Coil device

Abstract

The present invention provides a coil device that can be easily positioned with a substrate such as a circuit board. The coil device (10) comprises: a bobbin (40) having a winding portion (45) for winding a first electric wire (22) and a second electric wire (32) around the outer periphery; terminals (91, 92) connected to a first lead portion (22a) of the first electric wire (22); a first terminal block (70_1) on which the terminals (91, 92) are mounted and which is movably mounted on the bobbin (40) in both the X-axis direction and the Y-axis direction of the bobbin (40); and a bobbin-side guide portion (417) for guiding the first lead portion (22a) in a manner that forms a predetermined gap (G1) between an end portion (E1) of the first terminal block (70_1) in the Y-axis direction and the first lead portion (22a).

Description

Technical Field

[0001] The present invention can be suitably used as a coil device such as a transformer. Background Art

[0002] For example, as a coil device used in a transformer, there is a known coil device described in Patent Document 1. The coil device described in Patent Document 1 includes a bobbin, an electric wire wound around the outer periphery of the bobbin, and a terminal connected to a lead portion of the electric wire. A terminal block is formed on the bobbin, and the terminal can be fitted and fixed to the terminal block.

[0003] In such a coil device, when connecting to a circuit board, it is required to directly connect the terminal to the circuit board. However, this type of connection is not easy because it is necessary to align the mounting position of the circuit board with the position of the terminal with high precision.

[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 can be easily positioned with respect to a substrate such as a circuit board.

[0009] Technical solutions to solve problems

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

[0011] a bobbin having a winding portion for winding the electric wire around its outer circumference;

[0012] A terminal connected to a lead portion of the electric wire;

[0013] 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;

[0014] A guide portion guides the lead portion so as to form a predetermined gap between the end portion of the terminal block in the first axial direction and the lead portion.

[0015] The coil device of the present invention has a terminal block on which terminals are mounted and which is freely mounted on the bobbin in both the first axial direction and the second axial direction of the bobbin. Therefore, after roughly positioning a substrate such as a circuit substrate and the coil device, the terminals of the terminal block and the substrate can be accurately positioned and connected by only moving the terminal block relative to the bobbin.

[0016] In addition, in the coil device of the present invention, during the manufacturing stage of the coil device, it is not necessary to accurately align the position of the terminal of the terminal block with the mounting position of the substrate, so the manufacturing and assembly of the various parts constituting the coil device becomes easy, which helps to reduce manufacturing costs.

[0017] In particular, the coil device of the present invention has a guide portion for guiding the lead portion in a manner that a predetermined gap is formed between the end of the terminal block in the first axial direction and the lead portion. Thus, by having the guide portion, the terminal block can be smoothly moved in the first axial direction as shown below.

[0018] When the lead portion is connected to the terminal by means of thermocompression welding or the like, due to the influence of the heat, the lead portion sometimes hardens and becomes difficult to bend in the portion where the thermocompression welding or the like is performed. In this case, the movement of the terminal block connected to the lead portion via the terminal in the direction of the first axis may become difficult. Therefore, by providing a guide portion in the coil device and leading the lead portion back to the terminal along the path guided by the guide portion, the lead portion can have a sufficient length of wire. When the lead portion is connected to the terminal by means of thermocompression welding or the like, the proportion of the portion hardened due to the influence of the heat can be reduced, and the bendability of the lead portion can be fully maintained. Therefore, it is possible to prevent the movement of the terminal block in the direction of the first axis from being hindered by the hardened portion of the lead portion, thereby achieving smooth movement of the terminal block in the direction of the first axis and significantly improving the accuracy of positioning the terminal of the terminal block and the substrate.

[0019] In addition, the terminal block can move freely within the range of the gap without hindering the guide portion or the lead portion guided by the guide portion, so when moving in the first axial direction, the end of the terminal block in the first axial direction can be prevented from contacting the guide portion or the lead portion guided by the guide portion. Therefore, in this regard, the terminal block can also be smoothly moved in the first axial direction to obtain the above effect.

