Coil device

Abstract

The present invention provides a coil device that is easy to position with a connection object and that is easy to manufacture and assemble. The coil device (10) comprises: a bobbin (40) having a winding portion on which an electric wire is wound around the outer periphery; terminals (91 to 94) connected to the ends of the electric wire; and terminal blocks (70, 80) mounted on the bobbin (40) so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin (40). The terminals (91 to 94) are mounted relative to the terminal blocks (70, 80) so as to be movable in the Z-axis direction.

Description

Technical Field

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

[0002] For example, as a coil device for a transformer, there is known a coil device as shown in Patent Document 1. In this conventional coil device, a terminal block is fixed to a bobbin, a terminal metal fitting is fitted and fixed to the terminal block, an end of an electric wire constituting the coil is connected to the terminal metal fitting, and an external circuit is connected to the terminal metal fitting.

[0003] In this type of coil device, there is no problem when the terminal metal parts are connected to the leads from the external circuit. However, recently, there are increasing requests to directly position and connect the terminal metal parts of the coil device to the circuit substrate or connector as the connection object. In this case, there are the following problems: the position of the terminal metal parts and the position of the connection part of the connection object need to be highly accurately consistent, the manufacture and assembly of the various parts of the coil device are difficult, and the manufacturing cost increases.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-36194 Summary of the invention

[0007] Problems to be solved by the invention

[0008] 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 that is easy to position with respect to a connection object and that is easy to manufacture and assemble its components.

[0009] Solutions to Solve Problems

[0010] In order to achieve the above-mentioned object, a first aspect of the present invention provides a coil device having:

[0011] a bobbin having a winding portion on which the power supply wire is wound;

[0012] a terminal to which the end of the electric wire is connected;

[0013] a terminal block on which the terminal is mounted,

[0014] The terminal is movable in both a first axial direction and a second axial direction of the bobbin.

[0015] In the coil device of the first aspect of the present invention, the terminal is movable in both the first axial direction and the second axial direction of the bobbin. Therefore, after roughly positioning the connection object and the coil device, only the terminal is moved relative to the bobbin, so that the terminal and the connection object can be accurately positioned and connected.

[0016] In addition, in the coil device of the first aspect of the present invention, it is not necessary to accurately align the position of the terminal of the terminal block with the installation position of the connection object during the manufacturing stage of the coil device, which makes it easy to manufacture and assemble the various parts that constitute the coil device, thereby helping to reduce manufacturing costs.

[0017] In order to achieve the above object, a second aspect of the present invention provides a coil device having:

[0018] a bobbin having a winding portion on which the power supply wire is wound;

[0019] a terminal to which the end of the electric wire is connected;

[0020] The terminal block is mounted on the terminal and is mounted on the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin.

[0021] The coil device of the second aspect of the present invention has a terminal block mounted on the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin. Therefore, after roughly positioning the connection object and the coil device, the terminal block is only moved relative to the bobbin, so that the terminal of the terminal block and the connection object can be accurately positioned and connected.

[0022] In addition, in the coil device of the second aspect of the present invention, it is not necessary to accurately align the position of the terminal of the terminal block with the installation position of the connection object during the manufacturing stage of the coil device, which makes it easy to manufacture and assemble the various parts that constitute the coil device, thereby helping to reduce manufacturing costs.

[0023] The terminal block can also be mounted on a housing that accommodates the bobbin or a cover that covers at least a portion of the bobbin. By setting such a structure, after roughly positioning the connection object and the coil device, the terminal block is only moved relative to the housing or the cover, so that the terminal of the terminal block and the connection object can be accurately positioned and connected.

[0024] Preferably, the terminal is mounted on the terminal block so as to be movable in the third axial direction of the bobbin. With such a configuration, it is easy to fine-tune the installation position of the terminal and the connection object in the third axial direction. As a result, even along the third axial direction, it is not necessary to precisely align the position of the terminal with the installation position of the connection object, and the manufacture and assembly of the various parts constituting the coil device become easier, which further contributes to the reduction of manufacturing costs.

[0025] The terminal block can also be freely movable in the third axial direction of the bobbin. In this case, by moving the terminal block relative to the bobbin in the third axial direction, it is also easy to fine-tune the installation position of the terminal and the connection object in the third axial direction, and the above-mentioned effect can be obtained.

[0026] It is also possible that a relief fitting protrusion protruding in the first axial direction is formed on either the bobbin or the terminal block, and a relief fitting recess into which the relief fitting protrusion enters is formed on the other side, and the relief fitting protrusion is inserted within a predetermined range in the relief fitting recess so as to be movable in the first axial direction and the second axial direction. Alternatively, it is also possible that a relief fitting protrusion protruding in the second axial direction or the third axial direction is formed on either the bobbin or the terminal block, and a relief fitting recess into which the relief fitting protrusion enters is formed on the other side, and the relief fitting protrusion is inserted within a predetermined range in the relief fitting recess so as to be movable in the first axial direction and the second axial direction. By setting such a structure, the terminal block on which the terminal is mounted can be mounted on the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin.

[0027] A portion of the inner wall of the relaxing interlocking recess may be formed by an elastically deformable support sheet to open the width of the entrance of the relaxing interlocking recess, and a stopper convex portion that engages with the relaxing interlocking convex portion to prevent it from falling out is formed on the support sheet. With this structure, the relaxing interlocking convex portion is only inserted into the relaxing interlocking recess, and the relaxing interlocking convex portion is installed relative to the relaxing interlocking recess so that it can move freely in the first axial direction and the second axial direction, and the terminal block is prevented from falling out relative to the bobbin. Therefore, the installation of the terminal block relative to the bobbin is easier.

[0028] A stopper wall portion may also be provided, which is installed in the said relaxing fitting protrusion which enters the inside of the relaxing fitting concave portion and stops it from falling off, and the said stopper wall portion has a fitting portion which fits with the said relaxing fitting protrusion. By fitting the fitting portion with the relaxing fitting protrusion, the said terminal block can be prevented from falling off relative to the bobbin by using the stopper wall portion when the relaxing fitting protrusion is installed relative to the relaxing fitting concave portion so as to be movable in the first axial direction and the second axial direction.

[0029] A stopper wall portion may also be provided, which is mounted on the said relaxing fitting protrusion that enters the inside of the relaxing fitting concave portion and stops it from falling off, and the said stopper wall portion is connected to the said relaxing fitting protrusion via resin. By connecting the stopper wall portion to the relaxing fitting protrusion via resin, the terminal block can be stopped from falling off relative to the bobbin by using the stopper wall portion when the relaxing fitting protrusion is mounted relative to the relaxing fitting concave portion so as to be movable in the first axial direction and the second axial direction.

[0030] Preferably, the mitigation interlocking protrusion has a main protrusion and a secondary protrusion, and the mitigation interlocking recess has a main recess inserted by the main protrusion and a secondary recess inserted by the secondary protrusion, and the gap between the secondary protrusion and the secondary recess along the third axial direction is smaller than the gap between the main protrusion and the main recess along the third axial direction, and along the guide surface where the secondary protrusion and the secondary recess are in contact, the terminal block is maintained to be movable in the first axial direction and the second axial direction relative to the bobbin. By setting such a structure, the terminal block can move smoothly along the guide surface relative to the bobbin in the first axial direction and the second axial direction without shaking. Moreover, the gap between the main protrusion and the main recess along the third axial direction is relatively wide, so the operation of inserting the mitigation interlocking protrusion into the interior of the mitigation interlocking recess can be carried out relatively easily.

[0031] Preferably, two auxiliary protrusions are formed on both sides of the main protrusion, and two auxiliary concave portions are formed on both sides of the main concave portion. In addition, preferably, the protrusion height of the main protrusion in the first axial direction is greater than the protrusion height of the auxiliary protrusion in the first axial direction. By configuring in this way, it is possible to facilitate the operation of inserting the easing interlocking protrusion into the inside of the easing interlocking concave portion, and reduce the friction on the guide surface where the auxiliary protrusion and the auxiliary concave portion contact.

[0032] The terminal may also include: a wire connection portion that fixes and connects the end of the wire; and a hook portion that is formed at a position different from the wire connection portion and is inserted into a terminal groove formed in the terminal block so as to be movable in the third axial direction. By setting such a structure, the end of the wire can be easily connected to the terminal, and the terminal can be assembled relative to the terminal block so as to be easily movable along the third axial direction.

[0033] Preferably, the terminal has an insertion hole or an external circuit connection piece formed between the wire connection portion and the hook portion. A fastener such as a bolt or a screw can be installed in the insertion hole, and the terminal is positioned and installed on the substrate via the fastener. In addition, the external circuit connection piece can be directly positioned and installed on the substrate.

[0034] Preferably, an inner cover that engages with the hook portion and limits the movement range of the terminal in the third axial direction is installed on the terminal block. By installing only the inner cover, the terminal can be prevented from falling off relative to the terminal block. In addition, the movement of the terminal in the third axial direction relative to the terminal block can also be limited.

[0035] The terminal block may be movable in the third axial direction of the bobbin, and the terminal may be integrally formed with the terminal block. By setting such a structure, the process of attaching the terminal to the terminal block can be simplified, and the manufacture of the coil device becomes easy.

[0036] Alternatively, the terminal may be composed of a plurality of the terminals, the terminal block may be composed of a plurality of the terminal blocks, and the plurality of the terminals may be mounted on each of the plurality of terminal blocks. By setting such a structure, each terminal may be independently moved relative to the wire axis at each terminal block, so that the terminal and the connection object can be positioned and connected with high precision.

[0037] Preferably, an outer cover is mounted on the terminal block to cover the inner cover, the end of the terminal block in the first axial direction, and the end of the terminal block in the second axial direction. By forming the outer cover with an insulating member, it is expected that the insulation property will be improved.

[0038] Preferably, the outer cover covers the end of the third axial direction of the terminal block, exposing the wire connection portion. By setting such a structure, the outer cover can be used to cover the periphery of the ease fitting protrusion and the ease fitting recess, which can suppress the ease fitting protrusion and the ease fitting recess from being deformed due to external force, etc., and effectively prevent the terminal block from falling off relative to the wire shaft. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1A It is a perspective view of the coil device according to the first embodiment of the present invention.

[0040] Figure 1B It is a perspective view of a coil device according to a second embodiment of the present invention.

[0041] Figure 2A yes Figure 1A An exploded perspective view of the coil device shown.

[0042] Figure 2B yes Figure 2A An exploded perspective view of the spool is shown.

[0043] Figure 3 Is installed on Figure 1A An enlarged perspective view of a main portion of a terminal block of a bobbin of a coil device shown.

[0044] Figure 4 Yes Figure 3 This is an enlarged exploded perspective view of the main parts of the terminal block with the cover removed.

[0045] Figure 5A Yes Figure 4 This is an enlarged exploded perspective view of the main parts of the bobbin with the inner cover, terminal block, and terminal hardware removed.

[0046] Figure 5B It is an enlarged perspective view of only the terminal metal fitting shown in FIG. 2 .

[0047] Figure 5C is only Figure 1BAn enlarged perspective view of a terminal metal fitting used in the coil device according to the embodiment shown.

[0048] Figure 6 Observe from different angles Figure 5A A perspective view of the terminal block shown.

[0049] Figure 7 This is an exploded perspective view showing the relationship between the bobbin, terminal block, and inner cover.

[0050] Figure 8 is located with Figure 5A An exploded perspective view of the terminal block on the opposite side of the terminal block shown.

[0051] Fig. 9 Observe from different angles Figure 8 A perspective view of the terminal block shown.

[0052] Fig.10 It is a perspective view of a coil device according to a third embodiment of the present invention.

[0053] Fig.11 yes Fig.10 An exploded perspective view of the main parts of the coil device is shown.

[0054] Fig.12 is Fig.11 Top view of bobbin mounted terminal shown.

[0055] Fig.13 It is a perspective view of a coil device according to a fourth embodiment of the present invention.

[0056] Fig.14 yes Fig.13 An exploded perspective view of the main parts of the coil device is shown.

[0057] Fig.15 yes Fig.14 An enlarged perspective view of the terminal block, etc. shown.

[0058] Fig.16 It is a perspective view of a coil device according to a fifth embodiment of the present invention.

[0059] Fig.17 yes Fig.16 An exploded perspective view of the main parts of the coil device is shown.

[0060] Fig.18A is Fig.17 The enlarged perspective view of the bobbin mounted terminal block is shown.

[0061] Fig.18B is Fig.17 An enlarged side view of the bobbin-mounted terminal block is shown.

[0062] Fig.19A Yes means Fig.17 A perspective view of a modified example of the spool shown.

[0063] Fig.19B Yes means Fig.17 A perspective view of another variation of the spool shown.

[0064] Fig. 20 It is a perspective view of a coil device according to a sixth embodiment of the present invention.

[0065] Fig.21 yes Fig. 20 An exploded perspective view of the main parts of the coil device is shown.

[0066] Fig. 22 is Fig.21 The enlarged perspective view of the bobbin mounted terminal block is shown.

[0067] Fig.23 It is a perspective view of a coil device according to a seventh embodiment of the present invention.

[0068] Fig.24 yes Fig.23 An exploded perspective view of the main parts of the coil device is shown.

[0069] Fig.25 is Fig.24 The enlarged perspective view of the bobbin mounted terminal block is shown. DETAILED DESCRIPTION

[0070] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0071] First embodiment

[0072] like Figure 1A As shown, the coil device 10 according to one embodiment of the present invention is mounted on a substrate such as a circuit substrate 300 for use, the installation surface of the coil device 10 is located above the Z-axis direction, and has a first terminal block 70 and a second terminal block 80 on both sides of the X-axis. The coil device 10 can be used as a transformer, etc.

[0073] A pair of terminal metal parts 91 and 92 are mounted on both sides along the Y-axis direction in the first terminal block 70. A pair of terminal metal parts 93 and 94 are mounted on both sides along the Y-axis direction in the second terminal block 80. These terminal metal parts (terminals) 91 to 94 are formed integrally by stamping conductive plates such as metal plates.

[0074] In this embodiment, in the figure, the X-axis, Y-axis, and Z-axis intersect each other approximately perpendicularly, the vertical direction relative to the installation surface of the coil device 10 is the Z-axis, and the direction in which a pair of terminal metal fittings 91, 92 and a pair of terminal metal fittings 93, 94 are located on opposite sides of each other is the X-axis.

