Coil device

Abstract

The present invention provides a coil device that can be miniaturized and has excellent heat dissipation. A transformer (10) comprises: a bobbin (20) on which electric wires (37, 38) are wound; and a core cover (50) that covers the bobbin (20). The core cover (50) has an inlet forming member (57a to 57j) for forming an inlet for allowing resin to flow in together with a part of the bobbin (20) on one side along the X-axis orthogonal to the Z-direction of the winding axis of the electric wires (37, 38), and a leakage suppression portion (58) for suppressing the outflow of resin on the other side opposite to the inlet (57).

Description

Technical Field

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

[0002] Patent Document 1 proposes a coil device in which a resin is filled between a core and a case to improve heat dissipation.

[0003] However, in recent years, with the popularization of electric vehicles, the demand for coil devices that can pass large currents has increased. In addition, with the miniaturization of coil devices, it is difficult to fully dissipate the heat generated in the coil devices, especially the heat near the wires.

[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 conditions, and an object of the present invention is to provide a coil device that can be miniaturized and has excellent heat dissipation properties.

[0009] Technical solutions to solve problems

[0010] The present inventors conducted intensive research on a coil device having excellent heat dissipation performance and found that heat dissipation performance can be improved by providing a resin inlet and a leakage suppression portion instead of a resin inlet and an outlet on the core cover, thereby completing the present invention.

[0011] That is, the coil device of the present invention has:

[0012] a spool on which the wire is wound;

[0013] a core cover covering the bobbin, wherein

[0014] The core cover has an inlet forming member for forming an inlet allowing the inflow of resin together with a part of the bobbin on one side along a first axis orthogonal to the winding direction of the electric wire, and has a leakage suppression portion for suppressing the outflow of the resin on at least the other side opposite to the inlet.

[0015] In the coil device of the present invention, the core cover covers the bobbin, and has a leakage suppression portion that suppresses the outflow of the resin on the other side opposite to the inlet that allows the inflow of the resin formed together with a part of the bobbin. That is, before the bobbin with the core cover is stored in a housing, etc., the inlet is facing upward, and a resin with high thermal conductivity such as a casting resin can be filled near the wire. The resin is injected with gravity, so it is easy to enter even narrow parts such as the gap between wires, the gap between the wire and the bobbin, and the gap between the wire and the core cover. When the inlet is facing upward and the resin flows from the inlet, the resin reaches the opposite side of the inlet with the gravity, but the resin is blocked by the leakage suppression portion, and leakage from the opposite side of the inlet is suppressed.

[0016] Therefore, the resin contacts most of the wire wound on the bobbin. Moreover, after the resin is cured, the directions of the bobbin and the core cover are restored, and the entrance is oriented in the horizontal direction. For example, if the wire enters a housing filled with a casting resin, the heat generated by the wire is well dissipated from the bobbin and the core or from the core cover to the outside of the core through the resin. Furthermore, the heat is transferred to the resin in the housing, and the heat is dissipated to the outside through the housing. Therefore, the heat generated from the coil device can be effectively dissipated.

[0017] Preferably, the coil device is accommodated in a housing. The housing may be filled with a resin having excellent thermal conductivity.

[0018] Preferably, the core cover covers the bobbin from the inlet to form a resin storage portion between the core cover and the bobbin.

[0019] The leakage suppression portion is configured to retain the resin injected from the inlet in the resin storage portion.

[0020] The inlet forming member may also be constituted only by the end piece of the core cover, or may be formed integrally with the bobbin to form the inlet. In addition, preferably, the inlet forming member includes a frame body, which is arranged at the end of the core cover and protrudes along the first axis from the guide piece that restricts the movement of the core. By configuring in this way, even if the core is inserted into the barrel of the bobbin, the core abuts against the guide piece to restrict the movement along the first axis, and the core can be easily positioned relative to the bobbin.

[0021] In addition, the frame is an inlet forming component that forms an inlet for the resin, whereby the inlet for the resin protrudes from the guide piece along the first axis, and the inlet is directed upward to facilitate the flow of resin from the inlet, and the resin is suppressed from overflowing from the inlet when flowing in, thereby almost preventing leakage of the expensive resin and allowing the resin to be distributed near the wire.

[0022] Preferably, the core cover has a plurality of split pieces connected to each other. With such a configuration, the core cover can easily cover the bobbin. In addition, a resin storage portion can be easily formed according to the shape of the bobbin. Furthermore, the size of the inlet can also be easily changed.

[0023] Preferably, the core cover has a connecting portion where the ends of the split pieces overlap. By configuring in this way, it is possible to effectively prevent the resin from leaking out of the core cover from the connecting portion where the split pieces are connected.

[0024] The plurality of split pieces are arranged around the bobbin. By configuring in this way, the core cover can be assembled at at least one connecting portion along the circumference of the bobbin. In addition, the plurality of split pieces can also be arranged along the winding axis direction.

[0025] The plurality of split pieces may be connected by the leakage suppression part. Even with such a structure, the leakage of resin from the resin storage part can be suppressed by the connection part. By providing the connection part on the side opposite to the inlet, it is easy to assemble the core cover. The leakage suppression part may be the core cover itself, or may be a connection part between the split pieces of the core cover, or may be a connection part between the core cover and the bobbin. Furthermore, the leakage suppression part may be constituted by a component different from the core cover and the bobbin.

[0026] For example, the gap between the connecting parts of the core cover segments or the gap between the core cover and the bobbin may be blocked by other components (blocking components) such as wrapping tape, thereby forming a leakage prevention portion. Furthermore, the blocking components such as wrapping tape formed by such different components may be removed and then installed in the housing after the resin in the core cover is cured and before the coil device is installed in the housing.

[0027] The present invention provides a method for manufacturing a coil device, characterized by comprising:

[0028] The process of winding the wire on a spool;

[0029] the step of covering the bobbin with a core cover,

[0030] When the core cover is installed on the bobbin, an inlet allowing the inflow of resin is formed together with a part of the bobbin on one side along the first axis orthogonal to the winding direction of the electric wire, and a leakage suppression portion for suppressing the outflow of the resin is formed on at least the other side opposite to the inlet.

[0031] Alternatively, the bobbin with the core cover mounted thereon may be tilted so that the inlet faces upward in the vertical direction, the resin may be filled into the resin storage portion between the bobbin and the core cover from the inlet, and then the resin may be cured, and then the bobbin with the core cover mounted thereon may be placed inside the housing. In the case where the leakage prevention portion is formed by a blocking member that is a member different from the core cover, such as a wrapping tape, the blocking member may be accommodated in the housing while being mounted on the core cover or the bobbin, or the coil device may be placed in the housing after the blocking member is removed. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1It is a schematic cross-sectional view showing the structure of a coil device according to one embodiment of the present invention.

[0033] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0034] Figure 3 yes Figure 1 A perspective view of a first coil portion and a second coil portion included in the coil device shown.

[0035] Figure 4 yes Figure 1 A perspective view of a bobbin having a coil arrangement is shown.

[0036] Figure 5 yes Figure 1 A perspective view of a terminal block and a lead wire guide included in the coil device shown.

[0037] Figure 6 yes Figure 1 A perspective view of the terminals included in the coil device shown.

[0038] Figure 7 is from Figure 1 The coil device shown is a perspective view with the core removed.

[0039] Figure 8 yes Figure 1 A perspective view of the core cover of the coil arrangement is shown.

[0040] Fig. 9A yes Figure 2 An exploded perspective view of the core cover is shown.

[0041] Fig. 9B This is an exploded perspective view of a core cover used in a coil device according to another embodiment of the present invention.

[0042] Fig. 9C This is an exploded perspective view of a core cover used in a coil device according to another embodiment of the present invention.

[0043] Fig. 10A yes Figure 8 A cross-sectional view of the core cover along line VII-VII.

[0044] Fig. 10B yes Fig. 10A A cross-sectional view of a modified example of .

[0045] Fig.11 This is a perspective view showing a state where resin is filled into a resin reservoir from an inlet on a core cover of a coil device before assembly.

