the specification, without having to remake the entire bobbin from scratch. Therefore, it is possible to flexibly respond to the specification change of the terminal seat, and it is possible to provide a coil device with a high degree of freedom in design.

[0020] In addition, the bobbin and the terminal block can be formed separately, and materials suitable for each can be used for forming. For example, by forming the bobbin using a material with high thermal conductivity, a coil device with excellent thermal conductivity can be obtained. In addition, by including fillers in the material constituting the bobbin, a bobbin with excellent strength can be obtained, and the strength of the coil device can be improved. In addition, by forming the terminal block using a material with excellent formability, the dimensional accuracy can be improved even for a terminal block composed of a complex shape, which can contribute to the miniaturization of the coil device.

[0021] In addition, when forming the bobbin, it is not necessary to use a mold that takes into account the specifications of the terminal seat, and a mold corresponding to the specifications of the bobbin can be used. Therefore, compared with the case of forming a bobbin with an integrated terminal seat, the structure of the mold can be simplified and manufacturing becomes easier.

[0022] In addition, the terminal block can also be installed on the terminal block connection portion of the bobbin from a direction substantially perpendicular to the winding axis of the bobbin. In this case, it is easy to position the height of the terminal set on the terminal block with high precision relative to the bobbin, and it becomes easy to position the external terminal of the coil device connected to the terminal.

[0023] Preferably, a bobbin groove for allowing the lead part to pass through is formed in the terminal seat connecting part, and the lead part is pulled out through the bobbin groove located between the terminal seat and the terminal seat connecting part.

[0024] By adopting such a structure, the insulation between the plurality of lead parts can be improved.

[0025] Preferably, the terminal block is formed with a guide groove for guiding the lead wire portion passing through the spool groove to the wire connecting portion. By adopting such a structure, it is easy to guide the lead wire portion to the wire connecting portion, and connection of the lead wire portion becomes easy.

[0026] The terminal seat connection portion may also have a snap-on piece that snaps into a snap-on groove formed in the terminal seat. By embedding the snap-on piece in the snap-on groove, the joining operation of the terminal seat and the bobbin becomes easy, and the positioning of the terminal seat to the bobbin also becomes easy. In addition, the terminal seat can be firmly connected to the terminal seat connection portion.

[0027] A support body may be mounted on the terminal block or the terminal block connecting portion, the support body holding the connecting portion of the terminal from below and insulating it. By adopting such a structure, the support of the terminal protruding long from the terminal block is stabilized.

[0028] Preferably, the fixing portion of the terminal is fixed to the terminal block by insert molding. By adopting such a structure, even if a plurality of terminals are arranged on the terminal block, the insulation between the terminals is excellent, and space saving is easily achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a perspective view of a coil device according to an embodiment of the present invention.

[0030] Figure 2A yes Figure 1 An exploded perspective view of the coil device shown.

[0031] Figure 2B yes Figure 2A An enlarged perspective view of the terminal metal fitting is shown.

[0032] Figure 3 Yes Figure 2A A perspective view of the bobbin of the terminal block is shown.

[0033] Figure 4A yes Figure 2A An exploded perspective view of the bobbin, terminal block, and support body shown.

[0034] Figure 4B yes Figure 4A Exploded perspective view of the spool and insulating adapter shown.

[0035] Figure 4C From another perspective Figure 4B A perspective view of the spool is shown.

[0036] Figure 5 Yes Figure 2A An enlarged perspective view of the terminal base of the terminal metal fitting shown.

[0037] Figure 6 From another angle, only Figure 5 A perspective view of the terminal block is shown.

[0038] Figure 7 yes Figure 1 The coil device shown is a perspective view of a first coil portion and a second coil portion. DETAILED DESCRIPTION

[0039] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0040] Figure 1 The transformer 10 shown as an example of the coil device of the present embodiment can be used, for example, for an on-board charger for an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a commuter vehicle (vehicle), or a power supply circuit for a household or industrial electrical device, or a power supply circuit for a computer device, etc. Figure 2AAs shown, the transformer 10 includes a bobbin 20 , magnetic cores (split cores) 40 a and 40 b , and a terminal block 80 .

[0041] In addition, in the drawings, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other. In this embodiment, the X-axis corresponds to the length direction of the bobbin 20, and the Y-axis is roughly consistent with the direction of the dividing line that divides a pair of split cores 42a, 42a or a pair of split cores 42b, 42b. The direction of the dividing line can also be along the X-axis. The Z-axis corresponds to the height (thickness) direction of the transformer 10. In this embodiment, the lower side of the transformer 10 in the Z-axis direction becomes the installation surface of the transformer.

[0042] like Figure 2A As shown, the bobbin 20 has a bobbin body 24 and a terminal seat connection portion 22 formed at the upper portion of one end of the bobbin body 24 in the X-axis direction. In addition, the bobbin 20 is made of plastics such as PPS, PET, PBT, LCP, etc., but can also be made of other insulating components. Preferably, the bobbin 20 is made of a heat-resistant material. In order to improve strength and thermal conductivity, fillers such as glass can also be filled into these insulating components.

[0043] like Figure 2A As shown, in this embodiment, the magnetic cores 40a, 40b can be separated into two split cores 42a, 42a and 42b, 42b having the same shape. In this embodiment, the split cores 42a, 42a and 42b, 42b are all of the same shape, and have a cross-sectional E shape in the ZY cross section, forming a so-called E-shaped core. The other pair of split cores 42b, 42b arranged at the lower part in the Z-axis direction also have a cross-sectional E shape in the ZY cross section, forming a so-called E-shaped core.

[0044] Each split core 42a disposed on the upper side in the Z-axis direction includes: a base portion 44a extending in the Y-axis direction; and a pair of middle legs 46a and side legs 48a protruding in the Z-axis direction from both ends of the base portion 44a in the Y-axis direction. Each split core 42b disposed on the lower side in the Z-axis direction includes: a base portion 44b extending in the Y-axis direction; and a pair of middle legs 46b and side legs 48b protruding in the Z-axis direction from both ends of the base portion 44b in the Y-axis direction.

[0045] The outer surfaces of the base portions 44a, 44b abut against the inner surface of the terminal seat protrusion formed on the inner surface of the terminal seat 80 connected to the upper portion of one end of the bobbin body 24 (the center side of the X-axis direction of the bobbin 20) and the inner surface of the protrusion piece 29 formed on the upper portion of the other end of the bobbin body 24, thereby preventing the magnetic cores 40a, 40b from being misaligned in the X-axis direction or the Y-axis direction.