[0020] Preferably, the guide portion is disposed at a position away from the end of the terminal block in the first axial direction at a distance equal to or greater than the movable distance of the terminal block in the first axial direction. By setting such a structure, the guide portion is arranged outside the movable range of the terminal block in the first axial direction, thereby effectively preventing the terminal block from contacting the guide portion or the lead portion guided by the guide portion, and effectively achieving smooth movement of the terminal block in the first axial direction.

[0021] Preferably, the guide portion has a pair of protrusions protruding outward, and a lead wire insertion passage through which the lead wire portion is inserted is formed between each of the pair of protrusions. By inserting the lead wire portion into the lead wire insertion passage, the pair of protrusions can be used to limit the displacement of the lead wire portion in the first axial direction, thereby preventing the lead wire portion from entering the moving path of the terminal block in the first axial direction, and effectively achieving smooth movement of the terminal block in the first axial direction.

[0022] Preferably, the bobbin has a flange portion formed on the outer periphery of the winding portion, and the guide portion is formed at the end of the flange portion in the second axial direction outside the movable range of the terminal block in the first axial direction. By forming the guide portion and the flange portion as one piece, it is possible to prevent the coil device from being enlarged due to the formation of the guide portion. In addition, by forming the guide portion in the area, the lead portion can be led out to the terminal in a manner that bypasses the end of the terminal block in the first axial direction, and a sufficient length of wire can be given to the lead portion, reducing the proportion of the portion hardened due to the heat effect of thermocompression bonding, etc., and fully maintaining the bendability of the lead portion.

[0023] Preferably, the electric wire is composed of a first electric wire and a second electric wire, and a first coil portion formed by winding the first electric wire and a second coil portion formed by winding the second electric wire are formed on the bobbin. With such a structure, it can be used as a transformer in which either the first coil portion or the second coil is set as a primary coil and the other is set as a secondary coil.

[0024] Preferably, the first coil portion and the second coil portion are respectively arranged adjacent to each other along the winding axis direction. By setting such a structure, the number of parts can be reduced, and the miniaturization of the coil device can be achieved, for example, compared with the case where the first coil portion is arranged on the periphery of the bobbin and the second coil portion is arranged on the outside thereof.

[0025] Preferably, an insulating cover for insulating one of the first coil portion and the second coil portion from the lead portion of the other of the first coil portion and the second coil portion led out from the end of the second axial direction of the bobbin to the terminal is installed at the end of the second axial direction of the bobbin, and the guide portion is arranged on the insulating cover. By setting such a structure, the insulation of the first coil portion and the second coil portion can be well achieved. In addition, by forming the guide portion and the insulating cover as one piece, the enlargement of the coil device accompanying the formation of the guide portion can be prevented.

[0026] Preferably, the diameter of one of the first and second electric wires is larger than the diameter of the other, and the lead portion of the electric wire with the larger diameter is guided by the guide portion. Electric wires with a larger diameter are originally highly rigid and difficult to bend, so when the lead portion of the electric wire with the larger diameter hardens due to the heat of thermocompression bonding or the like, the bendability of the lead portion is particularly susceptible to damage. Therefore, by guiding the lead portion of the electric wire with the larger diameter back along the path guided by the guide portion, the proportion of the hardened portion of the lead portion can be reduced, and the bendability can be maintained as much as possible, which can effectively avoid the problem of hindering the movement of the terminal block in the first axial direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a perspective view of a coil device according to an embodiment of the present invention.

[0028] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0029] Figure 3A Yes means Figure 2 An exploded perspective view of the structure of the bobbin and various components mounted on the bobbin is shown.

[0030] Figure 3B It means to observe from another angle Figure 3A Exploded three-dimensional diagram of the structure.

[0031] Figure 4 Yes means Figure 2 The illustrated schematic is an exploded perspective view of the structure of the bobbin and the terminal blocks mounted on one side and the other side of the bobbin in the X-axis direction.