[0046] Fig.12 It means that Figure 1The coil device shown is a perspective view of a state accommodated in a housing. DETAILED DESCRIPTION

[0047] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0048] First embodiment

[0049] As Figure 1 The transformer 10 of the coil device of the present embodiment shown is used, for example, for EV (Electric Vehicle), PHV (Plug-in Hybrid Vehicle), a vehicle charger for commuting (vehicles), a power supply circuit of household or industrial electrical equipment, a power supply circuit of computer equipment, etc. Figure 2 As shown, the transformer 10 includes a bobbin 20 , magnetic cores (split cores) 40 a and 40 b , a terminal block 80 , and a lead wire guide 110 .

[0050] like Figure 2 As shown, in this embodiment, the magnetic cores 40a, 40b can be separated into two split cores 42a, 42a and 42b, 42b having the same shape. In this embodiment, each split core 42a, 42a and 42b, 42b has the same shape and has an E-shaped cross section in the Z-Y cross section, forming a so-called E-shaped core. Another pair of split cores 42b, 42b arranged at the lower part in the Z-axis direction also has an E-shaped cross section in the Z-Y cross section, forming a so-called E-shaped core.

[0051] In addition, in the drawings, the X-axis, Y-axis and Z-axis are perpendicular to each other, and the X-axis is Figure 3 The direction perpendicular to the winding axis (Z axis) of the wires 37 and 38 shown corresponds to the first axis, the Y axis corresponds to the second axis, and the Z axis corresponds to the third axis. Figure 2 The directions of the dividing lines of the pair of divided cores 42a and 42a or the pair of divided cores 42b and 42b shown are substantially the same, but these dividing lines may be along the X axis. In the present embodiment, the Z axis corresponds to the height (thickness) direction of the transformer 10 .

[0052] like Figure 2 As shown, each split core 42a arranged on the upper side in the Z-axis direction has a base portion 44a extending in the Y-axis direction and a pair of middle legs 46a and side legs 48a protruding in the Z-axis direction from both ends of the base portion 44a in the Y-axis direction. Each split core 42b arranged on the lower side in the Z-axis direction has a base portion 44b extending in the Y-axis direction and a pair of middle legs 46b and side legs 48b protruding in the Z-axis direction from both ends of the base portion 44b in the Y-axis direction.

[0053] A pair of middle legs 46a are inserted from the upper side in the Z-axis direction into the core pin through hole 26 of the bobbin 20. Similarly, a pair of middle legs 46b are inserted from the lower side in the Z-axis direction into the core pin through hole 26 of the bobbin 20, and inside the through hole 26, the front ends of the middle legs 46a are configured to contact or face each other at a predetermined interval.

[0054] On the inner peripheral surface of the winding tube portion 28 constituting the through hole 26, a separation projection 27 is formed along the Z-axis direction at a position opposite to the Y-axis direction (see Figure 2 The separation protrusion 27 is disposed between the middle legs 46a, 46a and between the middle legs 46b, 46b. The middle legs 46a, 46a or the middle legs 46b, 46b are mutually opposed with a predetermined gap inside the through hole 26 and are not in contact with each other. The predetermined gap can be adjusted by the thickness of the separation protrusion 27 in the Y-axis direction.

[0055] The middle legs 46a, 46a or the middle legs 46b, 46b have an elliptical cylindrical shape that is long in the X-axis direction so as to be consistent with the inner peripheral surface shape of the through hole 26 in the respective combined states, but the shape thereof is not particularly limited and may also be changed according to the shape of the through hole 26. In addition, the side legs 48a, 48b have an inner concave curved surface shape that is consistent with the outer peripheral surface shape of the core cover body 52 of the core cover (coil cover) 50, and the outer surface thereof has a plane parallel to the X-Z plane. In the present embodiment, the material of each split core 42a, 42b can include soft magnetic materials such as metal and ferrite, but is not particularly limited.

[0056] like Figure 2 As shown in the figure, the bobbin 20 has a bobbin body 24 and a connection portion 22 formed at the upper portion of one end of the bobbin body 24 in the X-axis direction. In addition, the bobbin 20 is made of plastic such as PPS, PET, PBT, LCP, etc., but can also be made of other insulating components. Preferably, the bobbin 20 is made of a heat-resistant material. In order to improve strength and thermal conductivity, fillers such as glass can also be filled in these insulating components.

[0057] like Figure 3 As shown, in Figure 2 The first electric wire 37 constituting the first coil portion 35 and the second electric wire 38 constituting the second coil portion 36 are wound around the bobbin body 24 shown.

[0058] like Figure 4 As shown, at both ends of the winding barrel portion 28 of the bobbin 20 in the transformer 10 of this embodiment in the Z-axis direction, end wall flanges 31 and 32 are integrally formed in a manner extending radially outward and substantially parallel to the X-Y plane. At the front end side ( Figure 4 The frame 31a is integrally formed with the front side along the X-axis. Fig.11 This will be explained later.

[0059] Located in Figure 4 The winding tube portion 28 between the end partition flanges 31 and 32 in the Z-axis direction shown in the figure has different positions arranged in the Z-axis direction (direction of the winding axis). Figure 3 The first coil portion 35 and the second coil portion 36 are shown. A first electric wire 37 constituting one of the primary coil and the secondary coil is wound around the first coil portion 35, and a second electric wire 38 constituting the other of the primary coil and the secondary coil is wound around the second coil portion 36.

[0060] In this embodiment, the first coil portion 35 and the second coil portion 36 are located between the Figure 4 The outer periphery of the winding barrel portion 28 shown in the figure is formed with an insulating partition flange 30 substantially parallel to the XY plane. Figure 3 The first coil portion 35 shown in the figure is formed with a winding partition flange 33 (see FIG. 1 ) for separating the adjacent wire winding portions along the winding axis (Z axis) of the first wire 37 into sections. Figure 4 ).

[0061] In addition, in this embodiment, Figure 3 The second coil portion 36 shown in the figure is also formed with a structure that separates the wire winding portions adjacent to each other along the winding axis (Z axis) of the second wire 38 into respective sections, similarly to the first coil portion 35. Figure 4 The winding partition wall flange 34 is shown. At least one communication groove is formed in each of the winding partition wall flanges 33 and 34 to connect the adjacent sections S1 and S2 or S1a and S2a.

[0062] Although detailed illustration is omitted, communication grooves are formed on the winding bulkhead flanges 33 and 34 on the opposite side of the X-axis from the side where the connection portion 22 is arranged in the X-axis direction. These communication grooves are formed in a portion of the circumferential direction of each bulkhead flange 33 and 34 to a depth reaching the outer peripheral wall of the winding barrel portion 28.

[0063] The partitions S1 and S2 separated in the Z-axis direction by the partition flanges 30, 33, and 31 are wound. Figure 3 The first electric wire 37 shown can separate the wire winding parts from each other in each section S1, S2. In the present embodiment, the section width along the Z axis in each section S1, S2 is set to a width that only enters one electric wire 37. However, in the present embodiment, the section width may be set to a width that enters two or more electric wires 37. In addition, in the present embodiment, the section widths are preferably the same, but may be slightly different.

[0064] Figure 3 The second coil portion 36 shown is also similar to the first coil portion 35. Figure 4 The partition wall flanges 30, 34, 32 shown are wound around the regions S1a and S2a separated in the Z-axis direction. Figure 3 The second electric wire 38 shown in the figure can separate the wire winding parts into each section S1a, S2a. In the present embodiment, the section width along the Z axis in each section S1a, S2a is set to a width that only allows one electric wire 38 to enter. In addition, the section width can also be set to be the same as the section width according to the wire diameter of the electric wire 38.

[0065] in addition, Figure 4 The radial width of the shown next-wall flanges 30 to 34 is set to the height of one (one layer or more) or more wires 37 or 38, and in this embodiment, it is preferably set to a radial width that can wind 2 to 10 layers of wires. The radial widths of the next-wall flanges 30 to 34 are preferably the same, but may be different.

[0066] like Figure 2 As shown, a connection portion 22 is provided on the front side of the bobbin 20 in the X-axis direction, and a lead wire guide portion 110 which is separate from the bobbin 20 is installed on the connection portion 22. The lead wire guide portion 110 is detachably connected to the bobbin 20 and serves to guide the bobbin 20. Figure 3 The lead wire portions 37a, 37b, 38a, 38b shown in the figure are used to lead out and fix the lead wire guide portion 110. Figure 3 The first lead portions 37a, 37b of the first wire 37 and the second lead portions 38a, 38b of the second wire 38 are shown. The Y-axis width and X-axis width of the connection portion 22 are determined by the Y-axis width and X-axis width of the bottom surface of the lead guide portion 110.