[0046] A pair of middle legs 46a are inserted from the upper side in the Z-axis direction into the core pin through hole 26 of the bobbin 20. Similarly, a pair of middle legs 46b are inserted from the lower side in the Z-axis direction into the core pin through hole 26 of the bobbin 20, and inside the through hole 26, their front ends are in contact with the front ends of the middle legs 46a or face each other with a predetermined gap.

[0047] The separation projection 27 (see Figure 2A , Figure 2B ) is formed along the Z-axis direction. The separation protrusion 27 is interposed between the middle legs 42a, 42a, and between the middle legs 42b, 42b, and these middle legs 42a, 42a or middle legs 42b, 42b are configured to face each other with a predetermined gap inside the through hole 26 without contacting each other. The predetermined gap can be adjusted by the thickness of the separation protrusion 27 in the Y-axis direction.

[0048] The middle legs 42a, 42a or the middle legs 42b, 42b are formed into an elliptical cylindrical shape that is long in the X-axis direction so as to conform to the inner peripheral surface shape of the through hole 26 in the respective combined states, but the shape is not particularly limited and may be changed according to the shape of the through hole 26. In addition, the side legs 48a, 48b have an inner concave curved surface shape corresponding to the outer peripheral surface shape of the cover body 52 of the cover 50, and the outer surface thereof has a plane parallel to the XZ plane. In the present embodiment, the material of each split core 42a, 42b can be a soft magnetic material such as metal or ferrite, but is not particularly limited.

[0049] The cover body 52 of the cover 50 has a shape covering the outer periphery of the bobbin body 24. Locking pieces 54 bent substantially perpendicularly from the cover body 52 to the bobbin body 24 are integrally formed at both ends of the cover body 52 in the Z-axis direction.

[0050] The pair of locking pieces 54 formed on both sides of the cover body 52 in the Z-axis direction includes a locking protruding piece 540. A hole 540a is formed substantially in the center of the locking protruding piece 540.

[0051] The locking protrusion 540 is fixed to Figure 4A More specifically, when the locking protrusion 540 is fixed to the step wide width portion 250, the protrusion 250a formed on the step wide width portion 250 is fitted into the hole 540a of the locking protrusion 540. Thus, the pair of locking pieces 54 are installed in a manner of sandwiching the upper and lower surfaces of the bobbin body 24 in the Z-axis direction, and are arranged on the step portion 25 formed on the upper surface of the bobbin body 24.

[0052] like Figure 2A , Figure 2BAs shown, side leg guide pieces 56 extending in the Z-axis direction are integrally formed on the outer surfaces of both ends of the cover body 52 in the X-axis direction. Figure 1 In the example shown, the side foot guide piece 56 abuts against the outer surface of the base parts 44a, 44b on the outer side in the X-axis direction, but it may also abut against the outer surface of the side foot parts 48a, 48b on the outer side in the X-axis direction. The inner surface of the side foot parts 48a, 48b contacts the outer surface of the cover body 52 located between the pair of side foot guide pieces 56, and the movement of the side foot parts 48a, 48b in the X-axis direction is restricted by the pair of side foot guide pieces 56.

[0053] One side foot guide piece 56 close to the terminal block 80 along the X-axis direction is formed in a larger manner than the other side foot guide piece 56. Figure 1 When the cover 50 is mounted on the bobbin 20, it is arranged at Figure 7 Therefore, a side foot guide piece 56 close to the terminal block 80 ensures the insulation distance (spatial distance and surface distance) between the first lead portion 37a of the first wire 37 and the cores 40a, 40b, and plays a role in guiding the first lead portion 37a upward in the Z axis. In addition, the cover 50 is made of an insulating member such as plastic similar to the bobbin 20.

[0054] The bobbin body 24 is wound around Figure 7 The first conductive wire 37 of the first coil portion 35 and the second conductive wire 38 constituting the second coil portion 36 are shown.

[0055] like Figure 3 , Figure 4A and Figure 4B As shown in FIG. 1 , at both ends of the winding drum portion 28 of the bobbin 20 in the Z-axis direction, end wall flanges 31 and 32 are integrally formed in a manner extending radially outward and substantially parallel to the XY plane. The winding drum portion 28 located between the end wall flanges 31 and 32 in the Z-axis direction, Figure 7 The first coil portion 35 and the second coil portion 36 are arranged at different positions in the Z-axis direction (direction of the winding axis). The first coil portion 35 is wound with a first conductive wire 37 constituting either the primary coil or the secondary coil, and the second coil portion 36 is wound with a second conductive wire 38 constituting either the other of the primary coil or the secondary coil.

[0056] In this embodiment, the winding barrel portion 28 (see Figure 3 ) is formed with an insulating partition flange 30 substantially parallel to the XY plane. Figure 7The first coil portion 35 shown in the figure is formed with a winding partition flange 33 (see FIG. 1 ) for separating the adjacent wire winding portions of the first wire 37 along the winding axis (Z axis) into respective partitioned areas. Figure 3 ).

[0057] In addition, in this embodiment, similarly to the first coil portion 35, Figure 7 The second coil portion 36 shown in the figure also has a winding partition flange 34 (see FIG. 3 ) for separating the adjacent wire winding portions of the second wire 38 along the winding axis (Z axis) into respective partitioned areas. Figure 3 ).like Figure 4C As shown, at least one connection groove 33a, 34a for connecting adjacent regions S1, S2 to each other or connecting S1a, S2a to each other is formed in each of the winding partition wall flanges 33 and 34, respectively.

[0058] like Figure 4C As shown, the connection grooves 33a, 34a are formed on the side of the winding wall flanges 33, 34 opposite to the side of the X-axis direction where the terminal block connection portion 22 is arranged. These connection grooves 33a, 34a are formed in a part of the circumference of each of the wall flanges 33 and 34, respectively, with a depth reaching the outer peripheral wall of the winding barrel portion 28.