[0075] like Figure 2A As shown, the coil device 10 has four cores 12, a bobbin 40, a pair of terminal blocks 70, 80, and two core covers 60, 60. The four cores 12 are assembled to form a magnetic circuit through which the magnetic flux generated by the coil described later passes. These cores 12 have a symmetrical shape and are connected to each other so as to clamp the core cover 60 and the bobbin 40 from the upper and lower directions (Z-axis direction in the figure).

[0076] Each core 12 is a core having a longitudinal cross section (including the cross section of the Y axis and the Z axis) in a substantially E-shaped shape. Each core 12 is made of a soft magnetic body such as ferrite or a metal magnetic body, and has: a flat plate-shaped base 13 extending in the Y-axis direction; a pair of side legs 16, 16 protruding from both ends of each base 13 in the Y-axis direction in the Z-axis direction; and a middle leg 14 protruding from the middle position of each base 13 in the Y-axis direction in the Z-axis direction.

[0077] In this embodiment, the middle 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 convex portion 44b formed on the inner peripheral wall of the first hollow cylinder 44. By allowing a high thermal conductivity resin such as a potting resin to enter the gap, the heat dissipation performance generated inside the coil device 10 is improved.

[0078] 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.

[0079] like Figure 2B As shown, the bobbin 40 has a substantially elliptical flat bobbin base plate 42 at its lower end in the Z-axis direction. 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.

[0080] At the upper Z-axis direction of the first hollow cylinder 44, the bobbin upper flange 48 is integrally formed in the Y-axis-X-axis plane to protrude radially from the first hollow cylinder 44. At both ends of the bobbin upper flange 48 in the X-axis direction, insulating walls 100 and 200 are integrally formed along the Y-axis to protrude upward along the Z-axis.

[0081] In this embodiment, the easing interlocking protrusions 102a and 202a are formed to protrude in the X-axis direction at the approximately central portion of the outer wall in the X-axis direction of the insulating walls 100 and 200. The easing interlocking recesses 72a and 82a of the terminal blocks 70 and 80 are respectively mounted on the respective easing interlocking protrusions 102a and 202a. Terminal metal fittings 91 and 92 as terminals are mounted on one terminal block 70, and terminal metal fittings 93 and 94 as terminals are mounted on the other terminal block 80. In this embodiment, it is preferred that the terminal blocks 70 and 80 are formed separately from the bobbin 40 and are formed using different resin materials, but they may also be formed using the same resin material.

[0082] like Figure 2B 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. A plurality of winding partition flanges 46 separating mutually adjacent wire winding portions along the winding axis (Z axis) of the first electric wire 22 constituting the inner coil 20 in the first winding portion 45 are formed integrally with the first hollow cylinder 44 at predetermined intervals along the winding axis so as to be substantially parallel to the bobbin base plate 42 (and the bobbin upper flange portion 48).

[0083] The bobbin base plate 42, the first hollow cylinder 44, the bobbin upper flange 48 and the winding partition flange 46 of the bobbin 40 are integrally formed by injection molding or the like. A first through hole 44a penetrating in the Z-axis direction is formed inside the first hollow cylinder 44 of the bobbin base plate 42.

[0084] like Figure 2A As shown, in the first through hole 44a, the middle leg 14 of the core 12 is inserted from the top and bottom of the Z-axis direction, and the front end of the middle leg 14 is butted at the approximate center of the through hole 44a in the Z-axis direction. In addition, at the approximate center of the through hole 44a in the Z-axis direction, the front ends of the middle legs 14 inserted from the top and bottom of the Z-axis do not contact each other, but a gap is formed at a predetermined interval.

[0085] like Figure 2B 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 using 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. After the first electric wire 22 is wound around the first winding portion 45 of the bobbin 40 to form the inner coil 20, the bobbin cover 50 is assembled on the outer periphery of the bobbin 40 and combined using the split connection portion 53.

[0086] The bobbin cover 50 has a second hollow cylinder 54 that covers the inner coil 20 from the outside, and a cover lower flange 52 and a cover upper flange 58 are formed along the circumferential direction at a predetermined interval in the Z-axis direction on the outer periphery of the second hollow cylinder 54. The lower flange 52 and the upper flange 58 are arranged parallel to the plane of the XY axis and extend parallel to the installation surface.

[0087] The lower flange portion 52 and the upper flange portion 58 form a second winding portion 55, in which, for example, the second electric wire 32 constituting the outer coil 30 forming the secondary coil is wound in a straight line (or α-winding). Straight line winding is a common winding method of winding the electric wire from one end of the winding shaft to the other end. α-winding will be described later.

[0088] like Figure 2A As shown, a pair of core covers 60 are mounted on both sides of the Y-axis direction on the outer periphery of the bobbin cover 50 mounted with the outer coil 30. The core cover 60 is formed of an insulating member such as synthetic resin, and has a cover body 62, whose outer peripheral surface serves as a guide surface for the side legs 16 of the guide core 12, and the outer coil 30 is located on its inner peripheral surface.

[0089] Mounting edges 64, 64 are integrally formed at both ends of the cover body 62 in the Z-axis direction. The mounting edge 64 on the upper side of the Z-axis engages with the upper surface of the bobbin upper flange portion 48, and the mounting edge 64 on the lower side of the Z-axis engages with the lower surface of the bobbin substrate 42, and the core cover 60 is mounted on the bobbin 40.

[0090] The cover body 62 has an inner circumferential shape corresponding to the outer circumferential shape of the core cover 60, and an insulating plate portion 66 is integrally formed at both ends in the X-axis direction. Engaging protrusions 66a protruding inward in the Y-axis direction are formed above and below the insulating plate portion 66 in the Z-axis direction. The engaging protrusions 66a on the upper side of the Z-axis engage with the inner surface of the insulating wall 100 or 200 of the bobbin 40, and the engaging protrusions 66a on the lower side of the Z-axis engage with the lower surface of the bobbin substrate 42 at both ends of the bobbin substrate 42 in the X-axis direction.

[0091] As a result, the insulating plate portion 66 of the core cover 60 is combined with the insulating wall 100 or 200 and the bobbin base plate 42 to improve the core 12 and Figure 2B The outer coil 30 shown is insulated. The inner surface (center side of the coil device 10) of the insulating plate portion 66 may be in contact with the core 12, or may have a shape that matches the outer shape of the core 12.

[0092] like Figure 2BAs shown, in this embodiment, the winding wall flange 46 of the elliptical ring shape is formed on a plane substantially parallel to the XY axis, so as to form a winding area with a predetermined interval along the Z axis direction on the outer periphery of the first hollow cylinder 44 of the substantially elliptical cylinder shape. In this embodiment, a plurality of winding wall flanges 46 are formed substantially in parallel at predetermined intervals along the Z axis direction, but the number is not particularly limited. The area where these winding wall flanges 46 are formed becomes the first winding portion 45.

[0093] The width of the winding region along the winding axis (Z axis) in each winding region separated by the winding partition flange 46 is set to a width that only one electric wire 22 can enter. That is, the winding region width w1 (not shown) is preferably in the relationship of d1<w1<(2×d1) with respect to the wire diameter d1 (not shown) of the electric wire 22, and more preferably in the relationship of d1<w1<(1.2×d1). When the winding region width w1 is too wide with respect to the wire diameter d1, winding disorder is likely to occur, which is contrary to the request for compactness of the coil device.

[0094] In addition, in each winding area, the winding area width is preferably the same, but may be slightly different. In addition, the winding area width between the bobbin 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 bobbin 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 is not particularly limited.

[0095] In this embodiment, a spacer convex piece 46a for positioning is intermittently formed in a part of the circumference of the winding partition wall flange 46 closest to the bobbin base plate 42 and inserted into the lower surface of the cover lower flange portion 52 of the bobbin cover 50. In addition to the spacer convex piece 46a, a flow gap through which a high thermal conductivity resin can flow in the axial direction is formed in a notch shape between the outer peripheral surface of the winding partition wall flange 46 and the inner peripheral surface of the bobbin cover 50.

[0096] It is preferable that the partitioning fin 46a protrudes from the outer peripheral surface of the winding partition wall flange 46 even at the position of the split connection portion 53 of the bobbin cover 50. The protruding height (radial height) of the partitioning fin 46a defines the radial width of the flow gap.

[0097] In 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 50 a and 50 b are connected to form the bobbin cover 50 .

[0098] The bobbin cover 50 includes: a second winding portion 54 in which a second electric wire 32 different from the first electric wire 22 is wound around the outer periphery, and a gap retaining piece 52a as a non-winding portion provided below the second winding portion 54 in the axial direction. The gap retaining piece 52a as the non-winding portion has an opening 52b or a cutout that connects the inside and the outside of the bobbin cover 50. The gap retaining piece 52a is formed to extend from the outer peripheral edge of the lower flange portion of the cover in the Z-axis downward direction, and its lower end can abut against the upper surface of the bobbin substrate 42.

[0099] The opening 52b is formed in each of the half-cut bodies 50a and 50b located on both sides in the X-axis direction, and is formed at a position corresponding to the flow gap of the partitioning convex piece 46a provided on the winding partition flange 46 of the bobbin 40. At both ends of the bobbin cover 50 in the X-axis direction, the gap retaining piece 52a is not formed on the outer peripheral edge of the cover lower flange portion 52, so that a high thermal conductivity resin or the like can freely enter from the gap between the cover lower flange portion 52 and the bobbin substrate 42.

[0100] In addition, the cover upper flange portion 58 of the connection portion 53a located in the half body 50a is formed with a step-shaped 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 below the connection upper flange portion 58a for connection.

[0101] In addition, a stopper protrusion 58e is formed on the cover flange portion 58 of the connection portion 53b located in the other half body 50b, which can abut against the connection front end of the connection upper flange portion 58a. The stopper protrusion 58e protrudes upward along the Z axis relative to the cover flange portion 58. Preferably, the protrusion height of the stopper protrusion 58e relative to the upper surface of the cover flange portion 58 is 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 58e and the upper surface of the connection upper flange portion 58a are in contact with the lower surface of the bobbin upper flange portion 48 of the bobbin 40, and an air outlet gap is formed between the upper surface of the cover flange portion 58 and the lower surface of the bobbin upper flange portion 48 of most of the parts other than the split connection portion 53.

[0102] Figure 2B The first electric wire 22 shown may be made of a single wire or a twisted wire, preferably an insulated coated wire. The outer diameter d1 (not shown) of the first electric wire 22 is not particularly limited, but when a large current is passed, for example, it is preferably The second electric wire 32 may be the same as the first electric wire 22 , or may be different.

[0103] In this embodiment, the inner coil 20 composed of the first electric wire 22 constitutes the primary coil of the transformer, and the outer coil 30 composed of the second electric wire 32 wound around the bobbin cover 50 constitutes the secondary coil. Therefore, in this embodiment, the wire diameter of the second electric wire 32 constituting the outer coil 30 is thicker than the wire diameter of the first electric wire 22, but the wire diameter is not particularly limited, and the wire diameters may be the same, or may be different. In addition, the materials of the first electric wire 22 and the second electric wire 32 may be the same or different.

[0104] In the bobbin 40 of the present embodiment, at least one connection groove for connecting adjacent winding regions is formed in each winding partition flange 46. In the present embodiment, the circumferential position of at least one of the pair of cutout edges formed in the winding partition flange 46 in a manner that limits the circumferential width of each connection groove is different between the adjacent winding partition flanges 46 along the Z-axis direction (winding axis), but may also be the same position. In addition, the circumferential direction is a direction along the elliptical outer peripheral surface of the hollow cylinder 44.

[0105] In the bobbin 40 of the present embodiment, the first electric wire 22 is α-wound, for example, from the center of the first winding portion 45 in the Z-axis direction. That is, the center portion 22b of the first electric wire 22 is arranged to pass through the connection groove located in the center of the first winding portion 45 in the Z-axis direction, and a lower winding portion is passed from the center of the first electric wire 22 toward the end through a winding area one layer below the center. In addition, the other upper winding portion is passed from the center of the first electric wire 22 toward the end through a winding area located on one of the winding areas passed by the lower winding portion.

[0106] Then, the lower winding part is wound more than one turn in the same winding area as viewed from the Z axis, and the upper winding part is wound more than one turn in the same winding area of ​​the upper layer as viewed from the Z axis. Then, the lower winding part passes through the connecting groove from the wound winding area to the winding area of ​​the next layer in the Z axis direction, and is wound in the same direction in the winding area. In addition, the upper winding part passes through the connecting groove from the wound winding area to the winding area of ​​the upper layer in the Z axis direction, and is wound in the same direction in the winding area.

[0107] By repeating this operation, the first electric wire 22 is wound around the first winding portion 45 by α. In the present embodiment, the first winding portion 45 is divided into a first main winding portion 45a located between the partitioning protrusion 46a and the bobbin upper flange portion 48, and a first auxiliary winding portion 45b located between the partitioning protrusion 46a and the bobbin base plate 42. In the first main winding portion 45a, the first electric wire 22 is α-wound in one or more layers in the radial direction, and in the first auxiliary winding portion 45b, the first electric wire 22 is α-wound in the number of layers (first auxiliary winding layers) that is equal to or greater than the number of winding layers (first main winding layers) in the radial direction of the first main winding portion 45a.

[0108] The outermost circumferential layer of the first electric wire 22 wound on the first auxiliary winding portion 45b is located outside the cylinder wall of the second winding portion 55. By configuring in this way, the flange-shaped coil portion of the first electric wire 22 wound on the first auxiliary winding portion 45b and the outer coil portion 30 of the second electric wire 32 wound on the second winding portion 55 can be overlapped when viewed from the axial direction. Figure 2B , the figure shows a case where the number of radial winding layers (the number of first main winding layers) wound on the first auxiliary winding portion 45b is equal to that wound on the first main winding portion 45a. Therefore, the flange-shaped coil portion of the first electric wire 22 wound on the first auxiliary winding portion 45b and the outer coil portion 30 of the second electric wire 32 wound on the second winding portion 55 do not overlap when viewed from the axial direction.