[0067] like Figure 4 As shown, the connecting portion 22 integrally formed with the bobbin 20 has a base portion 22a extending in the Y-axis direction and an insulating wall 22b rising substantially perpendicularly to the base portion 22a toward the upper direction of the Z-axis. The insulating wall 22b is formed parallel to the Z-Y plane to ensure Figure 2 The terminals 60a to 60d and Figure 1 The insulating component of the magnetic core 40a shown. In addition, Figure 4 The base portion 22a shown is formed parallel to the XY plane and is used for mounting Figure 5 The lead guide 110 is shown.

[0068] In addition, in the base portion 22a, in order to Figure 3 The lead wire portions 37a, 37b, 38a, 38b of the electric wires 37, 38 shown are guided Figure 2The terminals 60a to 60d of the terminal block 80 are shown as Figure 4 As shown, the four bobbin side cutouts 23a to 23d are formed to be intermittently recessed in the X-axis direction along the Y-axis. Figure 3 The lead wire portions 37a, 37b, 38b, 38a shown are passed through the bobbin side cutouts 23a, 23b, 23c, 23d, respectively.

[0069] exist Figure 4 The base portion 22a shown in FIG. 1 is provided with engaging pieces 22c at both ends along the Y axis, the wall thickness of which in the Z axis direction is thinner than that in the center. Figure 5 The back side of the lead wire guide portion 110 shown can be inserted into and engaged with the engaging grooves 114 c and 116 c formed below both ends in the Y-axis direction.

[0070] In this embodiment, using Figure 4 The connecting groove (not shown) formed on the other side of the X-axis of the winding bulkhead flange 34 shown in the figure is Figure 3 The second electric wire 38α is shown wound around Figure 4 The winding drum portion 28 shown. Figure 4 The connecting groove (not shown) formed on the other side of the X-axis of the winding bulkhead flange 33 shown in the figure is Figure 3 The first electric wire 37α shown is wound around the winding drum portion 28. In addition, the winding method of the first electric wire 37 and the second electric wire 38 is not limited to α winding, and ordinary winding may be used.

[0071] The insulating adapter 70 is across Figure 4 The connecting portion 22 and the insulating wall flange 30 are mounted on the Figure 4 The insulating adapter 70 includes a curved side surface 71, an upper surface 72 formed at an upper portion of the side surface 71 in the Z-axis direction, and a bottom surface 73 formed at a lower portion of the side surface 71 in the Z-axis direction. A guide groove 76 extending in the Z-axis direction is formed in a portion of the curved outer surface of the side surface 71. Figure 3 The other lead portion 37 b of the first electric wire 37 is shown to pass through the guide groove 76 in the Z-axis direction.

[0072] A sliding insertion piece 74 is formed outside the guide groove 76, and the sliding insertion piece 74 is inserted into the first sliding insertion hole 22e of the connecting portion 22, and then the upper surface portion 72 is inserted into the second sliding insertion hole 22f, so that the insulating adapter 70 is mounted on the connecting portion 22. The bottom surface portion 73 of the insulating adapter 70 is mounted to contact the lower surface of the insulating partition flange 30 in the Z-axis direction.

[0073] like Figure 7As shown, on the insulating wall 22b, six bobbin side engaging parts 26a to 26f are formed to protrude intermittently along the Y axis in the X axis direction. The bobbin side engaging parts 26a to 26f are respectively composed of protruding convex parts protruding along the X axis direction. These bobbin side engaging parts 26a to 26c and 26f can be engaged with the guide side engaging parts 113a to 113d, and the bobbin side engaging parts 26d and 26e can be inserted into the opposing cutouts 112c and 112d and fit.

[0074] like Figure 5 As shown, the lead guide 110 has a rod member 112 extending in the Y-axis direction, and the end blocks 114 and 116 are respectively integrated with the two ends of the rod member 112 in the Y-axis direction. A pair of snap hooks 114b, 114b are formed on the end block 114, and a pair of snap hooks 116b, 116b are formed on the end block 116. The connecting piece 87a of the terminal block 80 is sandwiched between the pair of snap hooks 114b, 114b and can be connected (engaged), and the connecting piece 87b of the terminal block 80 is sandwiched between the pair of snap hooks 116b, 116b and can be connected (engaged). As a result, the movement of the terminal block 80 in the Z-axis direction can be restricted.

[0075] The end block 114 is provided with an engaging protrusion 114a sandwiched between a pair of engaging hooks 114b, 114b, and the end block 116 is provided with an engaging protrusion 116a sandwiched between a pair of engaging hooks 116b, 116b. The connecting hole 870a of the terminal block 80 can be engaged with the engaging protrusion 114a, and the connecting hole 870b of the terminal block 80 can be engaged with the engaging protrusion 116a.

[0076] On the back side of the rod member 112 in the X-axis direction, Figure 4 The positions of the spool side cutouts 23a, 23b, 23c, and 23d in the Y-axis direction correspond to each other. Figure 5 As shown, facing cutouts 112a, 112b, 112c, and 112d are formed to extend intermittently in the Y-axis direction in the X-axis direction. The facing cutouts 112c and 112d are formed to be longer in the X-axis direction than the facing cutouts 112a and 112b.

[0077] Figure 3 The lead portions 37a, 37b, 38b, 38a are shown in Figure 7 The method shown is inserted through the opposing cutouts 112a, 112b, 112c, and 112d. Figure 5The rear side of the rod member 112 in the X-axis direction is provided with positioning recesses on one side and the other side in the Y-axis direction. The positioning protrusions 88a and 88b of the terminal block 80 can be inserted into and engaged with the positioning recesses 118a and 118b. In addition, in the present embodiment, the terminal block 80 and the lead guide 110 are formed of different components and engaged with each other, but they may be formed integrally.

[0078] exist Figure 5 The surface of the rod member 112 in the X-axis direction is formed with wire insertion passages 117a to 117d. The wire insertion passages 117a and 117b extend obliquely upward in the Z-axis direction and communicate with the corresponding cutouts 112a and 112b. The wire insertion passages 117c and 117d extend straight upward in the Z-axis direction and communicate with the corresponding cutouts 112c and 112d. Figure 3 The lead portions 37a and 37b shown in FIG. Figure 5 The wire insertion passages 117c and 117d are shown as leading out Figure 3 Lead portions 38b, 38a are shown.

[0079] exist Figure 5 The surface of the rod member 112 in the X-axis direction is Figure 7 The Y-axis direction positions of the bobbin-side engaging portions 26a, 26b, 26c, and 26f shown in FIG. Figure 5 As shown, the guide side engaging parts 113a, 113b, 113c, and 113d are formed intermittently (in a step-like manner) along the Y-axis direction and are recessed toward the X-axis direction. Figure 7 As shown, the bobbin-side engaging portions 26a to 26c and 26f engage with the guide-side engaging portions 113a to 113d.

[0080] like Figure 6 As shown, the terminal 60a (the same applies to the terminals 60b to 60d) has a wire connection portion 61, an external connection portion 62, and a connecting portion 63. The connecting portion 63 is formed of a substantially flat plate shape parallel to the XY plane, and connects (connects) the wire connection portion 61 and the external connection portion 62. The wire locking portion 63 is relative to Figure 5 The base portions 81 shown are arranged substantially in parallel.

[0081] The wire connection portion 61 is clamped and connected Figure 3 Lead portions 37a, 37b, 38a, 38b are shown. Figure 6 The wire connecting portion 61 shown has a protruding piece 610 and a clamping piece 611. The protruding piece 610 is formed in a substantially flat plate shape parallel to the XY plane. The protruding piece 610 is integrally connected to one end of the wire locking portion 63 in the Y-axis direction and protrudes outward in the Y-axis direction.

[0082] The clamping piece 611 is formed of a substantially flat plate parallel to the XY plane. The clamping piece 611 is connected to the front end of the protruding piece 610 in the Y-axis direction and is formed by bending the protruding piece 610 toward the inner side in the Y-axis direction (the side opposite to the protruding direction of the protruding piece 610). Figure 7 As shown, the lead wire parts 37a, 37b, 38a, 38b can be clamped. On the terminals 60a to 60d, the lead wire parts 37a, 37b, 38a, 38b can be clamped by the protruding pieces 610 and the clamping pieces 611 and fixed by thermal compression or the like.