[0032] Figure 5A Yes means Figure 4 The illustrated embodiment is an exploded perspective view of the structure of various components of the bobbin and the terminal block respectively mounted on one side of the bobbin in the X-axis direction.

[0033] Figure 5B yes Figure 4 The illustrated embodiment is an exploded perspective view of the structure of various components of the bobbin and the terminal block respectively mounted on the other side of the bobbin in the X-axis direction.

[0034] Fig. 6A yes Figure 1 The coil arrangement is shown in cross-sectional view along line VIA-VIA.

[0035] Figure 6B yes Figure 1 A cross-sectional view of the coil arrangement along line VIB-VIB is shown.

[0036] Figure 7 Yes means Figure 4The illustrated embodiment is an enlarged perspective view of the structure of a bobbin and a terminal block mounted on one end portion thereof in the X-axis direction. DETAILED DESCRIPTION

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

[0038] like Figure 1 As shown, the coil device 10 according to one embodiment of the present invention is used as a transformer, etc., and is mounted on a substrate such as a circuit board 300 for use. In the drawings, the X-axis and the bobbin 40 having a substantially elliptical shape (see Figure 2 ), the Y axis corresponds to the short axis direction of the bobbin 40, and the Z axis corresponds to the height direction of the bobbin 40.

[0039] like Figure 2 As shown, the coil device 10 includes: four cores 12, a first coil portion 20 ( Fig. 6A )、Second coil portion 30( Fig. 6A ), a bobbin 40, an insulating cover 50, a pair of core covers 60, 60, and a pair of terminal blocks 70_1, 70_2.

[0040] The four cores 12 are assembled to form a magnetic path through which magnetic flux generated by a coil described later passes. The cores 12 have symmetrical shapes and are connected to each other so as to sandwich the core covers 60, 60 and the bobbin 40 from the top and bottom (Z-axis direction in the figure).

[0041] 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 along the Y axis direction; a pair of side legs 16, 16 protruding from both ends of each base 13 in the Y axis direction toward the Z axis direction; and a middle leg 14 protruding from the middle position of each base 13 in the Y axis direction toward the Z axis direction.

[0042] The middle leg 14 of each core 12 enters the through hole 44a formed in the hollow cylinder 44 of the bobbin 40. The cores 12 and 12 adjacent to each other in the X-axis direction form a gap by the separation convex portion 44b formed on the inner peripheral wall of the hollow cylinder 44. By allowing a high thermal conductivity resin such as an adhesive resin to enter the gap, the heat dissipation performance generated inside the coil device 10 is improved.

[0043] 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 on both sides of the Y-axis direction along the Z-axis in the center of the X-axis direction inside the through hole 44a. 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.

[0044] The bobbin 40 has a hollow cylindrical portion 44. The hollow cylindrical portion 44 has a cylindrical shape extending in the Z-axis direction. Figure 3A As shown, at the lower part of the hollow cylinder 44 in the Z-axis direction, the bobbin lower flange 47 is integrally formed in a manner protruding radially from the hollow cylinder 44 on the XY-axis plane. In addition, at the upper part of the hollow cylinder 44 in the Z-axis direction, the bobbin upper flange 48 is integrally formed in a manner protruding radially from the hollow cylinder 44 on the XY-axis plane. A step portion 48a is formed on the upper surface of the bobbin upper flange 48, and a positioning recess 48b is formed on the step portion 48a, which is recessed toward the center of the bobbin 40. An engaging protrusion 48c is formed on the inner side of the positioning recess 48b, which can engage with the protrusion formed on the Figure 2 The core cover 60 shown is engaged with the interior of the opening 64b of the mounting edge 64.

[0045] A winding portion 45 is formed on the outer periphery of the hollow cylinder 44. On the winding portion 45, a plurality of winding wall flanges 46 are formed integrally with the hollow cylinder 44 substantially parallel to the bobbin lower flange portion 47 and the bobbin upper flange portion 48. The plurality of winding wall flanges 46 have an elliptical ring shape, and separate the wire winding portions of the first electric wire 22 constituting the first coil portion 20 and the second electric wire 32 constituting the second coil portion 30 that are adjacent to each other along each winding axis (Z axis).