[0059] like Figure 4C As shown, in the regions S1 and S2 separated in the Z-axis direction by the flanges 30, 33, and 31, the winding Figure 7 The first conductive wire 37 shown can separate the conductive wire winding parts from each other in each area S1, S2. In this embodiment, the area width along the Z axis in each area S1, S2 is set to a width that only one conductive wire 37 can enter. However, in this embodiment, the area width can also be set to a width that two or more conductive wires 37 can enter. In addition, in this embodiment, it is preferred that all area widths are the same, but they may be slightly different.

[0060] Figure 7 In the second coil portion 36 shown in FIG. 1 , similarly to the first coil portion 35, Figure 4C The partition wall flanges 30, 34, 32 shown in the figure are wound in the regions S1a and S2a separated in the Z-axis direction. Figure 7 The second conductor 38 shown can separate the conductor winding parts from each other in each area S1a, S2a. In this embodiment, the area width along the Z axis in each area S1a, S2a is set to a width that only one conductor 38 can enter. In addition, the area width can be matched with the wire diameter of the conductor 38 and can be the same as the area width.

[0061] in addition, Figure 4CThe radial width of the shown next-wall flanges 30 to 34 is set to a height that allows one or more (one layer or more) conductors 37 or 38 to enter, and in this embodiment, it is preferably set to a radial width that allows winding of 2 to 10 layers of conductors. The radial widths of the next-wall flanges 30 to 34 are preferably all the same, but may be different.

[0062] like Figure 4A As shown, a terminal block 80 that is separate from the bobbin 20 is mounted on the terminal block connecting portion 22 . Figure 7 The first lead portions 37a, 37b of the first wire 37 and the second lead portions 38a, 38b of the second wire 38 are drawn out and fixed to the terminal block 80. The Y-axis width and the X-axis width of the terminal block connecting portion 22 are determined based on the Y-axis width and the X-axis width of the bottom surface of the terminal block 80, etc.

[0063] like Figure 4A As shown, a terminal seat connection portion 22 is provided on the front side of the bobbin 20 in the X-axis direction, and a protrusion piece 29 is formed on the bobbin body 24 on the side opposite to the terminal seat connection portion 22 in the X-axis direction. The protrusion piece 29 has a surface substantially parallel to the YZ plane and protrudes from the upper surface of the bobbin body 24 toward the upper side of the Z-axis. Figure 1 The movement of the magnetic core 40a in the X-axis direction is shown.

[0064] The terminal block connection portion 22 integrally formed on the bobbin 20 includes: a base portion 22a extending in the Y-axis direction, and an insulating wall 22b rising upward in the Z-axis direction substantially perpendicularly to the base portion 22a. The insulating wall 22b is formed parallel to the ZY plane to ensure that the terminals (e.g., terminal metal fittings) 60a to 60d and Figure 2A Insulation of the magnetic core 40a shown. Figure 4A As shown, the base portion 22 a is formed parallel to the XY plane and is used to mount the terminal block 80 .

[0065] In the base portion 22a, in order to Figure 7 The lead portions 37a, 37b, 38a, 38b of the wires 37, 38 shown are guided toward the terminals 60a to 60d of the terminal block 80, as shown in FIG. Figure 4A As shown in FIG. 1 , four bobbin side notches (bobbin grooves) 23a to 23d are formed intermittently (intermittently in the Y-axis direction) along the Y-axis and recessed in the X-axis direction. In addition, at both ends of the base portion 22a along the Y-axis, there are respectively formed engaging pieces 22c whose wall thickness in the Z-axis direction is thinner than that in the center. Each engaging piece 22c can be inserted into Figure 6 The terminal block 80 shown is fitted into engagement grooves 84b and 86b formed on the back side and at the lower ends in the Y-axis direction.

[0066] like Figure 5As shown, the terminal block 80 has a rod member 82 extending in the Y-axis direction, and end blocks 84 and 86 are integrated at both ends of the rod member 82 in the Y-axis direction. Figure 6 As shown, the engaging hooks 84a and 86a are formed together with the engaging grooves 84b and 86b at the lower portions of the end blocks 84 and 86 in the Z-axis direction.

[0067] like Figure 6 As shown, on the back side of the rod member 82 in the X-axis direction, guide notches 82a to 82d are formed in a manner that they are intermittently recessed in the X-axis direction along the Y-axis direction. Figure 4A The bobbin side notches (bobbin grooves) 23a to 23d shown correspond to and face these notches in the Y-axis direction. These guide notches 82a to 82d are also connected to the upper surface side notches formed on the upper surface of the terminal block 80 in the Z-axis direction.

[0068] In addition, if Figure 4B As shown, only the bobbin groove 23b is formed with a slit groove 23b1 parallel to the plane including the X-axis and the Y-axis along the concave edge of the bobbin groove 23b. The flat upper surface portion 72 of the insulation adapter 70 is inserted into the slit groove 23b1, so that the insulation adapter 70 is installed on the terminal block connection portion 22. Figure 7 The second conductor 38 is shown mounted on Figure 4B After the bobbin 20 is shown, the terminal block connecting portion 22 is installed on the bobbin 20.

[0069] Figure 4A The guide notch 82b of the terminal block 80 shown in the figure is connected to the terminal block connecting portion 22, and is installed in the notch 23b on the side of the bobbin. Figure 4B The guide groove 76 of the insulating adapter 70 shown is in communication with the first lead wire portion 37 b at this portion.

[0070] like Figure 4B As shown, the insulating adapter 70 includes a curved plate-shaped side surface portion 71, a plate-shaped upper surface portion 72 formed at the upper portion of the side surface portion 71 in the Z-axis direction, and a plate-shaped bottom surface portion 73 formed at the lower portion of the side surface portion 71 in the Z-axis direction. A guide groove 76 extending in the Z-axis direction is formed in a portion of the curved outer surface of the side surface portion 71. Figure 7 The other lead portion 37 b of the first lead wire 37 is shown to pass through the guide groove 76 in the Z-axis direction.

[0071] Figure 4B The insulating adapter 70 shown is Figure 4A The terminal block 80 shown is mounted on the bobbin 20 before being connected to the terminal block connecting portion 22 . Figure 4B The insulating adapter 70 shown is installed before the terminal block connecting portion 22. Figure 4A The lead wire portions 37a, 38b, 38a shown in the figure pass through the bobbin side notches 23a, 23c, 23d, respectively. Only the lead wire portion 37b does not pass through the bobbin side notch 23b. Figure 4B After the insulation adapter 70 is mounted on the terminal block connecting portion 22 , only the lead wire portion 37 b passes through the guide groove 76 of the insulation adapter 70 .