[0109] The lead wire portion (one end portion of the electric wire 22) 22a from the flange-shaped coil portion at the lower end of the lower winding portion of the first electric wire 22 after winding is formed from Figure 8 The extraction groove 206 of the insulating wall 200 of the bobbin 40 is shown to be drawn out from the base 58f and out of the bobbin cover 50. The lead wire portion 22a drawn out of the bobbin cover 50 is clamped and joined by the wire connecting portion 93a of the terminal metal fitting 93.

[0110] in addition, Figure 2B The lead wire portion 22a from the upper winding portion of the first electric wire 22 after winding α shown in FIG. Figure 8 The extraction groove 206 of the insulating wall 200 of the bobbin 40 is shown to be extracted. Figure 2B The lead wire 22a is placed on the base 58f shown in the figure and is pulled out to the outside of the bobbin cover 50. The lead wire portion 22a pulled out to the outside of the bobbin cover 50 is clamped and joined by the wire connecting portion 94a of the terminal metal fitting 94.

[0111] In addition, if Figure 2BAs shown, the base 58f is formed as a part of the cover flange 58 at the end of the spool cover 50 in the X-axis direction. In the other spool cover 50, the base 58g is also formed as a part of the cover flange 58 at the end on the opposite side in the X-axis direction, but the width in the X-axis direction is shorter than that of the base 58f. In addition, in this embodiment, the "outside" is the side away from the central axis of the spool 40, and the "inside" is the side close to the central axis of the spool.

[0112] Figure 2B In the bobbin cover 50 shown, the second electric wire 32 constituting the outer coil 30 forming the secondary coil is wound in a straight line in its second winding portion 55. The straight line winding is a winding method in which the electric wire 32 is wound sequentially from one end to the other end in the Z-axis direction relative to the outer peripheral surface of the winding portion 55. In this embodiment, the electric wire 32 is wound in a straight line in the radial direction in one layer or two or more layers. Assuming that the winding is in a two-layer straight line, the first layer is completely wound and then the second layer is wound thereon.

[0113] like Figure 5A As shown, the lead wire portions 32a, 32a of the second electric wire 30 constituting the outer coil 30 are pulled out in opposite directions along the Y-axis direction below the Z-axis of the relaxing fitting protrusion 102a formed on the bobbin 40. One lead wire portion 32a is clamped and joined by the wire connecting portion 91a of the terminal metal fitting 91, and the other lead wire portion 32a is clamped and joined by the wire connecting portion 92a of the terminal metal fitting 92.

[0114] like Figure 5A As shown in FIG. 1 , the terminal metal fittings 91 and 93 are mounted on the terminal block 70. Figure 8 As shown, the terminal metal parts 93 and 94 are mounted on the terminal block 80. Figure 5B As shown, in this embodiment, there are four terminal metal fittings 91 to 94. A pair of terminal metal fittings 91 and 92 have mutually line-symmetrical shapes on the X-axis and the Z-axis, and another pair of terminal metal fittings 93 and 94 have mutually line-symmetrical shapes on the X-axis and the Z-axis.

[0115] like Figure 5A As shown, the terminal metal fittings 91 and 92 respectively have wire connection parts 91a and 92a for clamping and joining the lead part 32a of the wire 32. In addition, the terminal metal fittings 91 and 92 respectively have hook parts 91b and 92b formed at positions different from the wire connection parts 91a and 92a. The hook parts 91b and 92b are respectively inserted into the terminal grooves 74 formed in the terminal block 70 so as to be movable in the Z-axis direction.

[0116] The hook portions 91b and 92b are formed to protrude from the ends of the planar mounting portions 91c and 92c in the Y-axis direction to the lower side in the Z-axis direction, and the lower ends of the hook portions 91b and 92b are formed in a hook shape. Insertion holes 91d and 92d are formed in the central parts of the mounting portions 91c and 92c, respectively. The insertion holes 91d and 92d are roughly aligned with the bolt holes of the nuts 77 assembled in the mounting holes 76 provided in the terminal block 70, and each terminal metal fitting 91 and 92 is mounted on the terminal block 70. The inner diameter of the mounting hole 76 may be sufficiently larger than the inner diameter of the bolt hole of the nut 77.

[0117] The mounting parts 91c, 92c and the wire connecting parts 91a, 92a are integrally connected by connecting parts 91e, 92e, respectively. The connecting parts 91e, 92e are integrally formed into a plane flush with the plane of the mounting parts 91c, 92c. The width of the connecting parts 91e, 92e in the X-axis direction is narrower than the width of the mounting parts 91c, 92c in the X-axis direction.

[0118] Insertion protrusions 91f and 92f protruding downward in the Z-axis direction from the plane of the mounting portions 91c and 92c are formed at the ends of the mounting portions 91c and 92c, which are wider in the X-axis direction than the connecting portions 91e and 92e. The insertion protrusions 91f and 92f are respectively inserted into the fitting grooves 75 and 75 formed on the upper surface of the two ends of the terminal block 70 in the Y-axis direction.

[0119] like Figure 8 As shown, the terminal metal fittings 93 and 94 respectively have wire connection parts 93a and 94a for clamping and joining the lead part 22a of the wire 22. In addition, the terminal metal fittings 93 and 94 respectively have hook parts 93b and 94b formed at positions different from the wire connection parts 93a and 94a. The hook parts 93b and 94b are respectively inserted into the terminal grooves 84 and 84 formed in the terminal block 80 so as to be movable in the Z-axis direction.

[0120] The hook portions 93b and 94b are formed to protrude from the ends of the planar mounting portions 93c and 94c in the Y-axis direction to the lower side in the Z-axis direction, and the lower ends of the hook portions 93b and 94b are formed in a hook shape. Insertion holes 93d and 94d are formed in the central parts of the mounting portions 93c and 94c, respectively. The insertion holes 93d and 94d are roughly aligned with the bolt holes of the nuts (not shown) installed in the mounting holes 86 provided in the terminal block 80, and each terminal metal fitting 93 and 94 is installed on the terminal block 80.

[0121] The mounting parts 93c, 94c and the wire connecting parts 93a, 94a are integrally connected by connecting parts 93e, 94e, respectively. A step-shaped bending part is formed in each connecting part 93e, 94e so that the height of the wire connecting parts 93a, 94a in the Z-axis direction is lower than the plane of the mounting parts 93c, 94c. The width of the connecting parts 93e, 94e in the X-axis direction is narrower than the width of the mounting parts 93c, 94c in the X-axis direction.

[0122] Insertion protrusions 93f and 94f are formed at the ends of the mounting parts 93c and 94c, which are wider than the connecting parts 93e and 94e in the X-axis direction, on the opposite sides of the hook parts 93b and 94b. The insertion protrusions 93f and 94f protrude downward in the Z-axis direction from the plane of the mounting parts 93c and 94c. The insertion protrusions 93f and 94f are respectively inserted into the fitting grooves 85 and 85 formed on the upper surface of the two ends of the terminal block 80 in the Y-axis direction.

[0123] like Figure 5A As shown, the terminal block 70 has a block body 71. The block body 71 has a through hole 72 that penetrates the block body 71 in the X-axis direction. Terminal mounting parts 73, 73 are integrally formed on both sides of the block body 71 in the Y-axis direction. Mounting holes 76, 76 are respectively formed in the approximate center of the upper surface of the terminal mounting parts 73, 73, and nuts 77 can be respectively assembled in each mounting hole 76.

[0124] Terminal grooves 74, 74 are formed at the boundaries between the terminal mounting parts 73, 73 and the main body 71, respectively, and hooks 91b, 92b of the terminal metal fittings 91, 92 are inserted into the terminal grooves 74, 74 so as to be movable in the Z-axis direction. In addition, fitting grooves 75, 75 are formed on the upper surfaces of the ends of the terminal mounting parts 73, 73 in the Y-axis direction, and insertion protrusions 91f, 92f of the terminal metal fittings 91, 92 are inserted into the fittings 91f, 92f, respectively. As a result, the movement of the terminal metal fittings 91, 92 in the X-axis and Y-axis directions relative to the terminal block 70 is restricted, and each terminal metal fitting 91, 92 is only allowed to move in the Z-axis direction relative to the terminal block 70.

[0125] In this embodiment, the wire connection parts 91a and 92a of each terminal metal fitting 91 and 92 are located outside along the Y-axis direction from both ends of the terminal block 70, and the upper surfaces of the wire connection parts 91a and 92a are roughly flush with the upper surfaces of the mounting parts 91c and 92c.

[0126] A relaxing fitting recess 72a is formed on the side of the through hole 72 formed in the table body 71 facing the bobbin 40, into which the relaxing fitting protrusion 102a formed on the bobbin 40 enters. In addition, a mounting recess 72b is formed on the side of the through hole 72 opposite to the side facing the bobbin 40. Figure 7 The inner cover 78 is shown.

[0127] exist Figure 5A After the hook portions 91b and 92b of the terminal metal fittings 91 and 92 are inserted into the terminal grooves 74 and 74 of the terminal block 70, the inner cover 78 is mounted on the mounting recess 72b of the terminal block 70. As a result, the hook portions 91b and 92b of the terminal metal fittings 91 and 92 are hooked to the terminal grooves 74 and 74 of the terminal block 70. Figure 7 The inner cover 78 shown is engaged to prevent the terminal metal fittings 91 , 92 from being pulled out of the terminal block 70 , and to limit the Z-axis movement range of the terminal metal fittings 91 , 92 relative to the terminal block 70 .

[0128] Install on the outside of the inner cover 78 Figure 4 The outer cover 79 shown. The outer cover 79 covers the terminal block 70 with the inner cover 78 installed, together with the terminal metal fittings 91 and 92, from the outside of the X-axis and Y-axis, and also covers the bottom of the Z-axis, but does not cover the top of the Z-axis. The outer cover 79 is mounted on the terminal block 70, for example, and can move relative to the bobbin 40 in the X-axis and Y-axis directions together with the terminal block 70.

[0129] like Figure 5A As shown, the relaxing interlocking protrusion 102a protruding from the substantially central portion in the Y-axis direction to the outer side in the X-axis direction of the insulating wall 100 of the bobbin 40 includes a main protrusion 102a1 and a pair of sub-protrusions 102a2, 102a2 formed on both sides of the main protrusion 102a1 in the Y-axis direction. The thickness of each sub-protrusion 102a2 in the Z-axis direction is smaller than the thickness of the main protrusion 102a1 in the Z-axis direction. In addition, the protruding height of each sub-protrusion 102a2 in the X-axis direction is smaller than the protruding height of the main protrusion 102a1 in the X-axis direction.

[0130] A stop hole 104 is formed at the base end of the main protrusion 102a1 connected to the insulating wall 100. Figure 7 As shown, the anti-slip hole 104 passes through the main protrusion 102a1 along the Z-axis direction. Figure 7 The anti-slip hole 104 shown is constituted as follows: Figure 6 The stopper projection 72 a 4 at the front end of the support piece 72 a 3 shown in FIG. 1 enters, and the terminal block 70 is not stopped from falling off from the relaxing fitting projection 102 a of the bobbin 40 .

[0131] like Figure 6 As shown, the relaxed fitting recess 72a as one opening of the through hole 72 has a main recess 72a1 located in the center of the Y-axis direction and a pair of auxiliary recesses 72a2, 72a2 located on both sides of the Y-axis direction. The width of the auxiliary recess 72a2 in the Z-axis direction is narrower than the width of the main recess 72a1 in the Z-axis direction.

[0132] exist Figure 6 The secondary recess 72a2 is shown, Figure 7The auxiliary protrusion 102a2 of the bobbin 40 shown in the figure is fitted so as to be movable in the X-axis and Y-axis directions. Figure 6 The main recess 72a1 shown, Figure 7 The main protrusion 102a1 shown is inserted so as to be movable in the X-axis and Y-axis directions. Figure 6 The inner surface of the auxiliary recessed portion 72a2 shown in the figure, which is substantially parallel to the X-axis and the Y-axis, serves as a guide surface (sliding surface) for the auxiliary convex portion 102a2.

[0133] In this embodiment, the gap between the auxiliary protrusion 102a2 and the auxiliary recess 72a2 along the Z-axis direction is smaller than the gap between the main protrusion 102a1 and the main recess 72a1 along the Z-axis direction. Along the guide surface where the auxiliary protrusion 102a2 and the auxiliary recess 72a2 contact, the terminal block 70 is held relative to the bobbin 40 so as to be movable in the X-axis direction and the Y-axis direction. That is, the relaxing fitting protrusion 102a is inserted within a predetermined range in the relaxing fitting recess 72a1 so as to be movable in the X-axis direction and the Y-axis direction.

[0134] In addition, in this embodiment, if Figure 6 As shown, a portion of the inner wall of the relaxing fitting recess 72 is formed by a support piece 72a3 that can be elastically deformed to a width in the Z-axis direction that can open the opening entrance of the relaxing fitting recess 72. Figure 7 The anti-slip hole 104 of the relief fitting convex portion 102a shown in the figure is engaged to prevent slipping. Figure 6 In order to elastically deform the support piece 72a3 into a cantilever, slits are formed on both sides of the support piece 72a3 in the Y-axis direction.

[0135] in addition, Figure 6 The stopper protrusion 72a4 and Figure 7 The engagement of the anti-dropping hole 104 shown prevents the terminal block 70 from dropping out relative to the bobbin 40 , but allows the terminal block 70 to slide freely relative to the bobbin 40 in the X-axis and Y-axis directions.

[0136] Figure 2A The terminal block 80, inner cover 88 and outer cover 89 shown have the same structure as the terminal block 70, inner cover 78 and outer cover 79. In particular, the inner cover 88 and outer cover 89 are substantially the same as the inner cover 78 and outer cover 79, respectively, and therefore, description thereof is omitted.

[0137] Hereinafter, the relationship between the terminal block 80 and the bobbin 40 will be mainly described.

[0138] like Figure 8As shown, the terminal block 80 has a block body 81. The block body 81 has a through hole 82 that penetrates the block body 81 in the X-axis direction. Terminal mounting parts 83, 83 are integrally formed on both sides of the block body 81 in the Y-axis direction. Mounting holes 86, 86 are respectively formed in the approximate center of the upper surface of the terminal mounting parts 83, 83, and nuts (not shown) can be respectively assembled in each mounting hole 86.