[0083] The external connection part 62 is formed of a substantially flat plate shape parallel to the XZ plane. The external connection part 62 is integrally connected to one end of the wire retaining part 63 in the X-axis direction in a manner substantially orthogonal to the wire retaining part 63, and protrudes outward in the X-axis direction. Figure 5 The positioning grooves 84a to 84d of the terminal block 80 shown are connected to an external substrate or the like.

[0084] Figure 5 As shown in the embodiment, the terminal block 80 can be detachably mounted on the lead wire guide portion 110, but it can also be integrally formed. Figure 2 The terminal block 80 includes a base portion 81 .

[0085] On the opposite side of the base portion 81 from the front end along the X-axis ( Figure 5 The partition wall 85a to 85e are formed along the Y axis. The partition wall 85a is formed at one end side of the base 81 in the Y axis direction, and the partition wall 85e is formed at the other end side of the base 81 in the Y axis direction. The partition wall 85b to 85d are formed between the partition wall 85a and the partition wall 85e. The partition wall 85c is located approximately in the center along the Y axis of the base 81.

[0086] A terminal arrangement portion 83a is formed in a region surrounded by the partition wall portion 85a and the partition wall portion 85b. Figure 6 The wire locking portion 63 of the first end terminal 60a shown in FIG. Figure 5 The area surrounded by the partition wall portion 85b and the partition wall portion 85c shown in the figure forms a terminal arrangement portion 83b, which can be arranged Figure 6 The wire locking portion 63 of the first inner terminal 60b is shown.

[0087] In by Figure 5 The area surrounded by the partition wall portion 85c and the partition wall portion 85d shown in the figure forms a terminal arrangement portion 83c, which can be arranged Figure 6 The wire retaining portion 63 of the second inner terminal 60c is shown. Figure 5The area surrounded by the partition wall portion 85d and the partition wall portion 85e shown in the figure forms a terminal arrangement portion 83d, which can be arranged Figure 6 The wire locking portion 63 of the second end terminal 60d is shown.

[0088] like Figure 5 As shown in FIG. 1 , a housing engagement groove 82 is formed on the back surface (bottom surface) of the base portion 81 in the Z-axis direction. The housing engagement groove 82 is, for example, Fig.12 The upper edge of the housing 120 shown is formed to be engageable, and the terminal block 80 can be fixed to the housing 120 via the housing engagement groove 82 .

[0089] like Figure 5 As shown, the positioning grooves 84a to 84d are formed at predetermined intervals in the Y-axis direction along the X-axis of the base portion 81 at the front end side ( Figure 5 Along the left side of the X axis). Connect Figure 3 The lead portions 37a, 37b, 38b, 38a shown in FIG. Figure 6 The external connection portions 62 of the terminals 60a to 60d are shown inserted into the positioning grooves 84a to 84d.

[0090] like Figure 5 As shown in FIG. 1 , the positioning grooves 84a to 84d are formed by grooves penetrating the base 81 in the Z-axis direction and extending along the X-axis direction of the base 81. The positioning grooves 84a to 84d are open in directions orthogonal to the plane of the base 81 (above and below the Z-axis) and are not blocked. Figure 7 As shown, the external connection portion 62 of the terminals 60a to 60d of the connection lead portions 37a, 37b, 38b, 38a is slidably inserted into the interior of the positioning groove portions 84a to 84d from the upper side to the lower side in the Z-axis direction (vertical direction).

[0091] Located in Figure 2 The spool 20 is shown close to one side of Figure 5 One end of the positioning grooves 84a to 84d shown in the figure is formed with a Figure 6 The insertion openings 840a to 840d of the external connection portion 62 are shown. The insertion openings 840a to 840d are open toward the side where the terminal configuration portions 83a to 83d are configured, and the positioning groove portions 84a to 84d are connected to the terminal configuration portions 83a to 83d via the insertion openings 840a to 840d. In addition, in the example shown in the figure, grooves that are continuous with the positioning groove portions 84a to 84d are also formed in the terminal configuration portions 83a to 83d.

[0092] like Figure 5As shown, the connecting piece 87a is formed at one end of the base portion 81 in the Y-axis direction, and the connecting piece 87b is formed at the other end of the base portion 81 in the Y-axis direction. Connecting holes 870a and 870b are formed on the connecting pieces 87a and 87b. The engaging protrusions 114a and 116a engage with the connecting holes 870a and 870b, and the terminal block 80 and the lead guide portion 110 can be connected detachably via the connecting pieces 87a and 87b.

[0093] The positioning protrusions 88a and 88b are formed on the back side of the base portion 81 in the X-axis direction opposite to the lead guide portion 110. The positioning protrusion 88a is located on one side in the Y-axis direction, and the positioning protrusion 88b is located on the other side in the Y-axis direction. The positioning protrusions 88a and 88b are engaged with the positioning recesses 118a and 118b, so that the terminal block 80 and the lead guide portion 110 can be positioned.

[0094] In this embodiment, Figure 2 As shown, the core cover 50 has a shape covering the outer periphery of the bobbin body 24. The core cover 50 has two split pieces 50a and 50b. The split piece 50a and the split piece 50b each have a core cover body 52, and a pair of locking pieces 54 bent in a substantially vertical direction from the core cover body 52 toward the bobbin body 24 are integrally formed with both ends in the Z-axis direction.

[0095] A pair of locking pieces 54 formed on both sides of the core cover body 52 in the Z-axis direction have locking protruding pieces 540. A hole 540a is formed in the approximate center of the locking protruding piece 540. The locking protruding piece 540 is fixed to the step wide width portion 250 of the step portion 25 formed on both side surfaces along the Z-axis of the bobbin 20. In more detail, when the locking protruding piece 540 is fixed to the step wide width portion 250, the protrusion 250a formed on the step wide width portion 250 is engaged with the hole 540a of the locking protruding piece 540. Thus, the pair of locking pieces 54 are installed to clamp the upper and lower surfaces of the bobbin body 24 in the Z-axis direction, and are arranged on the step portion 25 formed on the upper surface of the bobbin body 24.

[0096] like Figure 7 and Figure 8 As shown, the core cover 50 is formed along the X-axis except for the front end side (along the Figure 7 In addition to the inlet 57 for resin injection (on the left side of the X-axis shown in the figure), the entire circumference of the bobbin 20 is surrounded, and a leakage suppression portion 58 is formed on at least the opposite side of the inlet 57 along the X-axis. In the present embodiment, a connecting portion 55 is formed on the rear end side of the pair of split pieces 50a and 50b constituting the core cover 50 in the X-axis direction, and the rear ends of these split pieces 50a and 50b are connected by the connecting portion 55 to form the leakage suppression portion 58. In addition, even if each split piece 50a and 50b is connected to the bobbin 20, the leakage suppression portion 58 is formed.

[0097] like Fig. 9A As shown, at the rear end of the split piece 50a in the X-axis direction, an upper overlapping portion 550a is integrally formed as an extension of the core cover body 52, and upper overlapping portions 550b and 550c are integrally formed as extensions of each locking piece 54. In addition, at the rear end of the split piece 50b in the X-axis direction, a lower overlapping portion 551a is integrally formed as an extension of the core cover body 52, and lower overlapping portions 551b and 551c are integrally formed as extensions of each locking piece 54.

[0098] At the connecting portion 55 of the core cover 50, the upper overlapping portions 550a, 550b, 550c of the split piece 50a overlap with the lower overlapping portions 551a, 551b, 551c of the split piece 50b from above to form a Figure 8 The connecting portion 55 shown constitutes a leakage suppression portion 58. Fig. 9A The upper overlapping portions 550a, 550b, 550c shown in the figure are provided with steps in such a way that even when they overlap with the lower overlapping portions 551b, 551b, 551c, these inner peripheral surfaces can form a continuous flush plane. Fig. 10A .