[0072] Then, by installing the terminal block 80 to the terminal block connecting portion 22, Figure 4A The lead wire portions 37a, 38b, 38a are shown sandwiched between the notches 23a, 23c, 23d and the notches 82a, 82c, 82d, respectively. In addition, the lead wire portion 37b is sandwiched between the guide groove 76 of the insulation adapter 70 mounted on the notch 23b and the notch 82b of the terminal block 80.

[0073] like Figure 5 As shown, terminal mounting portions 83a to 83d are formed at intervals along the Y-axis direction near adjacent notches 82a to 82d formed in the rod member 82. Terminals 60a to 60d are mounted on these terminal mounting portions 83a to 83d. The terminal 60a and the terminal 60b have the same shape, and the terminal 60c and the terminal 60d have the same shape.

[0074] like Figure 2B As shown in FIG. 1 , the terminal 60a and the terminal 60b each have a flat base plate 62α. A fixing portion 64α is formed as a part of the base plate 62α at one end of the base plate 62α in the X-axis direction, and a connecting portion 66α is formed as a part of the base plate 62α at the other end of the base plate 62α. A lead connecting portion 68α as a wire connecting portion, which is formed by protruding and folding back in the Y-axis direction at one side edge of the connecting portion 66α near the fixing portion 64α, is formed by being bent integrally with the connecting portion 66α.

[0075] In addition, an external connection portion 69 is formed as an insertion piece at the other side edge of the connection portion 66α away from the fixing portion 64α, which is offset from the lead connection portion 68α in the X-axis direction and is bent at a predetermined angle from the plane of the connection portion 66α to be formed integrally. The external connection portion 69 as an insertion piece is also in the shape of a flat plate like the base plate 62α, and in this embodiment, it is formed in a manner that is bent to form substantially right angles with each other. Compared with the end portion of the base plate 62α in the X-axis direction, the flat-plate-shaped external connection portion 69 further extends in the X-axis direction, and has an insertion edge portion 69a that can be inserted into a receiving-side terminal of an external circuit substrate (not shown) at the lower end edge of the external connection portion 69 in the Z-axis direction.

[0076] On the side of the flat plate-shaped external connection portion 69 opposite to the insertion edge portion 69a in the Z-axis direction, an anti-insertion edge portion 69b is preferably formed substantially parallel to the insertion edge portion 63a. Figure 1 The terminal cover 100 shown as an insulating cover member comes into contact with the protruding (or recessed) contact portion 102 on the back surface.

[0077] like Figure 2B As shown, a notch 67 is formed at the bent intersection of the front end portion of the connecting portion 66α in the X-axis direction and the reverse insertion edge 69b of the external connecting portion 69 as the insertion piece. By providing the notch 67, the bending process of the external connecting portion 69 as the insertion piece relative to the base plate 62α becomes easy, and it is easy to keep their angles at a predetermined angle. In addition, the insertion piece is not easy to bend, etc., and it is easy to insert it into the receiving side metal fitting of the circuit substrate not shown.

[0078] like Figure 3 As shown, in Figure 2B The lead connection portion 68α shown is riveted to each lead portion 37a, 37b, and connected by heat compression or the like. Alternatively, it can also be connected by other connection methods other than riveting. Examples of other connection methods include soldering, welding, resistance welding, ultrasonic welding, laser welding, riveting, heat compression, heat fusion, etc.

[0079] like Figure 2B As shown in FIG. 1 , the terminal 60c and the terminal 60d each have a flat base plate 62β. A fixing portion 64β is formed as a part of the base plate 62β at one end of the base plate 62β in the X-axis direction, and a connecting portion 66β is formed as a part of the base plate 62β at the other end of the base plate 62β. A lead connecting portion 68β as a wire connecting portion is formed by protruding and folding back in the Y-axis direction at one side edge of the connecting portion 66β near the fixing portion 64β and is formed by being bent integrally with the connecting portion 66β.

[0080] In addition, an external connection portion 69 as an insertion piece is formed on the same side edge of the connection portion 66β away from the fixing portion 64β, which is offset from the lead connection portion 68β in the X-axis direction and is bent at a predetermined angle from the plane of the connection portion 66β to be formed integrally. The external connection portion 69 as an insertion piece is also in the shape of a flat plate like the base plate 62β, and in this embodiment, it is formed in a manner that is bent to form substantially right angles with each other. Compared with the end portion in the X-axis direction of the base plate 62β, the flat plate-shaped external connection portion 69 further extends in the X-axis direction, and has an insertion edge portion 69a that can be inserted into a receiving-side terminal of an external circuit substrate (not shown) at the lower end edge portion in the Z-axis direction of the external connection portion 69.

[0081] On the side of the flat plate-shaped external connection portion 69 opposite to the insertion edge portion 69a in the Z-axis direction, an anti-insertion edge portion 69b is preferably formed substantially parallel to the insertion edge portion 63a. Figure 1 The terminal cover 100 shown as an insulating cover member comes into contact with the protruding (or recessed) contact portion 102 on the back surface.

[0082] like Figure 2B As shown, a notch 67 is formed at the bent intersection of the front end portion of the connecting portion 66β in the X-axis direction and the anti-insertion edge 69b of the external connecting portion 69 as the insertion piece. By providing the notch 67, the bending process of the external connecting portion 69 as the insertion piece relative to the base plate 62β becomes easy, and it is easy to keep their angles at a predetermined angle, and the insertion piece is not easy to bend, etc., and it is easy to insert it into the receiving side metal fitting of the circuit substrate not shown.

[0083] like Figure 3 As shown, in Figure 2B The lead connection portion 68β shown is connected to each lead portion 38b, 38a in the same connection manner as the lead connection portion 68α. In addition, in this embodiment, the external connection portion 69 of the terminals 60a, 60b and the external connection portion 69 of the terminals 60c, 60d have the same size and shape, but they may be different from each other.

[0084] In this embodiment, the lead connection portions 68α of the terminals 60a and 60b and the lead connection portions 68β of the terminals 60c and 60d have slightly different shapes. This is because the lead portions 37a, 37b, 38a, and 38b connected to these lead connection portions 68α and 68β are different in thickness.