[0139] Terminal grooves 84, 84 are formed at the boundaries between the terminal mounting parts 83, 83 and the table body 81, respectively. In each terminal groove 84, 84, the hooks 93b, 94b of the terminal metal parts 93, 94 are inserted so as to be movable in the Z-axis direction. In addition, fitting grooves 85, 85 are formed on the upper surface of the ends of the terminal mounting parts 83, 83 in the Y-axis direction, and the insertion protrusions 93f, 94f of the terminal metal parts 93, 94 are inserted into each fitting groove. As a result, the movement of the terminal metal parts 93, 94 in the X-axis and Y-axis directions relative to the terminal table 80 is restricted, and each terminal metal part 93, 94 is only allowed to move in the Z-axis direction relative to the terminal table 80.

[0140] In the present embodiment, the wire connection parts 93a and 94a of each terminal metal fitting 93 and 94 are located on the outside along the Y-axis direction from both ends of the terminal block 80, and the upper surfaces of the wire connection parts 93a and 94a are arranged at a position which is stepped down from the upper surfaces of the mounting parts 93c and 94c in the Z-axis direction.

[0141] A relaxing fitting recess 82a into which the relaxing fitting protrusion 202a formed on the bobbin 40 enters is formed on the side of the through hole 82 formed on the table body 81 facing the bobbin 40. In addition, a mounting recess 82b is formed on the side of the through hole 82 opposite to the side facing the bobbin 40. The inner cover 88 is mounted on the mounting recess 88b.

[0142] After the hooks 93b and 94b of the terminal metal fittings 93 and 94 are respectively inserted into the terminal grooves 84 and 84 of the terminal block 80, the inner cover 88 is mounted on the mounting recess 82b of the terminal block 80. As a result, the hooks 93b and 94b at the front ends of the terminal metal fittings 93 and 94 are engaged with the inner cover 88, so that the terminal metal fittings 93 and 94 are prevented from being pulled out of the terminal block 80, and the Z-axis movement range of the terminal metal fittings 93 and 94 relative to the terminal block 80 is limited.

[0143] An outer cover 89 is mounted on the outer side of the inner cover 88. The outer cover 89 covers the terminal block 80 mounted with the inner cover 88 from the outer side of the X-axis and Y-axis together with the terminal metal fittings 93 and 94, and also covers the lower side of the Z-axis, but does not cover the upper side of the Z-axis. The outer cover 89 is mounted with respect to, for example, the terminal block 80, and together with the terminal block 80, is relatively movable with respect to the bobbin 40 in the X-axis and Y-axis directions.

[0144] The relaxing interlocking protrusion 202a protruding from the substantially central portion in the Y-axis direction toward the outer side in the X-axis direction of the insulating wall 200 of the bobbin 40 includes a main protrusion 202a1 and a pair of sub-protrusions 202a2, 202a2 formed on both sides of the main protrusion 202a1 in the Y-axis direction. The thickness of each sub-protrusion 202a2 in the Z-axis direction is smaller than the thickness of the main protrusion 202a1 in the Z-axis direction. In addition, the protruding height of each sub-protrusion 202a2 in the X-axis direction is smaller than the protruding height of the main protrusion 202a1 in the X-axis direction.

[0145] The main protrusion 202a1 connected to the insulating wall 200 has a retaining hole 204 formed at its base end. The retaining hole 204 penetrates the main protrusion 202a1 in the Z-axis direction. Fig. 9 The stopper protrusion 82a4 at the front end of the support piece 82a3 shown in FIG. 8 enters, and the terminal block 80 is prevented from falling off from the relaxing fitting protrusion 202a of the bobbin 40.

[0146] like Fig. 9 As shown, the relaxed fitting recess 82a as one opening of the through hole 82 has a main recess 82a1 located in the center of the Y-axis direction and a pair of auxiliary recesses 82a2, 82a2 located on both sides of the main recess 82a1 in the Y-axis direction. The width of the auxiliary recess 82a2 in the Z-axis direction is narrower than the width of the main recess 82a1 in the Z-axis direction.

[0147] Figure 8 The auxiliary protrusion 202a2 and the auxiliary recess 82a2 of the bobbin 40 shown in the figure are engaged with each other so as to be movable in the X-axis and Y-axis directions. Fig. 9 The main recess 82a1 shown is inserted into Figure 8 The main protrusion 202a1 is shown. Fig. 9 The inner surface of the auxiliary recessed portion 82a2 shown in the figure, which is substantially parallel to the X-axis and the Y-axis, serves as a guide surface (sliding surface) for the auxiliary convex portion 202a2.

[0148] In this embodiment, the gap between the auxiliary protrusion 202a2 and the auxiliary recess 82a2 along the Z-axis direction is smaller than the gap between the main protrusion 202a1 and the main recess 82a1 along the Z-axis direction. Along the guide surface where the auxiliary protrusion 202a2 and the auxiliary recess 82a2 contact, the terminal block 80 is held relative to the bobbin 40 so as to be movable in the X-axis direction and the Y-axis direction. That is, the relaxing fitting protrusion 202a can move in the X-axis direction and the Y-axis direction within a predetermined range in the relaxing fitting recess 82a1.

[0149] In addition, in this embodiment, if Fig. 9 As shown, a portion of the inner wall of the relaxing fitting recess 82 is formed by a support piece 82a3 that can be elastically deformed to a width in the Z-axis direction that can open the opening entrance of the relaxing fitting recess 82. Figure 8The anti-slip hole 204 of the relief fitting convex portion 202a shown in the figure is engaged to prevent slipping. Fig. 9 In order to elastically deform the support piece 82a3 into a cantilever, slits are formed on both sides of the support piece 82a3 in the Y-axis direction.

[0150] in addition, Fig. 9 The stopper protrusion 82a4 and Figure 8 The engagement of the illustrated anti-dropping hole 204 prevents the terminal block 80 from dropping out relative to the bobbin 40 , but allows the terminal block 80 to slide freely relative to the bobbin 40 in the X-axis and Y-axis directions.

[0151] In this embodiment, the terminal blocks 70 and 80 are formed separately from the bobbin 40. As the material constituting the terminal blocks 70 and 80, for example, a resin that can be cleaned differently from the bobbin 40, for example, a resin that has good formability or good heat dissipation compared to the bobbin 40 can be selected. Specifically, for example, resin materials such as PET, PBK, or PPS can be cited.

[0152] The coil device 10 of the present embodiment is manufactured as follows: Figure 2A to Figure 2B The components shown are assembled, and the electric wires 22 and 32 are respectively wound around the bobbin 40 and the bobbin cover 50. The coil device 10 of this embodiment may be housed in a case (not shown) that can be filled with a potting resin or the like, but the case may not always be necessary.

[0153] An example of a method for manufacturing the coil device 10 is described below. In manufacturing the coil device 10, first, a Figure 2B The bobbin 40 shown. The material of the bobbin 40 is not particularly limited, and the bobbin 40 is formed of an insulating material such as resin.

[0154] Next, the first electric 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 electric wire 22 used in forming the inner coil 20 is not particularly limited, but preferably a stranded wire or the like is used. In the inner coil 20, a flange-shaped coil portion having an outer diameter thicker than other portions of the inner coil 20 can also be formed by α winding at the Z-axis lower end of the inner coil portion 20.

[0155] Next, the bobbin cover 50 is mounted on the bobbin 40 on which the inner coil 20 is formed. The second electric wire 32 constituting the outer coil 30 is wound around the outer periphery of the second hollow cylinder 54 of the bobbin cover 50. The flange-shaped coil portion is located inside the gap retaining piece 52a of the cover lower flange portion 52 of the bobbin cover 50.

[0156] The lead parts 22a, 22a are pulled out to the opposite sides in the Y-axis direction on the base 58f of the bobbin cover 50, and the lead parts 32a, 32a are pulled out to the opposite sides in the Y-axis direction from under the base 58g. Then, the terminal blocks 70 and 80 are moved and installed from the outside of the insulating walls 100, 200 of the bobbin 40 in the X-axis direction.

[0157] When the terminal blocks 70 and 80 are respectively equipped with the terminal metal fittings 91, 92 and the terminal metal fittings 93, 94, the lead parts 22a, 32a are then connected to the wire connecting parts 91a to 94a of the terminal metal fittings 91 to 94. The method for connecting the lead parts 22a, 32a to the wire connecting parts 91a to 94a of the terminal metal fittings 91 to 94 is not particularly limited, and examples thereof include soldering, welding, resistance welding, ultrasonic welding, laser welding, riveting, thermocompression, and heat fusion.

[0158] In addition, in the present embodiment, the lead wires 22a and 32a may be connected to the wire connection parts 91a to 94a of the terminal metal fittings 91 to 94 before the terminal blocks 70 and 80 are respectively mounted on the outside of the insulating walls 100 and 200 of the bobbin 40. In this case, the terminal blocks 70 and 80 are then respectively mounted on the outside of the insulating walls 100 and 200 of the bobbin 40, and the terminal metal fittings 91 to 94 are then mounted on the terminal blocks 70 and 80, and then the inner covers 78 and 88 are respectively mounted on the terminal blocks 70 and 80. The outer covers 79 and 89 may be respectively mounted on the terminal blocks 70 and 80 as needed.

[0159] Before and after it, Figure 2A The core cap 60 shown is mounted on both sides of the bobbin 40 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 center legs 14, 14 of the core 12 and the front ends of the side legs 16, 16 are butted against each other. In addition, a gap may be maintained between the front ends of the center legs 14, 14.

[0160] As the material of each core 12, soft magnetic materials such as metal and ferrite can be cited, but there is no particular limitation. The core 12 can also be fixed to the bobbin cover 50 and the bobbin 40 by bonding with an adhesive material or by winding a strip-shaped member around the outer periphery, but can also be simply installed. In the present embodiment, most of the coil device 10 assembled in this way can also be accommodated in the interior of a housing not shown in the figure. It is also possible to fill a high thermal conductivity resin such as a casting resin with the coil device 10 accommodated in the interior of the housing.

[0161] On the core 12, the heat sinks may be arranged so that the upper surface of the core 12 and the side surface in the Y-axis direction are in contact, and the side legs extending downward from both ends in the Y-axis direction of each heat sink may be immersed in the high-conductivity resin stored in the shell. By configuring in this way, the heat of the upper part of the core 12 is transferred to the high-conductivity resin stored in the shell, and heat is effectively dissipated. It is preferred that the heat sink is made of a high-conductivity material such as a metal such as aluminum.

[0162] Furthermore, the filling of the housing with the high thermal conductivity resin is preferably performed before the coil device 10 is accommodated in the housing, but the filling of the resin may be performed after the coil device 10 is accommodated in the housing.

[0163] The coil device 10 of the present embodiment can be used as a vertical coil device in which the winding axis of the coil is arranged perpendicular to the mounting substrate surface. Therefore, the core 12 inserted into the hollow portion of the bobbin 40 can be easily cooled.

[0164] In addition, in this embodiment, if Figure 2B As shown, the bobbin cover 50 can be divided by the dividing connection portion 53 parallel to the winding axis, so the bobbin cover 50 can be easily arranged on the outer periphery of the bobbin 40.

[0165] In addition, in the coil device 10 of the present embodiment, the electric wire 22 is wound in each winding area so that only a single electric wire winding portion exists along the winding axis direction. Therefore, it is easy to prevent the difference in the number of windings of the electric wire 22 per layer in the radial direction, which contributes to the stabilization of the leakage characteristics (coil coupling). That is, it is easy to strictly control the coupling coefficient between the outer coil 30 constituting the secondary coil and the inner coil 20 constituting the primary coil, and the coil device 10 of the present embodiment can also be used as a leakage transformer.

[0166] In addition, in this embodiment, if Figure 2B As shown, gap retaining pieces 52a are intermittently provided at the outer edge of the cover lower flange portion 52 of the bobbin cover 50. Therefore, it is easy to form a flange-shaped coil portion with a large number of radial winding layers at the lower end of the first coil 20 in the Z-axis direction.

[0167] In addition, in the present embodiment, a flow gap is uniformly formed between the outer peripheral edge of the winding partition flange 46 and the inner peripheral surface of the bobbin cover 50. With such a configuration, the distance between the coils 20 and 30 of the electric wire wound on the inner and outer sides of the bobbin cover 50 is easily constant, and the variation of the coil characteristic value is reduced.

[0168] In particular, in the coil device 10 of the present embodiment, the bobbin cover 50 has a gap retaining piece 52a, and an opening 52b or a cutout is formed in the gap retaining piece 52a. Therefore, a high thermal conductivity resin such as a casting resin enters the interior of the bobbin cover 50 through the opening 52b or the cutout, and enters between the bobbin cover 50 and the bobbin 40. As a result, the first electric wire 22 wound on the first winding portion 45 of the bobbin 40 contacts the high thermal conductivity resin, and the heat generated from the first electric wire 22 is transferred from the high thermal conductivity resin and well dissipated. Therefore, in the coil device 10 of the present embodiment, even if the coil device 10 is miniaturized, the heat dissipation is excellent.

[0169] In addition, in the present embodiment, the bobbin cover 50 has a cover lower flange portion 52 and a cover upper flange portion 58. Moreover, a gap retaining piece 52a is provided below the cover lower flange portion 52. In addition, the cover upper flange portion 58 is arranged on the lower side of the bobbin upper flange portion 48 in the axial direction, and an outlet gap is formed between the bobbin upper flange portion 48 and the cover upper flange portion 58 so that the air inside the bobbin cover 50 can be discharged to the outside. The outlet gap is formed by the connection upper flange portion 58a, the step convex portions 58c, 58d, and the stopper convex portion 58e formed on the upper surface of the cover upper flange portion 58 abutting against the lower surface of the bobbin upper flange portion 48.

[0170] With this configuration, when the high thermal conductivity resin enters the inside of the bobbin cover 50 from below the cover lower flange portion 52, the air inside the bobbin cover 50 is easily discharged from the outlet gap, and the resin flows more smoothly.

[0171] In addition, in this embodiment, the first electric wire 22 arranged on the inner circumference is the primary coil of the transformer, but it can also be the secondary coil (inner coil 20) to which a higher voltage is applied. In this case, by arranging the secondary coil (inner coil 20) to which a high voltage is applied inside the primary coil (outer coil 30) to which a lower voltage is applied, insulation is facilitated.