[0099] At the ends of the core cover body 52 and the locking piece 54 of each of the divided pieces 50a and 50b on the front end side along the X axis (along the Fig. 9A The side foot guide piece 56 is formed integrally with the front side of the X-axis of the side foot guide piece 56. Figure 2 The X-axis of the split cores 42a and 42b shown in the figure abuts against the outer surface of the front end side. An intermediate guide piece 56a may be formed on the outer peripheral surface located in the middle of the X-axis direction of each core cover body 52 in a manner protruding outward in the Y-axis direction along the Z-axis direction. The inner surface of the side foot portions 48a and 48b contacts the intermediate guide piece 56a to restrict the movement of the side foot portions 48a and 48b in the X-axis direction.

[0100] The side guide piece 56 is formed larger than the middle guide piece 56a, and when the core cover 50 is mounted on the bobbin 20, the insulation distance (spatial distance and creeping distance) between the first lead portion 37a of the first electric wire 37 and the cores 40a and 40b is ensured. In addition, the split pieces 50a and 50b constituting the core cover 50 are respectively made of insulating members such as plastics, which are the same as those of the bobbin 20.

[0101] like Figure 8As shown, a frame body 57a protruding from the side foot guide piece 56 to the front end outside along the X-axis is integrally formed on the front end side of one of the split pieces 50a along the X-axis as an extension of the core cover body 52. ​​In addition, a frame body 57b protruding from the side foot guide piece 56 to the front end outside along the X-axis is integrally formed with the frame body 57a on the front end side of the split piece 50a along the X-axis as an extension of the locking piece 54 arranged on the lower side along the Z-axis.

[0102] In addition, a frame 57c is integrally formed on the front end side of the other split piece 50b along the X-axis, and the frame 57c protrudes from the side foot guide piece 56 to the front end outside along the X-axis as an extension of the core cover body 52. ​​In addition, a frame 57d is integrally formed with the frame 57c on the front end side of the other split piece 50b along the X-axis, and the frame 57d protrudes from the side foot guide piece 56 to the front end outside along the X-axis as an extension of the locking piece 54 arranged on the lower side along the Z-axis. Fig.11 As shown, the frame bodies 57a to 57d of the side leg guide piece 56 together with the frame body 31a of the bobbin 20 constitute an inlet forming member for forming the inlet 57 for resin injection.

[0103] That is, the frame bodies 57b and 57d formed on the core cover 50 and the front end ( Fig.11 The thin wall portions on both sides of the frame 31a along the Y axis (the upper side along the X axis) of the core cover 50 overlap. The frames 57a to 57d of the core cover 50 surround the four sides of the inlet 57 for injecting resin together with the frame 31a and the base portion 22a of the bobbin 20. In addition, a part of the lead wire guide portion 110 or the terminal block 80 may also constitute a part of the inlet forming member for constituting the inlet 57 for injecting resin.

[0104] like Figure 7 and Fig.11 As shown, when the split pieces 50a and 50b of the core cover 50 are mounted on the bobbin 20, a space that can be filled with liquid resin, i.e., a resin storage portion, is formed between the bobbin 20 and the core cover 50 (see Figure 8 ) 59. The resin storage portion 59 is open to the external space of the core cover 50 only at the inlet 57, and the other parts are sealed by connecting the bobbin 20 and the core cover 50, so that the resin will not leak even at the connecting portion 55 of the core cover 50.

[0105] In manufacturing the transformer 10, first, the bobbin 20, the first electric wire 37, the second electric wire 38, the core cover 50, the magnetic cores (split cores) 40a, 40b, the lead guide 110 formed separately from the bobbin 20, the terminal block 80 formed separately from the bobbin 20 and the lead guide 110, and the potting resin are prepared.

[0106] Then, in Figure 4The outer periphery of the bobbin 20 shown is formed Figure 3 The first coil portion 35 and the second coil portion 36 are shown. In addition, Figure 3 The formation of the first coil portion 35 and the second coil portion 36 shown can also be performed using an automatic winding machine. In addition, the wires 37 and 38 can be composed of a single wire, or can also be composed of a twisted metal wire, preferably an insulated coated wire. The second wire 38 can be the same as the first wire 37, but can also be different. In this embodiment, the outer diameter of the first wire 37 is larger than the outer diameter of the second wire 38, for example, preferably

[0107] Next, insert the slide insert 74 into Figure 4 The insulating adapter 70 is attached to the connecting portion 22 by sliding the upper surface portion 72 into the sliding insertion groove 22 f and fixing the bottom surface portion 73 to the lower surface of the insulating partition flange 30 .

[0108] Next, the lead wire portions 37a, 37b, 38b, 38a are inserted into the bobbin-side cutouts 23a to 23d of the connection portion 22 and are led out upward in the Z-axis direction. At this time, the second lead wire portion 37b is inserted into the guide groove 76 of the insulation adapter 70.

[0109] Next, the lead parts 37a, 37b, 38b, 38a are clamped by the protruding pieces 610 and the clamping pieces 611 of the terminals 60a to 60d, and the lead parts 37a, 37b, 38b, 38a are riveted by the wire connecting part 61. In addition, this process can also be performed after the lead guide part 110 is attached to the connecting part 22. Next, in this state, the wire connecting part 61 to which the lead parts 37a, 37b, 38b, 38a are riveted is thermally compressed using a jig.

[0110] Next, the bobbin-side engaging portions 26a to 26c and 26f are engaged with the terminal-side engaging portions 113a to 113d, and the bobbin-side engaging portions 26d and 26e are inserted into and engaged with the opposing cutouts 112c and 112d. Figure 5 The lead wire guide portion 110 is thereby mounted on the connection portion 22 .

[0111] Then, if Figure 5 As shown, the engaging protrusions 114a and 116a are engaged with the connecting holes 870a and 870b to connect the terminal block 80 and the lead guide 110 via the connecting pieces 87a and 87b. Alternatively, the lead guide 110 to which the terminal block 80 is preliminarily mounted may be attached to the connecting portion 22.

[0112] Next, the lead parts 37a, 37b, 38b, 38a are respectively inserted into the opposed cutouts 112a to 112d, and the external connection parts 62 of the terminals 60a to 60d respectively connected to the lead parts 37a, 37b, 38b, 38a are respectively inserted into the interior of the positioning groove parts 84a to 84d from above. The front ends of the external connection parts 62 of the terminals 60a to 60d are abutted and fixed to the ends of the positioning groove parts 84a to 84d on the negative side of the X axis. In addition, the wire retaining parts 63 of the terminals 60a to 60d are arranged (fixed) on the terminal arrangement parts 83a to 83d. The terminals 60a to 60d may also be fixed to the terminal block 80 by adhesives or the like as needed.

[0113] Then, Fig. 9A The pair of split pieces 50a, 50b of the core cover 50 shown are mounted on Figure 4 The spool 20 shown in FIG. Fig. 9A The locking piece 54 shown holds Figure 4 The split pieces 50a and 50b are installed from both sides along the Y axis in the manner of the end wall flanges 31 and 32 shown. Figure 2 The protrusion 250a of the step width portion 250 shown is fitted into the hole 540a of the split pieces 50a and 50b and fixed. In addition, the ends of the split pieces 50a and 50b along the rear end side of the X axis are also connected to each other. In this way, the split pieces 50a and 50b are arranged around the bobbin 20.

[0114] like Fig.11 As shown, when the core cover 50 is mounted on the bobbin 20 , the frame bodies 57 b and 57 d protruding from the side leg guide pieces 56 of the split pieces 50 a and 50 b overlap with the frame body 31 a formed on the bobbin 20 .

[0115] Thus, when the core cover 50 is mounted on the bobbin 20, the inlet 57 for injecting resin is formed by the frame 57a to 57d including the side foot guide piece 56 and the inlet forming member of the frame 31a of the bobbin 20. Moreover, the leakage suppression part 58 including the connecting part 55 of the split piece 50a and the split piece 50b is formed on the opposite side of the inlet 57 in the X-axis direction. In addition, the core cover 50 covers the bobbin 20, and the resin storage part 59 is formed between the bobbin 20 and the core cover 50.

[0116] Then, if Fig.11 As shown, the Z axis which is consistent with the winding axis of the coil device 10 is tilted horizontally, and the front end side of the coil device 10 along the X axis is directed upward in the vertical direction, and liquid resin is injected into the core cover 50 from the inlet 57. The liquid resin is filled into the core cover 50. Fig.12 The potting resin inside the housing 120 shown is similarly made of a resin having excellent thermal conductivity, but it does not necessarily need to be made of the same resin.