[0085] In addition, in this embodiment, the base plate 62α of the terminals 60a and 60b and the base plate 62β of the terminals 60c and 60d have slightly different shapes. In addition, the bending direction of the external connection piece 69 relative to the base plate 62α of the terminals 60a and 60b and the bending direction of the external connection part 69 relative to the base plate 62β of the terminals 60c and 60d are opposite to each other. The reason is that, for example, Figure 3 As shown, the intervals between the external connection portions 69 of the terminals 60a to 60d in the Y-axis direction are substantially equal, and it is easy to ensure insulation between the lead portions 37a, 37b, 38a, and 38b connected to the terminals 60a to 60d.

[0086] like Figure 4A and Figure 7As shown, in this embodiment, one first lead portion 37a of the pair of first lead portions 37a and 37b of the first wire 37 is drawn out near the first end portion in the Y-axis direction on one side of the terminal block 80 and stands toward the first end-side terminal 60a.

[0087] The first lead portion 37a is Figure 3 The region S1 shown (the position farthest from the terminal block 80 along the Z axis on the outer circumference of the winding barrel 28) is drawn to the vicinity of the first end in the Y axis direction of one side of the terminal block 80. One end of the first lead portion 37a is connected to the first end-side terminal 60a.

[0088] In addition, of the pair of first lead portions 37a and 37b, the other first lead portion 37b stands up toward the first inner terminal 60b located between the first end terminal 60a and the second end terminal 60d of the terminal base 80. Figure 3 The first lead portion 37b rises from the region S2 shown in the figure in a direction parallel to the winding axis near the center of the terminal block 80 in the Y-axis direction relative to the first lead portion 37a. One end of the first lead portion 37b is connected to the first inner terminal 60b.

[0089] In addition, one of the pair of second lead portions 38a and 38b of the second lead wire 38 is drawn out near the second end portion in the Y-axis direction on the other side of the terminal block 80, and stands up to the second end terminal 60d near the second end portion and is connected. Figure 3 The region S1a shown stands upright.

[0090] In addition, of the pair of second lead portions 38a and 38b, the other second lead portion 38b stands up toward the second inner terminal 60c located between the first inner terminal 60b and the second end terminal 60d of the terminal base 80. Figure 3 The region S2a shown (a position closest to the terminal block 80 along the Z axis in the outer circumference of the winding barrel 28) is extracted and connected to the second inner terminal 60c.

[0091] In this embodiment, the Figure 4C The connecting groove 34a on the other side of the X-axis of the winding bulkhead flange 34 is shown. Figure 7 The second conductor 38 is shown in Figure 4C The winding drum portion 28 shown in FIG. Figure 4C The connecting groove 33a on the other side of the X-axis of the winding bulkhead flange 33 is shown. Figure 7 The first conductive wire 37 shown is α-wound on the winding drum 28. The winding method of the first conductive wire 37 and the second conductive wire 38 is not limited to α-wound, and normal winding may be used.

[0092] In manufacturing the transformer 10, first, the bobbin 20, the first conductive wire 37, the second conductive wire 38, the cover 50, the magnetic cores (split cores) 40a and 40b, and the terminal block 80 formed separately from the bobbin 20 are prepared. The first end terminal 60a, the first inner terminal 60b, the second end terminal 60c, and the second inner terminal 60d are insert-molded (or bonded) in the terminal block 80.

[0093] In this embodiment, Figure 2B The fixing portions 64α and 64β of the terminals 60a to 60d are shown in FIG. Figure 5 The positions of the terminal mounting portions 83a, 83b, 83c, and 83d of the terminal block 80 shown are embedded and fixed by insert molding in the resin constituting the terminal block 80. Portions other than the fixing portions 64α and 64β of the terminals 60a to 60d are exposed from the outer surface of the terminal block 80 in the X-axis direction and are formed to protrude in the X-axis direction.

[0094] Then, in Figure 4B The outer periphery of the bobbin 20 shown is formed Figure 7 The first coil portion 35 and the second coil portion 36 are shown. In addition, Figure 7 The formation of the first coil portion 35 and the second coil portion 36 shown can also be performed using an automatic winding machine. In addition, the wires 37 and 38 can be formed of single wires or twisted wires, preferably insulated coated wires. The second wire 38 can be the same as the first wire 37, but can also be different. In this embodiment, the outer diameter of the first wire 37 is larger than the outer diameter of the second wire 38, for example, preferably

[0095] like Figure 4A As shown, a first lead portion 37a passes through the notch 23a on the side of the bobbin, and the second lead portions 38a and 38b pass through the notches 23d and 23c on the side of the bobbin, respectively. The other lead portion 37b does not directly pass through the notch 23b on the side of the bobbin, but is installed in the notch 23b. Figure 4B After the insulating adapter 70 is shown, it passes through the guide groove 76 of the adapter 70 along the Z axis.

[0096] Next, Figure 4A The engaging piece 22c shown is inserted from the X-axis direction. Figure 6 The engaging grooves 84b and 86b formed by the engaging hooks 84a and 86a of the terminal block 80 shown in the figure attach the terminal block 80 to the terminal block connecting portion 22. An adhesive may be used as required.

[0097] Then, if Figure 3 As shown in FIG. 1 , each lead portion 37a to 37d is connected to the lead connection portions 68α and 68β of the terminals 60a to 60d, respectively. Figure 2AThe pair of covers 50 shown are mounted on the bobbin 20. Then, the middle legs 46a of the pair of split cores 42a, 42a separated in the X-axis direction and the middle legs 46b of the pair of split cores 42b, 42b separated in the X-axis direction are inserted from both sides of the core leg through hole 26 in the X-axis direction.

[0098] Then, use Figure 1 The terminal cover (cover member) 100 shown covers the upper part of the terminal seat 80 mounted on the bobbin 20 in the Z-axis direction. In addition, as required, the lower part of the transformer 10 (the part below the terminals 60a to 60d) is housed in a housing (not shown) with an upper end opening, and a casting resin is injected into the housing. The casting resin includes silicone resin, polyurethane resin, epoxy resin, etc. that become soft after injection, and the longitudinal elastic modulus of the casting resin is preferably 0.1 to 100 MPa.

[0099] Figure 1 The heat sink 110 shown has the function of transferring heat transferred from the inside of the transformer 10 to the upper part of the magnetic core 40a to, for example, the potting resin, and is made of aluminum, copper, etc. having excellent heat conductivity. The heat sink 110 is not necessarily provided, but is preferably provided from the viewpoint of improving heat dissipation.