[0172] In addition, in the present embodiment, the terminal blocks 70 and 80 are formed separately from the bobbin 40. Therefore, when the specification of the bobbin 40 is changed, it is sufficient to prepare the terminal blocks 70 and 80 corresponding to the specification and attach them to the bobbin 40. That is, there is no need to change the overall design of the bobbin, and it is possible to flexibly respond to the specification change.

[0173] In addition, in the coil device 10 of the present embodiment, the inter-coil coupling can be adjusted by the radial gap between the inner coil portion 20 of the first electric wire 22 wound on the first main winding portion 45a and the outer coil portion 30 of the second electric wire 32 wound on the second winding portion 55. In addition, in the coil device 10 of the present embodiment, the inter-coil coupling can be adjusted even by the gap in the Z-axis direction between the flange-shaped coil portion (not shown) of the first electric wire 22 wound on the first auxiliary winding portion 45b and the outer coil portion 30 of the second electric wire 32 wound on the second winding portion 55.

[0174] In addition, if the number of winding layers of the first electric wire 22 wound on the first secondary winding portion 45b is increased, the overlapping area of ​​the flange-shaped coil portion and the outer coil portion 30 observed from the axial direction also becomes larger, and the leakage characteristics can be adjusted. In this way, in the coil device 10 of this embodiment, the leakage characteristics can be adjusted by both the radial gap and the axial gap.

[0175] In addition, in the coil device 10 of the present embodiment, by increasing the number of winding layers of the first electric wire 22 wound on the first auxiliary winding portion 45b of the first winding portion 45, the total number of turns of the first electric wire 22 can be increased, and thus the axial dimension of the bobbin 40 can be shortened. Therefore, the coil device 10 can be made thinner.

[0176] In addition, in the present embodiment, the winding partition flange 46 is formed at a predetermined interval along the Z-axis direction in the first winding portion 45. With this configuration, the α winding of the first electric wire 22 is easy. In addition, the winding partition flange 46 that separates the first main winding portion 45a and the first auxiliary winding portion 45b is formed with a partitioning convex piece 46a (see FIG. 4 ) as a convex portion that protrudes outward from the outer edge end of the winding partition flange 46 formed within the range of the first main winding portion 45a. Figure 2B The partitioning protrusion 46 a can function as a positioning member for the bobbin cover 50 .

[0177] In addition, in this embodiment, the outer peripheral edge of the cover lower flange portion 52 of the bobbin cover 50 is intermittently formed with gap retaining pieces 52a along the circumferential direction, and the first auxiliary winding portion 45b is located inside the gap retaining pieces 52a and forms a flange-shaped coil portion. With this configuration, it is easy to wind the first electric wire 22 with a plurality of turns around the outer periphery of the first auxiliary winding portion 45b.

[0178] In addition, in the present embodiment, the first electric wire 22 is continuously α-wound around the first main winding portion 45a and the first auxiliary winding portion 45b. By adopting α-winding, the winding of the first electric wire 22 becomes easy, and the axial length of the inner coil 20 formed by the first electric wire 22 can be reduced. In addition, it is easy to wind the first electric wire 22 with a plurality of turns around the outer periphery of the first auxiliary winding portion 45b.

[0179] In particular, in the coil device 10 of this embodiment, Figure 2A and Figure 2B As shown, for example, the terminal blocks 70 and 80 to which the terminals constituted by the terminal metal fittings 91 to 94 are mounted are mounted on the bobbin 40 so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin 40. Figure 1A After the substrate and coil device 10 of the circuit substrate 300 shown are roughly positioned, the terminal blocks 70 and 80 are relatively moved in the X-axis and Y-axis directions relative to the bobbin 40, so that the insertion holes 91d to 94d of the terminal metal fittings 91 to 94 and the mounting hole 302 of the circuit substrate 300 can be accurately positioned. Therefore, it is easy to use fasteners such as screws 304 to accurately position and connect the circuit pattern of the circuit substrate 300 and each terminal metal fitting 91 to 94.

[0180] In addition, in the coil device 10 of the present embodiment, it is not necessary to accurately align the positions of the terminal metal parts 91 to 94 of the terminal blocks 70 and 80 with the positions of the mounting holes 302 of the circuit substrate 300 during the manufacturing stage of the coil device 10, so the manufacturing and assembly of the various parts constituting the coil device 10 becomes easy, which helps to reduce the manufacturing cost.

[0181] In addition, in the present embodiment, the terminal metal fittings 91 to 94 are mounted relative to the terminal blocks 70 and 80 so as to be independently movable in the Z-axis direction. With such a configuration, it is also easy to fine-tune the positions of the terminal metal fittings 91 to 94 and the mounting holes 302 of the circuit substrate 300 independently in the Z-axis direction. As a result, even along the Z-axis direction, it is not necessary to precisely align the mounting positions of the terminal metal fittings 91 to 94 to the terminal blocks 70 and 80 with the circuit substrate 300, and the manufacturing and assembly of the various parts constituting the coil device 10 becomes easier, further contributing to the reduction of manufacturing costs.

[0182] In addition, in the present embodiment, the bobbin 40 is provided with a relief fitting protrusion 102a, 202a protruding in the X-axis direction, and the terminal blocks 70, 80 are provided with relief fitting recesses 72a, 82a into which the relief fitting protrusions 102a, 202a enter, respectively. In addition, the relief fitting protrusions 102a, 202a are inserted into the relief fitting recesses 72a, 82a, respectively, within a predetermined range. The relief fitting protrusions 102a, 202a are inserted into the relief fitting recesses 72a, 82a, respectively, so as to be movable in the X-axis and Y-axis directions. With such a configuration, the terminal blocks 70 and 80 to which the end metal fittings 91 to 94 are mounted can be mounted on the bobbin 40 so as to be movable in both the X-axis and Y-axis directions of the bobbin 40.

[0183] In addition, in this embodiment, if Figure 6 and Fig. 9As shown in FIG. 1 , a portion of the inner wall of the relaxing fitting recess 72a, 82a is formed by a support piece 72a3, 82a3 that can be elastically deformed to a width in the Z-axis direction that can open the opening of the relaxing fitting recess 72a, 82a. Figure 7 and Figure 8 The stopper protrusions 72a4 and 82a4 (see FIG. 1 ) are engaged with the through holes 104 and 204 of the relief fitting protrusions 102a and 202a to prevent them from falling out. Figure 6 and Fig. 9 ).

[0184] By configuring in this way, in the present embodiment, the easing engagement protrusions 102a and 202a are inserted into the easing engagement recesses 72a and 82a, respectively, and the easing engagement protrusions 102a and 202a are mounted to the easing engagement recesses 72a and 82a so as to be movable in the X-axis and Y-axis directions, and the terminal blocks 70 and 80 are prevented from falling off relative to the bobbin 40. Therefore, the installation of the terminal blocks 70 and 80 relative to the bobbin 40 becomes easier.

[0185] In addition, in this embodiment, if Figure 7 and Figure 8 As shown in FIG. 1 , the mitigation fitting protrusions 102a and 202a respectively include main protrusions 102a1 and 202a1 and auxiliary protrusions 102a2 and 202a2. Figure 6 and Fig. 9 As shown, the mitigation recesses 72a and 82a have Figure 7 and Figure 8 The main recesses 72a1, 82a1 into which the main protrusions 102a1, 202a1 are inserted and the sub-recesses 72a2, 82a2 into which the sub-protrusions 102a2, 202a2 are inserted. The gap between the sub-protrusions 102a2, 202a2 and the sub-recesses 72a2, 82a2 along the Z-axis direction is smaller than the gap between the main protrusions 102a1, 202a1 and the main recesses 72a1, 82a1 along the Z-axis direction.

[0186] By configuring in this way, the terminal blocks 70 and 80 are held to be movable in the X-axis and Y-axis directions relative to the bobbin 40 along the guide surface where the auxiliary protrusions 102a2 and 202a2 and the auxiliary recesses 72a2 and 82a2 are in contact. Moreover, along the guide surface, the terminal blocks 70 and 80 can be smoothly moved in the X-axis and Y-axis directions relative to the bobbin 40 without shaking. Moreover, the gap between the main protrusions 102a1 and 202a1 and the main recesses 72a1 and 82a1 along the Z-axis direction is relatively wide, so it is relatively easy to insert the relaxing interlocking protrusions 102a and 202a into the relaxing interlocking recesses 72a and 82a.

[0187] Moreover, in the present embodiment, two sub-convex portions 102a2 and 202a2 are formed on both sides of the main convex portions 102a1 and 202a1, respectively, and two sub-concave portions 72a2 and 82a2 are formed on both sides of the main concave portions 72a1 and 82a1. In addition, the protruding height of the main convex portions 102a1 and 202a1 in the X-axis direction is greater than the protruding height of the sub-convex portions 102a2 and 202a2 in the X-axis direction. With such a configuration, the work of inserting the relaxing interlocking convex portions 102a and 202a into the relaxing interlocking concave portions 72a and 82a, respectively, is easy, and the friction on the guide surface where the sub-convex portions 102a2 and 202a2 contact with the sub-concave portions 72a2 and 82a2 can be reduced.

[0188] In addition, in this embodiment, if Figure 5B As shown, the terminal metal parts 91 to 94 are respectively fixed and connected as Figure 2B The wire connecting parts 91a to 94a and hook parts 91b to 94b of the lead parts 22a and 32a at the ends of the wires 22 and 32 are shown. By configuring in this way, the lead parts 22a and 32a of the wires 22 and 32 can be easily connected to the terminal metal fittings 91 to 94, and the terminal metal fittings 91 to 94 can be assembled relative to the terminal blocks 70 and 80 so as to be easily movable along the Z-axis direction.

[0189] In addition, the terminal metal fittings 91 to 94 have insertion holes 91d to 94d formed between the wire connecting parts 91a to 94a and the hook parts 91b to 94b. Figure 1A The terminal metal fittings 91 to 94 are positioned and mounted on the circuit board 300 by fasteners such as bolts or screws 304 shown.

[0190] In this embodiment, the inner covers 78 and 88 (see FIG. 1 ) are engaged with the hooks 91a to 94a of the terminal metal fittings 91 to 94 and limit the range of movement of the terminal metal fittings 91 to 94 in the Z-axis direction. Figure 2A ) are respectively mounted on the terminal blocks 70, 80. By mounting only the inner covers 78, 88, each terminal metal fitting 91-94 can be prevented from coming off relative to the terminal blocks 70, 80. In addition, the movement of the terminal metal fittings 91-94 relative to the terminal blocks 70, 80 in the Z-axis direction can also be restricted.

[0191] In addition, outer covers 79 and 89 that cover the inner covers 78 and 88, cover the ends of the terminal blocks 70 and 80 in the X-axis direction, and further cover the ends of the terminal metal fittings 91 to 94 in the Y-axis direction are attached to the terminal blocks 70 and 80. By forming the outer covers 79 and 89 with insulating members, it is expected that the insulation properties can be improved.

[0192] Second embodiment

[0193] Figure 1B and Figure 5C The coil device 10A of the second embodiment shown has the same structure as the coil device 10 of the first embodiment except for the following points, and achieves the same operation and effects. Figure 1B and Figure 5C In the drawings, the same components as those of the coil device 10 according to the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

[0194] The structure of each terminal metal fitting 95 to 98 of the coil device 10A of the present embodiment is slightly different from the structure of the terminal metal fittings 91 to 94 of the coil device 10 of the first embodiment, and thus, only the structure of the terminal blocks 70 and 80 is partially different.

[0195] In this embodiment, Figure 5C The components denoted by reference numerals 95 to 98 of the terminal metal fittings shown in FIG. Figure 5B The terminal metal fittings shown in FIG. 9 correspond to the components indicated by reference numerals 91 to 94 and are mostly the same. Figure 5B The mounting portions 91c to 94c shown are different. Figure 5C The mounting portions 95c to 98c of the present embodiment shown in the figure do not have mounting holes 91d to 94d formed therein. Figure 5C The mounting portions 95c to 98c of the illustrated embodiment are formed with external circuit connection pieces 95d to 98d rising upward in the Z-axis direction from the planes of the mounting portions 95c to 98c.

[0196] The external circuit connection pieces 95d to 98d formed on the terminal metal parts 95 to 98 can be inserted into the Figure 1B The circuit substrate 300a shown in FIG. Figure 1A The four slit-shaped mounting holes 302a of the circuit substrate 300 shown in FIG. 9A and 9B are connected to the circuit patterns formed on the circuit substrate 300a by welding or conductive adhesive.

[0197] In this embodiment, if Figure 5C As shown, the terminal metal parts 95 to 98 are not formed Figure 5B The mounting holes 91d to 94d are shown, therefore, Figure 5A The terminal block 70 and Figure 8 The terminal block 80 shown does not need to form the mounting holes 76 and 86 for the nuts 77 and the like. The other structures of the terminal blocks 70 and 80 are substantially the same in the first embodiment and the second embodiment. In addition, the structures of the bobbin 40 and other components are also substantially the same.

[0198] The coil device 10A of the present embodiment achieves the same effects as the coil device 10 of the first embodiment. Figure 1B The positioning of the circuit board 300a and other substrates shown is also easy, and the manufacture and assembly of the various parts are easy.

[0199] Third embodiment

[0200] Figure 10 to Figure 12 The coil device 10B of the third embodiment shown has the same structure as the coil device 10 of the first embodiment except for the following points, and achieves the same operation and effects. Figure 10 to Figure 12 In the drawings, the same components as those of the coil device 10 according to the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

[0201] like Fig.10 As shown in FIG. 1 , the coil device 10B is different from the coil device 10 of the first embodiment in that it includes a bobbin 40B, terminal blocks 70B and 80B, and terminal fittings 91B and 92B.

[0202] like Fig.11 As shown, the terminal metal fittings 91B and 92B are different from the terminal metal fittings 91 and 92 ( Figure 5B The shapes of the terminal metal fittings 91B and 92B are substantially the same as those of the terminal metal fittings 93 and 94, and the height of the wire connecting portions 91a and 92a in the Z-axis direction is lower than the plane of the mounting portions 91c and 92c.

[0203] The bobbin 40B is different from the bobbin 40 ( Figure 2A The terminal blocks 70B and 80B are formed integrally with the bobbin 40B, and are respectively arranged at one end and the other end of the bobbin 40B (the bobbin upper flange portion 48) in the X-axis direction.