[0117] The resin to be injected is not particularly limited, and for example, a resin with excellent heat dissipation having a thermal conductivity of 0.5 to 5, preferably 1 to 3 W / m·K is preferred. Examples of resins with excellent heat dissipation include silicone resins, polyurethane resins, epoxy resins, etc., among which silicone resins and polyurethane resins are preferred. In addition, in order to improve the heat dissipation, fillers with high thermal conductivity may be filled in the resin. The injected resin preferably has a Shore A hardness of 100 or less, preferably 60 or less. This is because even if the core 12 is deformed due to heat, the deformation can be absorbed, so that the core 12 does not generate excessive stress. As such a resin, a casting resin is exemplified.

[0118] The injected resin is accumulated in the resin reservoir between the bobbin 20 and the core cover 50 (see Figure 8 )59, in Figure 3 The wires 37, 38 and the gaps between the wires 37, 38 shown, Figure 3 The wires 37, 38 and Figure 2 The gap of the spool 20 shown, Figure 3 The wires 37, 38 and Figure 8 The gaps in the core cover 50 shown are also filled with the resin. The liquid level of the resin reaches the inlet 57, and the injection is stopped, so that the resin accumulated in the resin reservoir 59 is solidified.

[0119] Then, middle leg portions 46a of a pair of split cores 42a and 42a separated in the X-axis direction and middle leg portions 46b of a pair of split cores 42b and 42b separated in the X-axis direction are inserted from both sides of core leg through-hole 26 in the X-axis direction.

[0120] Then, if Fig.12 As shown, the transformer 10 is housed in the housing 120 and filled with a casting resin. In addition, a casting resin may be pre-filled in the housing 120, and the transformer 10 may be housed thereon. The casting resin is preferably a resin having excellent thermal conductivity similar to the resin injected into the core cover 50, and may be the same or different. The casting resin is composed of, for example, soft silicone resin, polyurethane resin, epoxy resin, etc. after injection, and the longitudinal elastic modulus of the casting resin is preferably 0.1 to 100 MPa.

[0121] Before and after this, the upper part and the side part of the split cores 42a, 42a may be covered by the heat sink 130. The heat sink 130 is made of, for example, a metal plate such as aluminum or copper having excellent heat dissipation, a resin plate such as PPS or PBT having good thermal conductivity, or a ceramic plate, a silicon wafer or other plate having excellent thermal conductivity. The material of the heat sink 130 is not particularly limited as long as it is a material having higher thermal conductivity than the material constituting the split cores 42a, 42a.

[0122] Furthermore, as necessary, the lead wire guide portion 110 attached to the bobbin 20 and the periphery of the terminal block 80 may be covered by the terminal cover 100 .

[0123] In the transformer 10 of the present embodiment, the terminal block 80 has the positioning grooves 84a to 84d into which the terminals 60a to 60d connected with the lead wires 37a, 37b, 38b, 38a are inserted, and is detachably connected to the bobbin 20 indirectly (via the lead wire guide 110). Therefore, in a state where the terminal block 80 is removed from the bobbin 20, the terminals 60a to 60d can be connected to the lead wires 37a, 37b, 38b, 38a, and a sufficient working area can be ensured when connecting the lead wires 37a, 37b, 38b, 38a to the terminals 60a to 60d.

[0124] In addition, after the terminal block 80 is indirectly connected to the bobbin 20, by inserting only the terminals 60a to 60d connected with the lead wire portions 37a, 37b, 38b, 38a into the positioning groove portions 84a to 84d, the terminals 60a to 60d can be accurately positioned relative to the terminal block 80, thereby preventing the problem of the front ends of the terminals 60a to 60d from being misaligned. Therefore, according to the transformer 10 of this embodiment, a transformer with high positioning accuracy and easy manufacturing can be provided.

[0125] In addition, in the present embodiment, the terminal block 80 has a base portion 81, and the positioning groove portions 84a to 84d are open in a direction perpendicular to the plane of the base portion 81. Therefore, the terminals 60a to 60d of the connecting lead portions 37a, 37b, 38b, 38a can be inserted slidably from a direction perpendicular to the plane of the base portion 81 (above the positioning groove portions 84a to 84d), and the terminals 60a to 60d can be easily positioned.

[0126] In addition, in the present embodiment, the other end of the positioning grooves 84a to 84d located away from the bobbin 20 is blocked by the base 81. Therefore, the front ends of the terminals 60a to 60d inserted into the positioning grooves 84a to 84d can be fixed to the other ends of the positioning grooves 84a to 84d, thereby effectively preventing the front ends of the terminals 60a to 60d from being misaligned.

[0127] In addition, the transformer 10 of the present embodiment has a lead guide portion 110, and the terminal block 80 is detachably connected to the lead guide portion 110. In this case, the terminal block 80 and the lead guide portion 110 are configured separately, so when the lead-out direction of the lead wires 37a, 37b, 38b, and 38a is changed, it can be dealt with by only changing the structure of the lead guide portion 110, without having to remake the terminal block 80. Therefore, it is possible to flexibly deal with changes in the specifications of the lead guide portion 110, and thus it is possible to provide a transformer 10 with a high degree of design freedom.

[0128] In addition, in the present embodiment, the lead wire guide 110 is detachably connected to the bobbin 20. In this case, the lead wire guide 110 is configured separately from the bobbin 20. Therefore, when the specification of the bobbin 20 is changed, it can be handled by simply changing the structure of the bobbin 20 without remaking the lead wire guide 110. Therefore, it is possible to flexibly handle the specification change of the bobbin 20, and it is possible to provide a transformer 10 with a high degree of design freedom.

[0129] In addition, in the present embodiment, the terminals 60a to 60d have the external connection portion 62 and the wire connection portion 61. Therefore, the external connection portion 62 and the positioning groove portions 84a to 84d can be positioned with good accuracy, and the lead portions 37a, 37b, 38b, 38a can be connected to the terminals 60a to 60d by sandwiching the lead portions 37a, 37b, 38b, 38a only by the wire connection portion 61, so that the manufacturing is easy.

[0130] In addition, in the present embodiment, the wire connection portion 61 has a clamping piece 611, and the clamping piece 611 is arranged substantially parallel to the base portion 81. Therefore, after the lead portions 37a, 37b, 38b, 38a are clamped by the clamping piece 611, the wire connection portion 61 is heat-pressed while the clamping piece 611 is arranged substantially parallel to the base portion 81, and the external connection portion 62 can be inserted into the positioning groove portions 84a to 84d as it is without changing the direction of the terminals 60a to 60d, so that the terminals 60a to 60d can be easily positioned.

[0131] In particular, in this embodiment, if Fig.12 As shown, before the transformer 10 is housed in the housing 120, etc. Fig.11 As shown, by pointing the inlet 57 upward, a resin with high thermal conductivity such as a casting resin can be filled into the Figure 3 The resin is injected by gravity, so it can easily enter narrow parts such as the gap between wires, the gap between wires and bobbins, and the gap between wires and core covers.

[0132] When the inlet 57 is facing upward and resin flows into the inlet, the resin also flows into the Figure 3 The wires 37, 38 and the gaps between the wires 37, 38 shown, Figure 3 The wires 37, 38 and Figure 4 The gap of the spool 20 shown, Figure 3 The wires 37, 38 and Figure 8 While narrowing the gap of the core cover 50 shown in FIG. Fig.11 The leakage suppression portion 58 shown suppresses leakage.

[0133] Therefore, the resin contacts most of the electric wires 37 and 38 wound on the bobbin 20. Then, after the resin is cured, the directions of the bobbin 20 and the core cover 50 are restored, as shown in FIG. Fig.12 As shown, the inlet 57 is oriented horizontally, for example, if entering the housing 120 filled with a casting resin or the like, Figure 3 The heat generated by the wires 37 and 38 shown is well dissipated from the bobbin 20 and the cores 40a and 40b or the core cover 50 to the outside of the cores 40a and 40b through the resin. Fig.12 The resin in the case 120 shown dissipates heat to the outside through the case 120. Therefore, the heat generated from the transformer 10 can be dissipated efficiently.