[0100] In the transformer 10 of the present embodiment, the terminal block 80 is formed separately from the bobbin 20 and is mounted on the bobbin 20. Therefore, when the specification of the terminal block 80 is changed, it is sufficient to replace the terminal block 80 mounted on the bobbin 20 with a terminal block corresponding to the specification, and there is no need to re-manufacture the entire bobbin 20 from scratch. Therefore, it is possible to flexibly cope with the specification change of the terminal block 80, and it is possible to provide a transformer 10 with a high degree of freedom in design.

[0101] In addition, the bobbin 20 and the terminal block 80 can be formed separately, and can be formed using materials suitable for each. For example, by forming the bobbin 20 using a material with high thermal conductivity, a transformer 10 with excellent thermal conductivity can be obtained. In addition, by including a filler in the material constituting the bobbin 20, a bobbin 20 with excellent strength can be obtained, and the strength of the transformer 10 can be improved. In addition, by forming the terminal block 80 using a material with excellent formability, even for the terminal block 80 composed of a complex shape, the dimensional accuracy can be improved, which can contribute to the miniaturization of the transformer 10.

[0102] In addition, when forming the bobbin 20, it is not necessary to use a mold that takes the specifications of the terminal block 80 into consideration, and a mold that corresponds to the specifications of the bobbin 20 can be used. Therefore, compared with the case of forming a bobbin with an integrated terminal block 80, the structure of the mold can be simplified, and manufacturing becomes easy.

[0103] In addition, in the present embodiment, the bobbin 20 has the terminal block connection portion 22 that can be connected to the terminal block 80. Since such a structure is adopted, the terminal block 80 can be easily attached to the bobbin 20 via the terminal block connection portion 22.

[0104] In this embodiment, if Figure 4A As shown, the terminal block connection portion 22 is formed only on one side of the X-axis of the bobbin 20, so Figure 6 The terminal block 80 shown is also disposed only on one side of the X axis of the bobbin 20. Therefore, compared with the conventional transformer in which the terminal block 80 is formed on both sides of the X axis of the bobbin 20, it is possible to achieve miniaturization.

[0105] In addition, in the present embodiment, the terminal block 80 is arranged on the X-axis side of the bobbin 20 and has a shape that is long in the Y-axis direction. That is, both ends of the terminal block 80 in the Y-axis direction protrude toward the dead zone (the corners of the four-corner space inscribed by the ellipse) located outside the elliptical bobbin body 24. In this way, by effectively utilizing the dead zone of the transformer 10, the terminal block 80 can be arranged to contribute to the miniaturization of the transformer 10.

[0106] In addition, in the present embodiment, the terminal block 80 can be mounted on the terminal block connection portion 22 of the bobbin 20 from a direction (X-axis direction) substantially perpendicular to the winding axis (Z-axis) of the bobbin 20. Therefore, it is easy to accurately position the height positions of the lead connection portions 68α and the external connection portion 69 of the terminals 60a to 60d provided on the terminal block 80 relative to the bobbin 20, and the connection of the lead portions 37a, 37b, 38a, and 38b becomes easy. In addition, it becomes easy to position the terminals 60a to 60d of the transformer 10 to the external terminals connected to the external connection portion 69.

[0107] In addition, if Figure 3 As shown, the lead connection parts 68α and 68β of each terminal 60a to 60d protrude horizontally from the terminal block 80 to the outside of the X-axis at approximately equal intervals in the Y-axis direction, so that the connection between the terminals 60a to 60d and the lead parts 37a, 37b, 38a, and 38b is easy. In addition, compared with the lead connection parts 68α and 68β, each external connection part 69 of each terminal 60a to 60d is configured to protrude further to the outside of the X-axis direction at approximately equal intervals in the Y-axis direction.

[0108] In addition, in this embodiment, Figure 7 A first lead portion 37a of the first wire 37 is shown Figure 3The first lead portion 37b of the first lead 37 and the second lead portion 38b of the second lead 38 are drawn out from the center of the terminal block 80 in the Y-axis direction so as to be located on opposite sides of each other, with a gap between them. Figure 4B That is, in this embodiment, the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are arranged outside and inside the insulation adapter 70 to be insulated.

[0109] By adopting this structure, the first lead portion 37a can be pulled out to a sufficient distance near the end of one side of the terminal seat 80, and can be erected toward the terminal 60a near the end of one side of the terminal seat 80. When erected, the first lead portion 37a is not easy to be loose or bent. Therefore, the first lead portion 37a can be compactly erected toward the terminal 60a near the end of one side of the terminal seat 80, and the transformer 10 can be miniaturized. In addition, the second lead portion 38a can also obtain the same effect.

[0110] In addition, by insulating the other first lead portion 37b of the first wire 37 and the other second lead portion 38b of the second wire 38 by the insulating adapter 70, it is possible to prevent a short circuit failure between the lead portions 37b and 38b. In addition, the space distance between the first lead portion 37b and the second lead portion 38b can be sufficiently ensured, and the insulation between the first lead portion 37b and the second lead portion 38b can be improved.

[0111] In addition, the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are arranged on the outside and inside of the insulation adapter 70 (side surface portion 71). By adopting this structure, the other first lead portion 37b of the first lead wire 37 and the other second lead portion 38b of the second lead wire 38 are isolated by the insulation adapter 70, and the insulation between the first lead portion 37b and the second lead portion 38b can be effectively achieved.

[0112] In addition, in this embodiment, by locking the first lead portion 37 a to the extended flange portion 331 , the first lead portion 37 a can be effectively prevented from being displaced, and the first lead portion 37 a can be easily raised when it is raised to the terminal block connecting portion 22 .

[0113] In the present embodiment, the first conductive wire 37 and the second conductive wire 38 are α-wound on the winding barrel 28. By adopting such a structure, the transformer 10 can be made thinner and the leakage characteristic of the transformer 10 can be easily adjusted.

[0114] In addition, in the transformer 10 of this embodiment, Figure 2B As shown in FIG. 1 , the fixing portions 64α, 64β and the external connection portion 69 of the terminals 60a to 60d are arranged along the X-axis, and the wire connection portions 68α, 68β are formed between them. Figure 3 As shown, even if a plurality of terminals 60a to 60d are arranged on the terminal block 80, the insulation between adjacent terminals 60a to 60d is excellent, and space saving can be achieved. Figure 1 The transformer 10 is shown to be miniaturized.