[0204] The terminal blocks 70B and 80B protrude outward in the X-axis direction by a predetermined length and have a predetermined width in the Y-axis direction. The terminal blocks 70B and 80B have a block body 71 and 81, a terminal mounting portion 73 and 83, and mounting holes 76 and 86, similarly to the terminals 70 and 80 of the first embodiment, but do not have through holes 72 and 82. In addition, the terminal blocks 70B and 80B have terminal grooves 74B and 84B that replace the terminal grooves 74 and 84, and have fitting grooves 75B and 85B that replace the fitting grooves 75 and 85. The terminal grooves 74B and 84B and the fitting grooves 75B and 85B penetrate from the front surface to the back surface of the terminal blocks 70B and 80B.

[0205] In addition, the hook portions 91b and 92b of the terminal metal fittings 91B and 92B include a portion extending downward in the Z-axis direction and having a reduced width in the X-axis direction, and a portion extending outward in the X-axis direction and having an increased width in the X-axis direction. Hereinafter, the former portion is referred to as the reduced width portion 91b1 and 92b1, and the latter portion is referred to as the increased width portion 91b2 and 92b. Similarly, for the hook portions 93b1 and 94b1 of the terminal metal fittings 93 and 94, the portion extending downward in the Z-axis direction and having a reduced width in the X-axis direction is referred to as the reduced width portion 93b1 and 94b1, and the portion extending outward in the X-axis direction and having an increased width in the X-axis direction is referred to as the increased width portion 93b2 and 94b2.

[0206] The terminal grooves 74, 74 ( Figure 5A ), the two terminal grooves 74B, 74B of the terminal block 70B are formed so that the groove widths in each direction of the X-axis direction and the Y-axis direction are larger. The X-axis width of the terminal grooves 74B, 74B is larger than the X-axis width of the hook portions 91b, 92b (width reduction portions 91b1, 92b1) of the terminal metal parts 91B, 92B, and the Y-axis width of the terminal grooves 74B, 74B is larger than the Y-axis width (plate thickness of the terminal metal parts 91B, 92B) of the hook portions 91b, 92b (width reduction portions 91b1, 92b1) of the terminal metal parts 91B, 92B. Therefore, in a state where the hook portions 91b, 92b are inserted into the terminal grooves 74B, 74B, as Fig.12 As shown, a gap G1 is formed between the hook portions 91b, 92b and the inner walls of the terminal grooves 74B, 74B.

[0207] In addition, compared with the fitting grooves 75, 75 of the first embodiment, the two fitting grooves 75B, 75B of the terminal block 70B are formed so that the groove width in each direction of the X-axis direction and the Y-axis direction becomes larger. The width of the fitting grooves 75B, 75B in the X-axis direction becomes larger than the width of the insertion protrusions 91f, 92f of the terminal metal fittings 91B, 92B in the X-axis direction, and the width of the fitting grooves 75B, 75B in the Y-axis direction becomes larger than the width of the insertion protrusions 91f, 92f of the terminal metal fittings 91B, 92B in the Y-axis direction (the plate thickness of the terminal metal fittings 91B, 92B). Therefore, in the state where the insertion protrusions 91f, 92f are inserted into the fitting grooves 75B, 75B, a gap G2 is formed between the insertion protrusions 91f, 92f and the inner wall of the fitting grooves 75B, 75B.

[0208] Therefore, inside the terminal grooves 74B, 74B, the hooks 91b, 92b can move freely in both the X-axis direction and the Y-axis direction within the range of the gap G1. In addition, inside the fitting grooves 75B, 75B, the insertion protrusions 91f, 92f can move freely in both the X-axis direction and the Y-axis direction within the range of the gap G2. As a result, in the present embodiment, the terminal metal fittings 91B, 92B can move freely in both the X-axis direction and the Y-axis direction of the bobbin 40B. In addition, as in the first embodiment, the terminal metal fittings 91B, 92B can also move freely in the Z-axis direction of the bobbin 40B.

[0209] In addition, the width of the width expansion portion 91b2, 92b2 of the hook portion 91b, 92b in the X-axis direction is larger than the width of the terminal groove 74B, 74B in the X-axis direction, thereby preventing the hook portion 91b, 92b from escaping from the terminal groove 74B, 74B. A portion of the width expansion portion 91b2, 92b2 is arranged inside a groove (not shown) formed inside the terminal block 70B, and can move freely inside the groove along the XYZ axes. In addition, the terminal metal parts 91B, 92B can also be provided with the insertion protrusion 91f, 92f relative to the terminal block 70B, or provided on both the hook portion 91b, 92b and the insertion protrusion 91f, 92f.

[0210] In the example shown in the figure, the widths of the gaps G1 and G2 in the X-axis direction are the same, but they may be different. In addition, the widths of the gaps G1 and G2 in the Y-axis direction are the same, but they may be different. The widths of the gaps G1 and G2 in the X-axis direction and the Y-axis direction may be appropriately determined according to the predetermined amount of movement of the terminal metal fittings 91B and 92B relative to the bobbin 40B in the X-axis direction and the Y-axis direction.

[0211] The structure shown above is also provided in the terminal block 80B. In the terminal grooves 84B and 84B, the hooks 93b and 94b can move freely in both the X-axis direction and the Y-axis direction within the range of the gap G1. In addition, in the fitting grooves 75B and 75B, the insertion protrusions 93f and 94f can move freely in both the X-axis direction and the Y-axis direction within the range of the gap G2. As a result, in the present embodiment, the terminal metal fittings 93 and 94 can also move freely in both the X-axis direction and the Y-axis direction of the bobbin 40B. In addition, as in the first embodiment, the terminal metal fittings 93 and 94 can also move freely in the Z-axis direction of the bobbin 40B.

[0212] In this embodiment, the terminal blocks 70B and 80B are formed integrally with the bobbin 40B, and therefore, they do not move relative to the bobbin 40B in both the X-axis direction and the Y-axis direction, and their positions are fixed. On the other hand, the terminal metal fittings 91B, 92B, 93, and 94 themselves move relative to the bobbin 40B in both the X-axis direction and the Y-axis direction. Thus, in this embodiment, the terminal metal fittings 91B, 92B, 93, and 94 can move freely in both the X-axis direction and the Y-axis direction of the bobbin 40B, and therefore, by roughly positioning Figure 1A After the circuit substrate 300 and the coil device 10B are connected, the insertion holes 91d to 94d of the terminal metal fittings 91B, 92B, 93, and 94 and the mounting hole 302 of the circuit substrate 300 can be accurately positioned by only moving the terminal metal fittings 91B, 92B, 93, and 94 relative to the bobbin 40B. Therefore, it is easy to use fasteners such as screws 304 to accurately position and connect the circuit pattern of the circuit substrate 300 and the terminal metal fittings 91B, 92B, 93, and 94.

[0213] Fourth embodiment

[0214] Figure 13 to Figure 15 The coil device 10C of the fourth embodiment shown has the same structure as the coil device 10 of the first embodiment except for the following points, and achieves the same operation and effects. Figure 13 to Figure 15 In the drawings, the same components as those of the coil device 10 according to the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

[0215] like Fig.13 As shown, the coil device 10C is different from the coil device 10 of the first embodiment in that it has a bobbin 40C and terminal blocks 70C and 80C, and in addition to these, it also has a housing 400. As shown below, in this embodiment, the coil device 10C is configured so that the terminal blocks 70C and 80C can move freely in both the X-axis direction and the Y-axis direction of the housing 400.

[0216] like Fig.14 As shown, the bobbin 40C is different from the bobbin 40 of the first embodiment in that the relaxing fitting protrusions 102 a and 202 a are not formed on the insulating walls 100 and 200 .

[0217] The housing 400 is a container for accommodating the bobbin 40C and the core 12, etc., and is filled with a resin 600. The housing 400 has a side portion 410, two terminal block mounting portions 420, 420, and two relaxing fitting protrusions 430, 430.

[0218] The side portion 410 constitutes the side wall of the housing 400 and surrounds the housing 400 on all sides. The terminal block mounting portions 420, 420 are respectively formed at the ends of the side portion 410 in the X-axis direction and are integrally formed to protrude upward from the Y-axis to the Z-axis. The easing interlocking protrusions 430, 430 are respectively formed at the approximate center of the terminal block mounting portions 420, 420 in the Y-axis direction and protrude from the outer side walls in the X-axis direction to the outside in the X-axis direction. The easing interlocking protrusions 430, 430 have a roughly prismatic shape, and the easing interlocking recesses 72a, 82a of the terminal blocks 70C, 80C are respectively mounted on the easing interlocking protrusions 430, 430.

[0219] like Fig.15 As shown, the terminal block 70C has a pair of clamping portions 740, 740 formed on one side of the Y-axis direction and a pair of clamping portions 740, 740 formed on the other side of the Y-axis direction, which is different from the terminal block 70 ( Figure 5A ) is different. The hook portion 91b (width expansion portion 91b2) of the terminal metal fitting 91B is inserted and clamped in one clamping portion 740, 740, thereby the terminal metal fitting 91B is fixed to the terminal block 70C in a stable state. The hook portion 92b (width expansion portion 92b2) of the terminal metal fitting 92B is inserted and clamped in the other clamping portions 740, 740, thereby the terminal metal fitting 92B is fixed to the terminal block 70C in a stable state. The terminal block 80C is also constructed in the same manner, and the above-mentioned pair of clamping portions are respectively provided on one side and the other side in the Y-axis direction.

[0220] The Y-axis width of the relaxing fitting recess 72a is larger than the Y-axis width of the relaxing fitting protrusion 430. Therefore, when the relaxing fitting protrusion 430 is mounted on the relaxing fitting recess 72a of the terminal block 70C, a gap G3 is formed between the relaxing fitting protrusion 430 and the inner wall of the relaxing fitting recess 72a. Therefore, the relaxing fitting protrusion 430 can be inserted into the inside of the relaxing fitting recess 72a within the range of the gap G3 so as to be movable in the Y-axis direction, and the terminal block 70C to which the terminal metal fittings 91B and 92B are mounted is mounted on the housing 400 so as to be movable in the Y-axis direction of the bobbin 40C.

[0221] In addition, the relaxing fitting protrusion 430 is different from the relaxing fitting protrusion 102a ( Figure 5A ) is inserted so as to be movable in the X-axis direction, and the terminal block 70C on which the terminal metal fittings 91B and 92B are mounted can be mounted in the housing 400 so as to be movable in the X-axis direction of the bobbin 40C.

[0222] The above-described structure is also provided in the terminal block 80C, and the terminal block 80C can be similarly mounted on the housing 400 so as to be movable in both the X-axis direction and the Y-axis direction of the housing 400 or the bobbin 40C.

[0223] In this embodiment, the same effects as those of the first embodiment can be obtained. In particular, in this embodiment, the terminal blocks 70C and 80C are mounted on the housing 400 that accommodates the bobbin 40C. Therefore, by roughly positioning Figure 1A After the circuit substrate 300 and the coil device 10C are connected, the terminal blocks 70C and 80C are relatively moved relative to the housing 400, and the terminal blocks 70C and 80C are relatively moved relative to the bobbin 40C, so that the insertion holes 91d to 94d of the terminal metal fittings 91B, 92B, 93, and 94 of the terminal blocks 70C and 80C and the mounting hole 302 of the circuit substrate 300 can be accurately positioned. Therefore, it is easy to use fasteners such as screws 304 to accurately position and connect the circuit pattern of the circuit substrate 300 and the terminal metal fittings 91B, 92B, 93, and 94.

[0224] Fifth embodiment

[0225] Figure 16 to Figure 19B The coil device 10D of the fifth embodiment shown has the same structure as the coil device 10 of the first embodiment except for the following points, and achieves the same operation and effects. Figure 16 to Figure 19B In the drawings, the same components as those of the coil device 10 according to the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

[0226] like Fig.16 As shown, the coil device 10D is different from the coil device 10 of the first embodiment in that it has a bobbin 40D and terminal blocks 70D and 80D. As shown below, the coil device 10D of this embodiment is configured so that the terminal blocks 70D and 80D can move freely in the Z-axis direction in addition to the X-axis and Y-axis directions of the bobbin 40D. In addition, the drawings only record the conceptual features for realizing the above-mentioned structure, and the anti-slip mechanism (such as Figure 5A The anti-slip holes 104, 204 or Figure 6 The stopper protrusions 72a4, 82a4) shown are omitted in the illustration.

[0227] The bobbin 40D is different from the bobbin 40 of the first embodiment in that the relaxation fitting protrusion 102a does not include the sub-protrusion 102a2 but includes only the main protrusion 102a1.

[0228] In this embodiment, the terminal metal fittings 91B, 92B, 93, 94 are pressed or embedded in the terminal blocks 70D and 80D. The hooks 91b to 94b and the insertion protrusions 91f to 94f of the terminal metal fittings 91B, 92B, 93, 94 are embedded in the interior of the terminal blocks 70D and 80D, and the terminal metal fittings 91B, 92B, 93, 94 are integrated with the terminal blocks 70D and 80D.

[0229] The terminal blocks 70D and 80D are different from the terminal blocks 70 and 80 of the first embodiment in that the block bodies 71D and 81D include through holes 72D and 82D having relaxing fitting recesses 72aD and 82aD. Fig.18A and Fig.18B As shown, the Y-axis width of the relaxing fitting recess 72aD is larger than the Y-axis width of the relaxing fitting protrusion 102a. In addition, the Z-axis width of the relaxing fitting recess 72aD is larger than the Z-axis width of the relaxing fitting protrusion 102a. Therefore, in a state where the relaxing fitting recess 72aD of the terminal block 70D is installed with the relaxing fitting protrusion 102a, a gap G4 is formed between the relaxing fitting protrusion 102a and the inner wall of the relaxing fitting recess 72aD to surround the relaxing fitting protrusion 102a. Therefore, inside the relaxing fitting recess 72aD, the relaxing fitting protrusion 102a can be inserted within the range of the gap G4 so as to be movable in both the Y-axis direction and the Z-axis direction, and the terminal block 70D on which the terminal metal fittings 91B and 92B are installed is installed on the bobbin 40D so as to be movable in both the Y-axis direction and the Z-axis direction of the bobbin 40D.