[0134] In addition, the inlet forming member may also be composed only of Figure 8 The end piece of the core cover 50 shown in FIG. Fig.11 As shown, the inlet 57 is formed integrally with the frame 31a of the bobbin 20. In addition, the member for forming the inlet 57 includes the frame 57a to 57d disposed at the end of the core cover 50 and formed on the guide piece 56 for limiting the movement of the cores 40a and 40b. By configuring in this way, even in Figure 2 The barrel 28 of the bobbin 20 shown is inserted into the middle legs 46a, 46b of the cores 40a, 40b, and the cores 40a, 40b can also abut against the guide piece 56, thereby limiting the movement along the X-axis and facilitating the positioning of the cores 40a, 40b relative to the bobbin 20.

[0135] In addition, if Fig.11 As shown, the frame 57a~57d is an inlet forming component for forming the resin inlet 57, whereby the resin inlet 57 protrudes from the guide piece 56 along the X-axis, and the inlet 57 is directed upward to facilitate the flow of resin from the inlet, and the resin is suppressed from overflowing from the inlet 57 when flowing in, so that the expensive resin is almost not leaked, and the resin is spread around the vicinity of the wire wound on the reel 20.

[0136] like Figure 2 As shown in FIG. 1 , the core cover 50 has a plurality of split pieces 50a and 50b connected to each other. By configuring in this way, the core cover 50 can easily cover the bobbin 20. In addition, the resin storage portion 69 (see FIG. 1 ) can be easily formed according to the shape of the bobbin 20. Figure 8 ). Furthermore, it is also easy to change Fig.11 The size of the inlet 57 is shown.

[0137] In this embodiment, the core cover 50 has a connecting portion 55 where the ends of the split pieces 50a and 50b overlap. By configuring in this way, it is possible to effectively prevent the resin from leaking out of the core cover 50 from the connecting portion 55 connecting the split pieces 50a and 50b. In addition, since the plurality of split pieces 50a and 50b are arranged around the bobbin 20, the core cover 50 can be assembled at at least one connecting portion 55 along the circumference of the bobbin 20.

[0138] In addition, in this embodiment, if Fig. 10B As shown, upper overlapping portions 552b, 552c and lower overlapping portions 554b, 554c are formed at the ends of the split piece 50a, and intermediate overlapping portions 553b, 553c formed at the ends of the split piece 50b can also be inserted into the gaps between them to form a connecting portion 55.

[0139] In addition, in the present embodiment, the winding barrel portion 28 and the end wall flanges 31, 32 of the bobbin 20 are elliptical in plan view, but may be circular or rectangular, etc. Furthermore, the core cover 50 only needs to cover the end wall flanges 31, 32 of the bobbin 20 as described above, and therefore, is consistent with the shape of the bobbin 20, and is elliptical, but may be other shapes such as circular or rectangular.

[0140] Second embodiment

[0141] like Fig. 9B As shown, the transformer of this embodiment is the same as the transformer 10 of the first embodiment except that the core cover 50 is composed of divided pieces 50c to 50e. In the following description, the description of the parts common to the first embodiment will be omitted.

[0142] like Fig. 9B As shown, the core cover 50 has three divided pieces 50c to 50e in the circumferential direction. The divided piece 50c has a U shape when viewed from the Z-axis direction. One end of the divided piece 50c is connected to the divided piece 50d, and the other end is connected to the divided piece 50e, respectively constituting a connecting portion 55.

[0143] The upper overlapping parts 550a to 550c overlap the lower overlapping parts 551a to 551c in each connecting portion 55. The split piece 50d has a side leg guide piece 56 and frames 57a and 57b, and the split piece 50e has a side leg guide piece 56 and frames 57c and 57d.

[0144] When the core cover 50 is connected to the bobbin 20, the core cover 50 is clamped by the locking piece 54 in the Z-axis direction. Figure 4 The end wall flanges 31 and 32 shown in the figure are installed along the X-axis direction. Fig. 9B Next, the split piece 50c is clamped by the locking piece 54 from the Z-axis direction. Figure 4The end wall flanges 31 and 32 are installed along the Y-axis direction. Fig. 9B The split pieces 50d, 50e are shown.

[0145] The ends of the split pieces 50c and 50d are fitted together so that the upper overlapping parts 550b and 550c overlap with the lower overlapping parts 551b and 551c in the Z-axis direction and the upper overlapping part 550a overlaps with the lower overlapping part 551a in the X-axis direction.

[0146] In this way, when the core cover 50 is mounted on the bobbin 20, the core cover 50 is formed similarly to the first embodiment. Fig.11 Inlet 57 is shown. In addition, leakage suppression portion 58 is formed by split piece 50c on the opposite side of inlet 57 in the X-axis direction. Furthermore, core cover 50 covers bobbin 20 from inlet 57, and resin reservoir 59 is formed between bobbin 20 and core cover 50.

[0147] In this embodiment, the locking protrusion 540 and the hole 540a are formed on the split piece 50c. Therefore, even if the inlet 57 is facing upward, the split piece 50c can be prevented from falling off the bobbin 20. In addition, the locking protrusion 540 and the hole 540a are also provided on the locking piece 54 of the split pieces 50d and 50e, and the protrusion 250a corresponding thereto can also be provided on the bobbin 20. In this way, the split pieces 50d and 50e are prevented from falling off the bobbin 20.

[0148] Third embodiment

[0149] like Fig. 9C As shown, the transformer 10 of this embodiment is the same as the transformer 10 of the first or second embodiment except that the core cover 50 is composed of divided pieces 50f and 50g. In the following description, the description of the parts common to the above-mentioned embodiment will be omitted.

[0150] like Fig. 9C As shown, the core cover 50 has two divided pieces 50f and 50g divided along the Z axis. The divided pieces 50f and 50g have the same shape in a plan view from the Z axis direction, are arranged along the Z axis, and form a connecting portion 55 along the circumferential direction.

[0151] In the connecting portion 55, the upper overlapping portions 550d to 550f of the split piece 50f overlap with the lower overlapping portions 551d to 551f of the split piece 50g. In the present embodiment, the upper overlapping portions 550d to 550f of the split piece 50f are provided with steps that expand outward so that even if the upper overlapping portions 550d to 550f overlap with the lower overlapping portions 551d to 551f, the inner peripheral surface of the connecting portion can be flush with the plane. However, the lower overlapping portions 551d to 551f of the split piece 50g can also be provided with steps that are recessed inward so that even if the upper overlapping portions 550d to 550f overlap with the lower overlapping portions 551d to 551f, the outer peripheral surface of the connecting portion can be flush with the plane.

[0152] like Fig. 9C As shown, the outer surfaces of both ends of the core cover body 52 and the locking piece 54 of the split piece 50f are respectively integrally formed with side foot guide pieces 56 protruding outward along the Z-axis and the Y-axis. In addition, the outer surfaces of both ends of the core cover body 52 and the locking piece 54 of the split piece 50g are also integrally formed with side foot guide pieces 56 protruding outward along the Z-axis direction and the Y-axis.

[0153] A frame 57e that protrudes from the side foot guide piece 56 toward the X-axis direction is formed at one end of the core cover body 52 of the split piece 50f, and a frame 57h that protrudes from the side foot guide piece 56 toward the X-axis direction is formed at the other end of the core cover body 52. ​​In addition, a frame 57f that protrudes from the side foot guide piece 56 toward the X-axis direction is formed at one end of the core cover body 52 of the split piece 50g, and a frame 57i that protrudes from the side foot guide piece 56 toward the X-axis direction is formed at the other end of the core cover body 52. ​​In addition, frames 57g and 57j that protrude from the side foot guide piece 56 toward the X-axis direction are formed on the locking piece 54 of the split piece 50g. The side foot guide piece 56 and the frames 57e to 57j are connected to the core cover body 52. Fig.11 The frame 31a shown together constitutes an inlet forming member.

[0154] In order to Fig. 9C The core cover 50 shown is Figure 4 The bobbin 20 shown is connected, the split piece 50f covers the bobbin 20 from the upper direction of the Z axis, and the locking piece 54 of the split piece 50f overlaps the end wall flange 31. Then, the protrusion 250a of the step wide width portion 250 is fitted and fixed with the hole 540a of the split piece 50a. In addition, the split piece 50g covers the bobbin 20 from the lower direction of the Z axis, and the locking piece 54 of the split piece 50g is overlapped with the end wall flange 32. Moreover, the protrusion 250a of the step wide width portion 250 is fitted and fixed with the hole 540a of the split piece 50a. In this way, the upper overlapping parts 550d~550f overlap with the lower overlapping parts 551d~551f, and the split piece 50f and the split piece 50g are fitted. In this way, the split pieces 50f and 50g are arranged along the Z axis direction.