[0115] In addition, in the present embodiment, the external connection portion 69 of each terminal 60a to 60d has an insertion piece formed by bending at a predetermined angle (90 degrees) from the connecting portion 66α, 66β which is a part of the base plate 62α, 62β. The external connection portion 69 as each insertion piece has an insertion edge 69a which can be inserted into an external circuit substrate (not shown) along the Z axis.

[0116] By adopting such a structure, the terminals 60a to 60d can be easily formed by press working or the like using a conductive plate such as a metal plate. Furthermore, even if a plurality of terminals 60a to 60d are arranged on the terminal block 80, the insulation between the terminals 60a to 60d is excellent, and space can be saved. In addition, this also contributes to miniaturization of the transformer 10.

[0117] In addition, the terminals 60a to 60d can be connected to an external circuit board very easily.

[0118] In addition, if Figure 1 As shown, the transformer 10 has a terminal cover 100 formed with a contact portion 102 that can contact the reverse insertion edge 69b on the opposite side of the insertion edge 69a of the insertion piece, and the terminal cover 100 receives the reaction force when each external connection portion 69 as an insertion piece is inserted into the receiving side terminal (not shown) of the external circuit substrate, so that the connection of the terminals 60a to 60d to the external circuit substrate becomes easier. In addition, no excessive force is applied to each terminal 60a to 60d.

[0119] Moreover, if Figure 2B As shown, in each terminal 60a to 60d, a notch 67 is formed at the front end of the connecting portion 66α, 66β and the bent intersection portion of the external connecting portion 69. By adopting such a structure, the strain and deformation of the external connecting portion 69 as an insertion piece can be effectively prevented, and the external connecting portion 69 can be easily inserted into the receiving side terminal of the external circuit substrate.

[0120] Furthermore, in the present embodiment, in each terminal 60a to 60d, the external connection portion 69 and the lead connection portion 68α or 68β may be mutually offset along the Y axis. By adopting such a structure, the lead portion 37a, 37b, 38a or 38b of the wire can be easily connected to the lead connection portion 68α or 68β by welding or fusing.

[0121] In addition, in this embodiment, Figure 4A As shown, the terminal block connection portion 22 is provided with bobbin side notches 23a to 23d for respectively passing the lead portions 37a, 37b, 38a, and 38b. The lead portions 37a, 37b, 38a, and 38b are respectively drawn out through the bobbin side notches 23a to 23d located between the terminal block 80 and the terminal block connection portion 22. By adopting such a structure, the insulation between the plurality of lead portions 37a, 37b, 38a, and 38b can be improved.

[0122] In addition, guide grooves 82a to 82d are formed in the terminal block 80 to guide the lead wire portions 37a, 37b, 38a, 38b passing through the notches 23a to 23d on the bobbin side to the lead wire connection portions 68α and 68β. By adopting such a structure, it is easy to guide the lead wire portions 37a, 37b, 38a, 38b to the lead wire connection portions 68α and 68β, respectively, and the connection of the lead wire portions 37a, 37b, 38a, 38b becomes easy.

[0123] In addition, in this embodiment, if Figure 4A As shown, on both sides of the Y-axis direction of the terminal base connecting portion 22, there are Figure 6 The engaging piece 22c is engaged with the engaging grooves 84b and 86b of the terminal seat 80 shown. By embedding the engaging piece 22c in the engaging grooves 84b and 86b, the joining operation of the terminal seat 80 and the bobbin 20 becomes easy, and the positioning of the terminal seat 80 to the bobbin 20 also becomes easy. In addition, the terminal seat 80 can be firmly connected to the terminal seat connecting portion 22.

[0124] In addition, in this embodiment, if Figure 4A As shown, an insulating support body 90 for holding and insulating the connecting portions 62α and 62β and the lead connecting portions 68α and 68β of the terminals 90a to 90d from below in the Z-axis direction may be installed on the terminal block 80 or the terminal block connecting portion 22. By adopting such a structure, the support of the terminals 60a to 60d protruding long from the terminal block 80 is stabilized.

[0125] In addition, a mounting recess 92 may be formed along the Y axis on the bottom surface of the support body 90 in the Z axis direction. The upper end of a housing for accommodating a potting resin, for example, is mounted on the mounting recess 92. In this case, the external terminals 69 of the terminals 60a to 60d held by the terminal block 80 and the support body 90 protrude from the upper end of the housing to the outside in the X axis direction at the upper part of the housing.

[0126] In addition, in this embodiment, if Figure 5 As shown, Figure 2B The fixing portions 64α and 64β of the terminals 60a to 60d are fixed to the terminal mounting portions 83a to 83d of the terminal block 80 by insert molding. By adopting such a structure, even if a plurality of terminals 60a to 60d are arranged on the terminal block 80, the insulation between adjacent terminals 60a to 60d is excellent, and space saving is easy.

[0127] In addition, the present invention is not limited to the above-mentioned embodiment, and various changes can be made within the scope of the present invention.

[0128] In the above-mentioned embodiments, examples in which the present invention is applied to a transformer are described. However, the present invention is applicable not only to a transformer but also to other coil devices.

[0129] Furthermore, in each of the above-described embodiments, the magnetic core is configured by a combination of E core-E core as split cores, but the magnetic core may be assembled by a combination of E core-I core.

[0130] Furthermore, the first coil portion 35 and the second coil portion 36 may be arranged along the winding axis of the bobbin 20 in the opposite direction to the above embodiment, and the arrangement of the first lead portions 37a, 37b and the second lead portions 38a, 38b may be reversed.

[0131] In the above embodiment, the X axis as the first axis, the Y axis as the second axis, and the Z axis as the third axis are substantially perpendicular to each other, but the angle between these axes is not limited to 90 degrees and may be other angles.

[0132] Moreover, in the present embodiment, the terminal metal fittings 60a to 60d may be fixed to the terminal seat 80 by a method other than insert molding. In addition, in the above-mentioned embodiment, the terminal seat 80 and the bobbin 20 are formed separately, and the terminal seat 80 is mounted on the terminal seat mounting portion 22 of the bobbin 20 from the X-axis direction, but the terminal seat 80 may also be mounted on the terminal seat mounting portion 22 of the bobbin 20 from the upper part in the Z-axis direction. Alternatively, the terminal seat 20 may also be formed integrally with the bobbin 20.