[0230] Further, similar to the first embodiment, the relaxing fitting projection 102a can be inserted to be movable in the X-axis direction, and the terminal block 70D to which the terminal fittings 91B and 92B are mounted can be mounted to the bobbin 40D to be movable in the X-axis direction.

[0231] For example, the circuit board 300 ( Figure 1A ) When the coil device 10D is installed, as shown in the figure, the relaxing interlocking protrusion 102a is fixed in the internal space of the relaxing interlocking recess 72aD in a suspended state without contacting the inner wall thereof. Alternatively, the relaxing interlocking protrusion 102a may be fixed in a state of contacting the inner wall (upper inner wall or lower inner wall) of the relaxing interlocking recess 72aD.

[0232] The above-described structure is also provided in the terminal block 80D. The terminal block 80D can also be mounted on the bobbin 40D so as to be movable in the Z-axis direction in addition to the X-axis direction and the Y-axis direction of the bobbin 40D.

[0233] The same effects as those of the first embodiment can also be obtained in this embodiment. In particular, in this embodiment, by relatively moving the terminal blocks 70D and 80D relative to the bobbin 40D in the Z-axis direction, it is easy to finely adjust the installation positions of the insertion holes 91d to 94d of the terminal metal fittings 91B, 92B, 93, and 94 and the installation holes 302 of the circuit substrate 300 in the Z-axis direction. Therefore, it is easy to accurately position and connect the circuit pattern of the circuit substrate 300 and the terminal metal fittings 91B, 92B, 93, and 94 using fasteners such as screws 304.

[0234] In addition, in this embodiment, the terminal blocks 70D and 80D are movable in the Z-axis direction of the bobbin 40D, and the terminals 91B, 92B, 93, and 94 are integrally formed with the terminal block 40D. Therefore, the process of mounting the terminals 91B, 92B, 93, and 94 on the terminal blocks 70D and 80D can be simplified, and the manufacture of the coil device 10D becomes easy.

[0235] also, Fig.17 In the example shown, the easing interlocking protrusion 102a protrudes outward in the X-axis direction, but the protruding direction of the easing interlocking protrusion 102a is not limited to this and can be changed appropriately. The same is true for the easing interlocking protrusion 202a. Fig.19A The bobbin 40D' shown is formed with a relaxing interlocking protrusion 102a' protruding outward in the Z-axis direction. The relaxing interlocking protrusion 102a' and the insulating wall 100 are connected by the terminal block mounting portion 105, and the relaxing interlocking protrusion 102a' extends from the upper surface of the terminal block mounting portion 105 along the Z-axis direction. When the relaxing interlocking protrusion 102a' enters the relaxing interlocking recess 72aD of the terminal block 70D, the terminal block 70D can be mounted on the terminal block mounting portion 105.

[0236] Although detailed illustration is omitted, a relaxing fitting recess 72a (82a) extending in the Z-axis direction is formed in the terminal block 70D (80D), and the relaxing fitting protrusion 102a' is inserted into the inside of the relaxing fitting recess 72a (82a), thereby enabling the terminal block 70D (80D) to be mounted on the bobbin 40D so as to be movable in the Z-axis direction. In addition, by making the X-axis direction width and the Y-axis direction width of the relaxing fitting recess 72a (82a) larger than the X-axis direction width and the Y-axis direction width of the relaxing fitting protrusion 102a', the terminal block 70D (80D) can be mounted on the bobbin 40D so as to be movable in both the X-axis direction and the Y-axis direction.

[0237] In addition, Fig.19BThe bobbin 40D" shown is formed with a relaxing interlocking protrusion 102a" protruding outward in the Y-axis direction. One end of the relaxing interlocking protrusion 102a" in the Y-axis direction is connected to the insulating wall 100 by a connecting portion 106 extending from the outer wall surface of the insulating wall 100 in the X-axis direction toward the outside in the X-axis direction.

[0238] Although detailed illustrations are omitted, a relaxing interlocking recess 72a (82a) extending in the Y-axis direction is formed in the terminal block 70D (80D), and the relaxing interlocking protrusion 102a" is inserted into the interior of the relaxing interlocking recess 72a (82a), thereby allowing the terminal block 70D (80D) to be installed on the bobbin 40D so as to be movable along the Y-axis direction. In addition, by making the X-axis direction width and the Z-axis direction width of the relaxing interlocking recess 72a (82a) larger than the X-axis direction width and the Z-axis direction width of the relaxing interlocking protrusion 102a", the terminal block 70D (80D) can be installed on the bobbin 40D so as to be movable in both the X-axis direction and the Z-axis direction.

[0239] Sixth Embodiment

[0240] Figure 20 to Figure 22 The coil device 10E of the sixth embodiment shown has the same structure as the coil device 10 of the first embodiment except for the following points, and achieves the same operation and effects. Figure 20 to Figure 22 In the drawings, the same components as those of the coil device 10 according to the first embodiment are denoted by the same reference numerals, and description thereof is partially omitted.

[0241] like Fig. 20 As shown, the coil device 10E has a bobbin 40E and terminal blocks 70D and 80D, and in addition to these, it also has a stopper wall portion 500, which is different from the coil device 10 of the first embodiment. As shown below, in the coil device 10E of this embodiment, the cover portion 500 is used to prevent the terminal blocks 70D and 80D from falling off relative to the bobbin 40E.

[0242] like Fig.21 As shown, the bobbin 40E is different from the bobbin 40 of the first embodiment in that it has relaxing fitting protrusions 102aE and 202aE. Figure 5A On the other hand, the anti-slip hole 104 shown in the figure is replaced by an insertion hole 102a3. The insertion hole 102a3 extends along the long side direction (X-axis direction) of the relaxing fitting protrusion 102aE, and the length of the insertion hole 102a3 in the X-axis direction is longer than the length of the fitting part 520 of the stopper wall part 500 described later. The fitting part 520 of the stopper wall part 500 can be inserted into the insertion hole 102a3.

[0243] The stopper wall portion 500 is mounted on the relaxing fitting protrusion 102aE that enters the relaxing fitting recess 52aD, and functions as a stopper for the terminal block 70D to be disengaged from the bobbin 40E. The stopper wall portion 500 includes a wall portion 510 and a fitting portion 520. The wall portion 510 has a substantially flat plate shape, and the area of ​​each surface of the wall portion 510 in the X-axis direction is larger than the opening area of ​​the mounting portion 72b of the relaxing fitting recess 72aD.

[0244] The fitting portion 520 is formed on the inner surface of the wall portion 510 in the X-axis direction and protrudes inward in the X-axis direction. The fitting portion 520 has a solid shape and is inserted into the insertion hole 102a3 of the relaxing fitting protrusion 102aE and is fitted with the relaxing fitting protrusion 102aE when the relaxing fitting protrusion 102aE is arranged inside the relaxing fitting recess 72aD.

[0245] In a state where the fitting portion 520 is fitted with the relaxing fitting protrusion 102aE, the terminal block 70D is arranged so as to be sandwiched between the insulating wall 100 and the wall portion 510 (see Fig. 20 ). The terminal block 70D is freely movable in the X-axis direction within the range between the insulating wall 100 and the wall portion 510. When the terminal block 70D moves a predetermined amount to the outside in the X-axis direction, the peripheral portion of the mounting portion 72b of the terminal block 70D contacts the wall portion 510, preventing the terminal block 70D from moving to the outside in the X-axis direction relative to the contact position. Thus, the wall portion 510 can prevent the terminal block 70D from detaching to the outside in the X-axis direction relative to the bobbin 40E.

[0246] like Fig. 22 As shown, the Y-axis width of the relaxing fitting recess 72aD is larger than the Y-axis width of the relaxing fitting protrusion 102aD. In addition, the Z-axis width of the relaxing fitting recess 72aD is larger than the Z-axis width of the relaxing fitting protrusion 102aD. Therefore, in a state where the relaxing fitting protrusion 102aE is installed to the relaxing fitting recess 72aD of the terminal block 70D, a gap G5 is formed between the relaxing fitting protrusion 102aE and the inner wall of the relaxing fitting recess 72aD to surround the relaxing fitting protrusion 102aE. Therefore, inside the relaxing fitting recess 72aE, the relaxing fitting protrusion 102a can be inserted within the range of the gap G5 so as to be movable in both the Y-axis direction and the Z-axis direction, and the terminal block 70D on which the terminal metal fittings 91B and 92B are installed is installed on the bobbin 40D so as to be movable in both the Y-axis direction and the Z-axis direction of the bobbin 40E.

[0247] Further, similar to the first embodiment, the relaxing fitting projection 102aE is inserted to be movable in the X-axis direction, and the terminal block 70D to which the terminal fittings 91B and 92B are mounted can be mounted to the bobbin 40E to be movable in the X-axis direction of the bobbin 40E.

[0248] The above structure also has a relaxing engagement protrusion 202aE, and the terminal block 80D can be mounted on the bobbin 40E to be movable along the XYZ axes of the bobbin 40E. In addition, the wall 510 can prevent the terminal block 80D from detaching from the bobbin 40E to the outside in the X-axis direction.

[0249] In this embodiment, the same effect as in the first embodiment can be obtained. In addition, in this embodiment, by fitting the fitting portion 510 with the relaxing fitting protrusion 102aE, the terminal block 70D can be prevented from falling off relative to the bobbin 40E by using the stopper wall portion 500 while the relaxing fitting protrusion 102aE is installed relative to the relaxing fitting recess 72aD so as to be movable in the X-axis direction and the Y-axis direction.

[0250] In addition, instead of connecting the stopper wall portion 500 and the relaxing interlocking protrusion 102aE via the interlocking portion 520, the stopper wall portion 500 and the relaxing interlocking protrusion 102aE may be connected by resin (for example, a paste-like filler or adhesive). In this case, the shape of the stopper wall portion 500 is not particularly limited as long as it can be installed in the shape of the relaxing interlocking protrusion 102aE entering the inside of the relaxing interlocking recess 72aD via resin. By connecting the stopper wall portion 500 to the relaxing interlocking protrusion 102aE by resin, the terminal blocks 70D and 80D can be prevented from falling off relative to the bobbin 40E by using the stopper wall portion 500 while the relaxing interlocking protrusion 102aE is installed relative to the relaxing interlocking recess 72aD so as to be movable in the X-axis direction and the Y-axis direction.

[0251] Seventh embodiment

[0252] Figure 23 to Figure 25 The coil device 10F of the sixth embodiment shown has the same structure as the coil device 10E of the fifth embodiment except for the following points, and achieves the same operation and effects. Figure 23 to Figure 25 In the drawings, the same reference numerals are given to the same components as those of the coil device 10E according to the fifth embodiment, and description thereof is partially omitted.

[0253] like Fig.23 As shown, the coil device 10F is different from the coil device 10E of the fifth embodiment in that it has a bobbin 40F, two terminal blocks 70F, 70F, and two terminal blocks 80F, 80F. In this embodiment, a plurality of terminal metal fittings 91B, 92B, 93, 94 are respectively installed with respect to the plurality of terminal blocks 70F, 70F, 80F, 80F, and each terminal metal fitting has a terminal block.

[0254] like Fig.24As shown, the bobbin 40F is different from the bobbin 40E of the fifth embodiment in that two relaxing fitting protrusions 102aE, 102aE are formed on the insulating wall 100, and two relaxing fitting protrusions 202aE, 202aE are formed on the insulating wall 200. The two relaxing fitting protrusions 102aE, 102aE are respectively arranged at a predetermined interval along the Y-axis direction, and extend from the insulating wall 100 to the outside in the X-axis direction in a manner substantially parallel to each other. The two relaxing fitting protrusions 202aE, 202aE are respectively arranged at a predetermined interval along the Y-axis direction, and extend from the insulating wall 200 to the outside in the X-axis direction in a manner substantially parallel to each other.

[0255] The terminal block 70F and the terminal block 80F have the same structure, so the description of the structure of the terminal block 80F is omitted below. The terminal block body 71F, the through hole 72D, the terminal mounting portion 73, the terminal groove 74, the fitting groove 75 and the mounting hole 76 are respectively provided in each terminal block 70F.

[0256] like Fig.25 As shown, the relaxing fitting protrusion 102aE formed on one side of the insulating wall 100 in the Y-axis direction enters the inside of the relaxing fitting recess 72aD of the terminal block 71F arranged on one side in the Y-axis direction. The relaxing fitting protrusion 102aE formed on the other side of the insulating wall 100 in the Y-axis direction enters the inside of the relaxing fitting recess 72aD of the terminal block 71F arranged on the other side in the Y-axis direction.

[0257] In this state, as in the fifth embodiment, the relaxing fitting protrusion 102aE can be inserted into the relaxing fitting recess 72aD so as to be movable in both the Y-axis direction and the Z-axis direction within the range of the gap G5, and the terminal block 70F to which the terminal metal fittings 91B and 92B are attached can be attached to the bobbin 40F so as to be movable in both the Y-axis direction and the Z-axis direction of the bobbin 40F. In addition, the relaxing fitting protrusion 102aE can be inserted so as to be movable in the X-axis direction, and the terminal block 70F to which the terminal metal fittings 91B and 92B are attached can be attached to the bobbin 40F so as to be movable in the X-axis direction of the bobbin 40F.

[0258] The above-described structure is also provided in each terminal block 80F, and each terminal block 80F can be installed on the bobbin 40F so as to be movable along the XYZ axes of the bobbin 40F. In addition, the various anti-slip mechanisms shown in the first embodiment or the fifth embodiment can be applied to the anti-slipping of the terminal blocks 70F and 80F relative to the bobbin 40F.

[0259] In the present embodiment, a plurality of terminal metal fittings 91B, 92B (93, 94) are mounted on each of the plurality of terminal blocks 70F (80F). Therefore, each terminal metal fitting 91B, 92B (93, 94) can be independently moved relative to the bobbin 40F at each terminal block 70F (80F), and the insertion holes 91d to 94d of the terminal metal fittings 91B, 92B, 93, 94 and the mounting holes 302 of the circuit substrate 300 can be accurately positioned at each terminal metal fitting 91B, 92B, 93, 94. Therefore, it is easy to use fasteners such as screws 304 to accurately position and connect the circuit pattern of the circuit substrate 300 and each terminal metal fitting 91B, 92B, 93, 94.