[0155] When the core cover 50 is mounted on the bobbin 20, the frame bodies 57g and 57j protruding from the side foot guide piece 56 of the split piece 50g overlap with the frame body 31a formed on the bobbin 20. The frame body 57f is connected to the frame body 57g, and the frame body 57i is connected to the frame body 57j. In this way, when the core cover 50 is mounted on the bobbin 20, the side foot guide piece 56 and the frame bodies 57e to 57j form a connection with the bobbin 20. Fig.11 Inlet 57 is shown.

[0156] In this embodiment, the inner end of the locking piece 54 may also be Figure 4 The core pin shown is bent inside the through hole 26. In this way, the resin is less likely to leak from the resin reservoir 59.

[0157] In addition, the present invention is not limited to the above-mentioned embodiment, and various changes can be made within the scope of the present invention.

[0158] For example, in the connection portion 55 of the split piece constituting the core cover, the repeated end pieces of the split piece may be connected to each other using an adhesive, or the overlapping portion may not be provided in the connection portion 55, but the butted end portions may be bonded to each other as the connection portion. Furthermore, in the above-mentioned embodiment, the connection portion 55 serves as the leakage suppression portion 58 to prevent the leakage of the resin, but in the present invention, the leakage suppression portion is used for the purpose of not completely preventing the leakage of the resin but allowing a little leakage.

[0159] For example, in Fig.11 In the state shown, when the resin is filled into the core cover 50 from the inlet 57, the resin may be filled into the core cover 50 while the resin slightly leaks from the gap of the connecting portion at the connecting portion 55 located at the leakage suppression portion 58 of the core cover 50. The leaked resin is wasted, so the amount of leakage is preferably smaller than the amount of resin filled from the inlet 57.

[0160] In the above-mentioned embodiment, the ends of the split pieces of the core cover are connected to each other to form the connection part, but the ends of the split pieces may be connected to each other using a member other than the split pieces of the core cover to form the connection part. For example, the gaps between the ends of the split pieces of the core cover may be connected by a wrapping tape (blocking member) or the like to form the connection part as the leakage suppression part.

[0161] Alternatively, after the resin in the core cover has solidified, the tape can be removed and then Fig.12The coil device 10 is accommodated inside the housing 120 shown. The leakage suppression part of the present invention is the gap between the ends of the divided pieces of the core cover, and the solidified surface of the resin formed by removing the member covering the gap (such as the wrapping tape) is also included in the leakage prevention part as a connecting part. In addition, the leakage suppression part of the present invention is the gap between the connecting parts of the core cover and the bobbin, and the solidified surface of the resin formed by removing the member covering the gap (such as the wrapping tape) is also included in the leakage prevention part as a connecting part.

[0162] Explanation of symbols

[0163] 10…Transformer

[0164] 20…spools

[0165] 22…Connection

[0166] 22a…base part

[0167] 22b…Insulation wall

[0168] 22c…Snap-on piece

[0169] 22d…Engagement slot

[0170] 22e, 22f…Sliding insertion hole

[0171] 22g, 22h…Spool side fixing part

[0172] 22i, 22j…sliding engagement portion

[0173] 23a~23d…Spool side cut

[0174] 24…Spool body

[0175] 25…Step

[0176] 26a to 26f ... bobbin side engaging portion

[0177] 250…Stair width

[0178] 250a…protrusion

[0179] 26…Through hole for core pin

[0180] 27…Separation convex portion

[0181] 28…Winding drum

[0182] 30…Insulating bulkhead flange

[0183] 31, 32…End bulkhead flange

[0184] 31a...frame (inlet forming member)

[0185] 33, 34…Wrapping the flange of the next wall

[0186] 35…First coil part

[0187] 36…Second coil portion

[0188] 37…First Wire

[0189] 37a, 37b ... first lead portion

[0190] 38…Second wire

[0191] 38a, 38b...second lead portion

[0192] 40a, 40b…magnetic core

[0193] 42a, 42b…split core

[0194] 44a, 44b ... base portion

[0195] 46a, 46b…midfoot

[0196] 48a, 48b…side foot

[0197] 50…core cover

[0198] 50a~50g…dividable tablets

[0199] 52…Core cover body

[0200] 54…Stop piece

[0201] 540…Lock-on protrusion

[0202] 540a…hole

[0203] 55…Connection

[0204] 550a to 550f, 552b, 552c ... upper overlapping portion

[0205] 551a to 551f, 554b, 554c ... lower overlapping portion

[0206] 553b, 553c ... middle overlapping part

[0207] 56…Side foot guide (entrance forming component)

[0208] 56a…Intermediate guide plate

[0209] 57…Entrance

[0210] 57a~57j…frame (inlet forming member)

[0211] 58…Leakage suppression unit

[0212] 59…Resin storage unit

[0213] 60a~60d…terminal

[0214] 61…Wire connection part

[0215] 610…protruding piece

[0216] 611…Clamping piece

[0217] 62…External connection

[0218] 63…Wire stopper

[0219] 70…Insulation adapter

[0220] 71…side view

[0221] 72…upper surface

[0222] 73…Bottom

[0223] 74…Sliding insert

[0224] 76…Guide slot

[0225] 80…Terminal block

[0226] 81…Base

[0227] 82…Housing engagement groove

[0228] 83a~83d…Terminal arrangement portion

[0229] 84a~84d…positioning groove part

[0230] 840a~840d…Insert port

[0231] 85a~85e…Next door

[0232] 850a~850d…Part of the step wall

[0233] 86a~86c…lower partition wall

[0234] 87a, 87b…Connecting piece

[0235] 870a, 870b…Connection hole

[0236] 88a, 88b…positioning convex portion

[0237] 88c, 88d… positioning recess

[0238] 110…Wire guide

[0239] 112…Rod parts

[0240] 112a, 112b, 112c, 112d ... opposite cutouts

[0241] 113a~113d…Terminal block side engagement portion

[0242] 114, 116…end block

[0243] 114a, 116a ... engagement protrusions

[0244] 114b, 116b…Snap hook

[0245] 114c, 116c…engagement groove

[0246] 117a, 117b, 117c, 117d…wire insertion passage

[0247] 100…Terminal cover

[0248] Housing…120

[0249] Heat sink…130.

Claims

1. A coil device, comprising: a spool on which the wire is wound; and a core cover covering the bobbin, The bobbin has a bobbin frame for forming a portion of an inlet for allowing the inflow of resin on one side along a first axis orthogonal to the winding direction of the electric wire, The core cover has a side foot guide piece provided at the end of the front end side of the core cover body. The inlet is formed by combining a frame protruding from the side foot guide piece and the bobbin frame in such a manner that the inlet protrudes from the side foot guide piece along the first axis to form an inlet forming member for forming the inlet. A leakage suppressing portion for suppressing outflow of the resin is provided at least on the other side opposite to the inlet.

2. The coil device according to claim 1, wherein: The core cover covers the bobbin from the inlet and forms a resin storage portion between the core cover and the bobbin. The leakage suppression portion is configured to store the resin injected from the inlet in the resin storage portion.

3. The coil device according to claim 1 or 2, wherein: The inlet forming member includes a frame body that is disposed at an end portion of the core cover and protrudes along the first axis from a guide piece that restricts movement of the core.

4. The coil device according to claim 1 or 2, wherein: The core cover has a plurality of divided pieces connected to each other.

5. The coil device according to claim 4, wherein: The core cover has a connecting portion where ends of the divided pieces overlap.

6. The coil device according to claim 4, wherein: A plurality of the split pieces are arranged along the circumference of the bobbin.

7. The coil device according to claim 6, wherein: The plurality of divided pieces are connected by the leakage suppression portion.

8. The coil device according to claim 4, wherein: The plurality of split pieces are arranged along the reel direction.

9. The coil device according to claim 1 or 2, wherein: The coil device is accommodated in the housing.

Images