[0133] In addition, in the present embodiment, the four terminals 60a to 60d are mounted on a single terminal block 80, but for example, a pair of terminals 60a and 60b may be mounted on one terminal block, and another pair of terminals 60c and 60d may be mounted on another terminal block, and these terminal blocks may be mounted on both ends of the bobbin 20 in the X-axis direction. In addition, the internal structure of the bobbin may be a double-layered cylinder structure, for example, the second coil portion 36 may be arranged to be insulated from the outside of the first coil portion 35, or vice versa.

[0134] Description of Reference Numerals

[0135] 10. Transformer

[0136] 20... spools

[0137] 22...Terminal block connection

[0138] 22a……base

[0139] 22b...Insulating wall

[0140] 22c... snap-on piece

[0141] 22d... snap-in slot

[0142] 23a~23d……Notch on the side of the bobbin (bobbin groove)

[0143] 23b1... Slit groove

[0144] 24... Spool body

[0145] 25... Steps

[0146] 250...Stair width

[0147] 250a...protrusion

[0148] 26...Through hole for the core pin

[0149] 27... Separation convex part

[0150] 28...Winding drum

[0151] 29... protruding piece

[0152] 30...Insulating bulkhead flange

[0153] 31, 32...end bulkhead flange

[0154] 33, 34...Wrapping the flange of the next wall

[0155] 331……Extended flange

[0156] 33a, 34a...Connection slot

[0157] 35……First coil section

[0158] 36... Second coil section

[0159] 37……First conductor

[0160] 37a, 37b... first lead portion

[0161] 38...Second wire

[0162] 38a, 38b..... second lead portion

[0163] 40a, 40b... magnetic core

[0164] 42a, 42b...divided core

[0165] 44a, 44b...base part

[0166] 46a, 46b…midfoot

[0167] 48a, 48b...lateral foot

[0168] 50...Hood

[0169] 52……Hood body

[0170] 54……Stop piece

[0171] 540......Locking protrusion

[0172] 540a...hole

[0173] 56...Side foot guide

[0174] 60a~60d……Terminal

[0175] 62α, 62β...base plate

[0176] 64α, 64β...Fixed part

[0177] 66α, 66β...Connection

[0178] 67...Gap

[0179] 68α, 68β...lead connection part (wire connection part)

[0180] 69...External connection

[0181] 69a... Insertion rim

[0182] 69b... Reverse insertion

[0183] 70...Insulation adapter

[0184] 71... Side view

[0185] 72…Upper surface

[0186] 73... bottom part

[0187] 76...Boot slot

[0188] 80...Terminal Block

[0189] 82……Rod parts

[0190] 82a, 82b, 82c, 82d...guide notches (guide grooves)

[0191] 83a~83d……Terminal mounting portion

[0192] 84, 86...end block

[0193] 84a, 86a... snap hook

[0194] 84b, 86b... snap-fit ​​slot

[0195] 88......Engagement convex part

[0196] 90……Support

[0197] 92...Installation recess

[0198] 100...Terminal cover (cover part)

[0199] 102...butt part

[0200] 110……Heat sink.

Claims

1. A coil device comprising: a bobbin for winding a wire; a terminal for connecting a lead portion of the wire; and a terminal seat for mounting the terminal, The coil device is characterized by: The terminal has: A fixing portion fixed to the terminal seat; an external connection portion formed integrally with the fixing portion at a front end position protruding from the terminal base along the first axis; and a wire connection portion, which is located between the fixing portion and the external connection portion, protrudes from the terminal block along the first axis, is formed integrally with the external connection portion, and is connected to the external connection portion by sandwiching the lead portion, The terminal seat is separated from the bobbin. The bobbin is provided with a terminal base connection portion for mounting the terminal base. A guide groove for guiding the lead portion toward the wire connecting portion is formed on the back side of the terminal block along the first axis. The guide groove is also connected to the notch on the upper surface of the terminal seat. The lead portion passes through the guide groove and the upper surface side notch, connected to the wire connection portion existing outside the end portion of the notch on the upper surface side, The notch on the upper surface is arranged corresponding to the position of the wire connecting portion. A connection portion connecting the external connection portion, the wire connection portion, and the fixing portion exists outside the terminal block along the first axis direction.

2. The coil device according to claim 1, characterized in that: The fixing portion and the external connection portion are integrally connected at the connection portion exposed from the terminal block, and the lead connection portion is integrally formed at the connection portion.

3. The coil device according to claim 1 or 2, characterized in that: The fixing portion and the connecting portion are formed continuously as a part of the base plate. The wire connection portion is formed by being bent back from a side edge of the connection portion so as to sandwich the lead portion.

4. The coil device according to claim 1 or 2, characterized in that: The external connection portion includes an insertion piece that is bent at a predetermined angle from the connection portion.

5. The coil device according to claim 4, characterized in that: The insertion piece has an insertion edge portion that can be inserted into the external substrate along a third axis parallel to the winding axis of the lead wire.

6. The coil device according to claim 5, characterized in that: A cover member is further provided on which a contact portion capable of coming into contact with a counter-insertion edge portion of the insertion piece on the side opposite to the insertion edge portion is formed.

7. The coil device according to claim 4, characterized in that: A notch is formed at a front end portion of the connection portion and a bent intersection portion of the insertion piece.

8. The coil device according to claim 1 or 2, characterized in that: The external connection portion and the wire connection portion are offset from each other on a second axis intersecting the first axis.

9. The coil device according to claim 1, characterized in that: The terminal seat connection portion is formed with a bobbin groove for allowing the lead portion to pass through. The lead portion is drawn out through the spool groove located between the terminal block and the terminal block connecting portion.

10. The coil device according to claim 9, characterized in that: The terminal block is formed with a guide groove that guides the lead wire portion that has passed through the bobbin groove toward the wire connecting portion.

11. The coil device according to claim 1, characterized in that: The terminal block connecting portion has an engagement piece that engages with an engagement groove formed in the terminal block.

12. The coil device according to claim 1, characterized in that: A support body is attached to the terminal block or the terminal block connecting portion, and the support body holds and insulates the connecting portion of the terminal from below.

13. The coil device according to claim 1 or 2, characterized in that: The fixing portion of the terminal is fixed to the terminal base by insert molding.

Images