[0260] The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention.

[0261] For example, the first electric wire 22 does not need to be α-wound, and can also be wound in an orderly manner. Even if the winding is arranged in an orderly manner, the effect of the present invention can be expected. In addition, the specific shape of the bobbin 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, etc., as a use other than a transformer for a charger.

[0262] In each of the above-mentioned embodiments, the relief fitting protrusion and the relief fitting recess may also be opposite. That is, the relief fitting protrusion may also be formed on the terminal block 70 or 80, and the relief fitting recess may be formed on the bobbin 40. In addition, the winding method of the electric wires 22 and 32 wound on the inside of the coil device 10, 10A is not limited to the above-mentioned embodiments. For example, in the above-mentioned example, the outer coil portion 30 is wound on the outside of the inner coil portion 20, but it is also applicable to the coil device in the manner of separating into the upper coil portion and the lower coil portion along the Z axis. In addition, the coil device of the present invention can also be applied to a coil device having a terminal block only on the side of the X-axis.

[0263] In the above-mentioned embodiments, 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 angles between these axes are not limited to 90 degrees and may be other angles.

[0264] The technology shown in the third embodiment can also be applied to the first, second, and fourth to seventh embodiments, and in addition to the terminal blocks 70 and 80 , the terminal metal fittings 91 to 94 can also be moved freely in both the X-axis direction and the Y-axis direction of the bobbin 40 .

[0265] The technology described in the fourth embodiment may be applied to the first to third embodiments and the fifth to seventh embodiments, and the terminal blocks 70 and 80 may be configured to be movable in both the X-axis direction and the Y-axis direction of the housing 400 .

[0266] The technique described in the fifth embodiment may be applied to the first, second, and fourth embodiments, and the terminal blocks 70 and 80 may be configured to be movable in the XYZ axis directions of the bobbin 40 .

[0267] The technique described in the sixth embodiment may be applied to the fifth and seventh embodiments, and the terminal blocks 70 and 80 may be prevented from falling off relative to the bobbin 40 by using the stopper wall portion 500 .

[0268] The technique described in the seventh embodiment may be applied to the first to sixth embodiments so that each of the terminal metal fittings 91 to 94 is provided with a terminal block.

[0269] In the above-mentioned embodiments, the electric wires 22 and 32 may be formed by various electric wires such as round wires or rectangular wires. When rectangular wires are used, any type of electric wires, such as flat-wound or flat-wound ones, may be used. In addition, a plate-shaped conductor such as a copper plate may be used instead of the electric wires 22 and 32.

[0270] In the above-mentioned embodiments, as Figure 1A The connection object (mounting object) of the coil device 10 shown in the figure is the circuit board 300, but the coil device 10 may be mounted on a connector, etc. For example, in the second embodiment, the external circuit connection pieces 95d to 98d may be inserted into the connector.

[0271] In the first embodiment and the third to seventh embodiments described above, the insertion holes 91d to 94d may be used in conjunction with Figure 1A The screw holes for screwing the screws 304 are formed as shown. In the second embodiment, screw holes may be formed in the external circuit connection pieces 95d to 98d, and the screws 304 may be screwed into the screw holes, thereby fixing the coil device 10A to the circuit board 300a.

[0272] In the first embodiment, the outer covers 79 and 89 may cover the ends of the terminal blocks 70 and 80 in the Z-axis direction to expose the wire connecting portions 91a to 98a of the terminals 91 to 94. By setting such a structure, the outer covers 79 and 89 can cover the periphery of the relaxing fitting protrusion 102a and the relaxing fitting recess 72a, suppressing their deformation due to external force, etc., and effectively preventing the terminal blocks 70 and 80 from falling off relative to the bobbin 40.

[0273] Explanation of symbols

[0274] 10, 10A~10F…Coil device

[0275] 12…core

[0276] 13…Base

[0277] 14…Middle leg

[0278] 16…Side leg

[0279] 20…Inner coil

[0280] 22…First Wire

[0281] 22a…lead portion (end of the electric wire)

[0282] 30…Outer coil

[0283] 32…Second wire

[0284] 32a…lead part (end of the electric wire)

[0285] 40, 40B~40F…spool

[0286] 42…spool base plate

[0287] 42a…Legs

[0288] 44…first hollow cylinder

[0289] 44a…first through hole

[0290] 44b ... Separation convex portion

[0291] 45…First winding portion

[0292] 45a ... first main winding portion

[0293] 45b ... first secondary winding portion

[0294] 46…Wrap around the flange

[0295] 46a...separating convex piece (convex part)

[0296] 48… Flange on the spool

[0297] 48a…Step

[0298] 48b…positioning recess

[0299] 48c…Engagement convex portion

[0300] 50…Spool cover

[0301] 50a, 50b…half-cut

[0302] 52…Flange under cover

[0303] 52a ... Gap retaining sheet (non-winding portion)

[0304] 52b…Opening

[0305] 53…Dividing the connection part

[0306] 53a…Inner connecting piece

[0307] 53b…Outer connecting piece

[0308] 54…Second hollow cylinder

[0309] 55…Second winding section

[0310] 58… Cover flange

[0311] 58a ... connected to the upper flange

[0312] 58b ... connected to the lower flange

[0313] 58c, 58d...stepped convex part

[0314] 58e…stopper convex part

[0315] 58f, 58g…base

[0316] 60…Core cover

[0317] 62…Cover body

[0318] 62a…Split piece

[0319] 64…Installation edge

[0320] 64a…protruding piece

[0321] 64b…Opening

[0322] 66…Insulation board

[0323] 66a ... engagement protrusion

[0324] 70, 70B~70F, 80, 80B~80F, …Terminal block

[0325] 71, 71B, 71D, 71F, 81, 81B, 81D, 81F… Main body

[0326] 72, 72D, 82, 82D…Through hole

[0327] 72a, 72aD, 82a, 82aD ...relaxed fitting recess

[0328] 72a1, 82a1…main concave portion

[0329] 72a2, 82a2…sub-concave

[0330] 72a3, 82a3 ... supporting sheet

[0331] 72a4, 82a4…stopper convex part

[0332] 72b, 82b ... installation recess

[0333] 73, 83…Terminal mounting part

[0334] 74, 74B, 84, 84B…Terminal slot

[0335] 740…Clamping part

[0336] 75, 75B, 85, 85B…Matching groove

[0337] 76, 86…Mounting holes

[0338] 77…Nut

[0339] 78, 88…Inner cover

[0340] 79, 89…Outer cover

[0341] 91~98, 91B, 92B…Terminal metal parts (terminals)

[0342] 91a~98a…Wire connection part

[0343] 91b~98b…Hook

[0344] 91c~98c…Installation

[0345] 91d~94d…Through hole

[0346] 95d~98d…External circuit connection sheet

[0347] 91e~98e, 91e', 92e'…Connection

[0348] 91f~98f…insert convex part

[0349] 100, 200…Insulation wall

[0350] 102a, 102a', 102a", 202a, 202a', 202a" ... relieved fitting protrusions

[0351] 102a1, 202a1 ... main convex part

[0352] 102a2, 202a2…auxiliary convex part

[0353] 102a3…Through hole

[0354] 104, 204…Anti-loosening hole

[0355] 105…Terminal block mounting part

[0356] 106…Connection

[0357] 206…Removal slot

[0358] 300, 300a…Circuit board

[0359] 302, 302a…Mounting hole

[0360] 304…Screw

[0361] 400…Housing

[0362] 410…lateral part

[0363] 420…Terminal block mounting section

[0364] 430…Relaxing the fitting convex part

[0365] 500…Stop wall

[0366] 510…Wall

[0367] 520…Chimerism part.

Claims

1. A coil device, comprising: a bobbin having a winding portion on which the power supply wire is wound; a terminal to which the end of the electric wire is connected; a terminal block on which the terminal is mounted, The direction of the winding axis of the winding portion of the bobbin is parallel to the third axial direction, and the directions perpendicular to the third axial direction are the first axial direction and the second axial direction. The terminal block has a terminal groove and a fitting groove. The terminal has a hook portion and an insertion protrusion, The widths of the terminal groove in the first and second axial directions are greater than the widths of the hook portion in the first and second axial directions. The widths of the fitting groove in the first axial direction and the second axial direction are larger than the widths of the insertion protrusion in the first axial direction and the second axial direction. The terminal is movable in both a first axial direction and a second axial direction of the bobbin.

2. The coil device according to claim 1, wherein: The terminal block is attached to a housing that accommodates the bobbin or a cover that covers at least a portion of the bobbin.

3. The coil device according to claim 1, wherein: The terminal is mounted on the terminal block so as to be movable in a third axial direction of the bobbin.

4. The coil device according to claim 1, wherein: The terminal block is movable in a third axial direction of the bobbin.

5. The coil device according to claim 1, wherein: A relaxing fitting protrusion protruding in the first axial direction is formed on one of the bobbin and the terminal block, and a relaxing fitting recess into which the relaxing fitting protrusion enters is formed on the other of the bobbin and the terminal block. The relaxing fitting protrusion is inserted into the relaxing fitting recess within a predetermined range so as to be movable in the first axial direction and the second axial direction.

6. The coil device according to claim 1, wherein: A relaxing fitting protrusion protruding in the second axial direction or the third axial direction is formed on one of the bobbin and the terminal block, and a relaxing fitting recess into which the relaxing fitting protrusion enters is formed on the other of the two terminals. The relaxing fitting protrusion is inserted into the relaxing fitting recess within a predetermined range so as to be movable in the first axial direction and the second axial direction.

7. The coil device according to claim 5, wherein: A portion of the inner wall constituting the relaxing fitting recess is formed by an elastically deformable support piece to open the width of the entrance of the relaxing fitting recess. The support piece is formed with a stopper protrusion that engages with the relaxing fitting protrusion to prevent it from coming off.

8. The coil device according to claim 5, wherein: A stopper wall portion is provided, which is installed into the said relaxing fitting protrusion inside the said relaxing fitting concave portion and stops it from falling off, The stopper wall portion has a fitting portion that fits with the relaxing fitting protrusion.

9. The coil device according to claim 5, wherein: A stopper wall portion is provided, which is mounted on the said relaxing fitting protrusion that enters the inside of the said relaxing fitting concave portion and stops it from falling off, The stopper wall portion is connected to the relaxing fitting protrusion via resin.

10. The coil device according to claim 6, wherein: The relaxing engagement protrusion has a main protrusion and a secondary protrusion. The relaxing fitting recess has a main recess into which the main protrusion is inserted and a secondary recess into which the secondary protrusion is inserted. The gap between the auxiliary protrusion and the auxiliary recess along the third axial direction is smaller than the gap between the main protrusion and the main recess along the third axial direction. The terminal block is held relative to the bobbin so as to be movable in the first axial direction and the second axial direction along the guide surface where the auxiliary convex portion and the auxiliary concave portion are in contact.

11. The coil device according to claim 1, wherein: The terminal has: An electric wire connecting portion, which fixes and connects the ends of the electric wires; The hook portion is formed at a position different from the electric wire connecting portion and is inserted into a terminal groove formed in the terminal block so as to be movable in the third axial direction.

12. The coil device according to claim 11, wherein: The terminal has an insertion hole or an external circuit connection piece formed between the wire connection portion and the hook portion.

13. The coil device according to claim 11, wherein: An inner cover that engages with the hook portion and limits the movement range of the terminal in the third axial direction is mounted on the terminal block.

14. The coil device according to claim 1, wherein: having a plurality of said terminals, There are a plurality of terminal blocks, Each of the plurality of terminals is mounted on each of the plurality of terminal blocks.

15. The coil device according to claim 13, wherein: An outer cover is mounted on the terminal block, which covers the inner cover, covers the end portion of the terminal block in the first axial direction, and further covers the end portion of the terminal block in the second axial direction.

16. The coil device according to claim 15, wherein: The outer cover covers an end portion of the terminal block in a third axial direction so that the wire connecting portion is exposed.

17. A coil device, comprising: a bobbin having a winding portion on which the power supply wire is wound; a terminal to which the end of the electric wire is connected; a terminal block on which the terminal is mounted and which is mounted on the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin, The direction of the winding axis of the winding portion of the bobbin is parallel to the third axial direction, and the directions perpendicular to the third axial direction are the first axial direction and the second axial direction. A relaxing fitting protrusion protruding in the first axial direction is formed on one of the bobbin and the terminal block, and a relaxing fitting recess into which the relaxing fitting protrusion enters is formed on the other of the bobbin and the terminal block. The width of the relaxing fitting recess in the second axial direction is greater than the width of the relaxing fitting protrusion in the second axial direction. The relaxing fitting protrusion is inserted into the relaxing fitting recess within a predetermined range so as to be movable in the first axial direction and the second axial direction. A portion of the inner wall constituting the relaxing fitting recess is formed by an elastically deformable support piece to open the width of the entrance of the relaxing fitting recess. The support piece is formed with a stopper protrusion that engages with the relaxing fitting protrusion to prevent it from coming off.

18. The coil device according to claim 17, wherein: The terminal block is movable in a third axial direction of the bobbin, and the terminal is integrally formed with the terminal block.

19. A coil device, comprising: a bobbin having a winding portion on which the power supply wire is wound; a terminal to which the end of the electric wire is connected; a terminal block on which the terminal is mounted and which is mounted on the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin, The direction of the winding axis of the winding portion of the bobbin is parallel to the third axial direction, and the directions perpendicular to the third axial direction are the first axial direction and the second axial direction. A relaxing fitting protrusion protruding in the first axial direction is formed on one of the bobbin and the terminal block, and a relaxing fitting recess into which the relaxing fitting protrusion enters is formed on the other of the bobbin and the terminal block. The width of the relaxing fitting recess in the second axial direction is greater than the width of the relaxing fitting protrusion in the second axial direction. The relaxing fitting protrusion is inserted into the relaxing fitting recess within a predetermined range so as to be movable in the first axial direction and the second axial direction. A stopper wall portion is provided, which is installed into the said relaxing fitting protrusion inside the said relaxing fitting concave portion and stops it from falling off, The stopper wall portion has a fitting portion that fits with the relaxing fitting protrusion.

20. The coil device according to claim 19, wherein The terminal block is movable in a third axial direction of the bobbin, and the terminal is integrally formed with the terminal block.

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