[0046] The winding section 45 is α-wound (or aligned winding), for example, the first electric wire 22 to be the primary coil and the second electric wire 32 to be the secondary coil. α-winding will be described later. Aligned winding is a common winding method of winding electric wires from one end of a winding shaft to the other end.

[0047] like Fig. 6A and Figure 6B As shown, the winding wall flange 46 is formed on the outer periphery of the hollow cylinder 44 in a plane substantially parallel to the XY axis in such a manner that winding areas S1 to S4 are formed at predetermined intervals along the Z-axis direction. The winding area S1 is a winding area formed between the upper flange portion 48 of the bobbin and the winding wall flange 46 at the uppermost position, the winding area S2 is a winding area formed between the winding wall flange 46 at the uppermost position and the winding wall flange 46 at the central position, the winding area S3 is a winding area formed between the winding wall flange 46 at the central position and the winding wall flange 46 at the lowermost position, and the winding area S4 is a winding area formed between the winding wall flange 46 at the lowermost position and the bobbin lower flange portion 47. In the present embodiment, a plurality of winding wall flanges 46 are formed substantially in parallel at predetermined intervals along the Z-axis direction, and the number thereof is not particularly limited. The area where these winding wall flanges 46 are formed becomes the winding portion 45.

[0048] The width of the winding area along the winding axis (Z axis) in each winding area S1 to S4 separated by the winding partition flange 46 is set to a width that only one first electric wire 22 (or second electric wire 32) can enter. That is, the winding area width w1 (not shown) is preferably in the relationship of d1<w1<(2×d1) relative to the wire diameter d1 (not shown) of the first electric wire 22 (or second electric wire 32), and more preferably in the relationship of d1<w1<(1.2×d1). When the winding area width w1 is too wide relative to the wire diameter d1, winding disorder is likely to occur, and the requirement for miniaturization of the coil device is violated.

[0049] In addition, in each of the winding regions S1 to S4, the winding region widths are preferably all the same, but may be slightly different. In the present embodiment, the predetermined total number of windings wound in each of the winding regions S1 to S4 is not particularly limited.

[0050] like Figure 2 As shown, the hollow cylinder portion 44, the winding partition flange 46, the bobbin lower flange portion 47 and the bobbin upper flange portion 48 in the bobbin 40 are preferably integrally formed by injection molding or the like.

[0051] The middle leg 14 of the core 12 enters the through hole 44a from the top and bottom in the Z-axis direction, and the front end of the middle leg 14 is butted against the through hole 44a 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 end of the middle leg 14 inserted from the top and bottom of the Z-axis may not contact each other but form a gap at a predetermined interval (see Fig. 6A , 6B ).

[0052] A pair of core covers 60, 60 are mounted on the outer periphery of the bobbin 40 from both sides in the Y-axis direction. The core cover 60 is made of an insulating member such as a synthetic resin, and has a cover body 62, whose outer peripheral surface serves as a guide surface for the side legs 16 of the guide core 12, and the first coil portion 20 and the second coil portion 30 are located on its inner peripheral surface.

[0053] Mounting flanges 64, 64 are integrally formed at both ends of the cover body 62 in the Z-axis direction. The mounting flange 64 on the upper side of the Z-axis engages with the upper surface of the bobbin upper flange portion 48, and the mounting flange 64 on the lower side of the Z-axis engages with the lower surface of the bobbin lower flange portion 47. More specifically, a protruding piece 64a is formed at the substantially central portion of the mounting flanges 64, 64 in the Y-axis direction, and is engaged with the protruding portion 48c ( Figure 3A ) is engaged with the inside of the opening portion 64b formed in the protruding piece 64a, so that the mounting edges 64, 64 can be engaged with the flange portions 48, 48 on the bobbin.

[0054] The cover body 62 has an inner peripheral surface shape corresponding to the outer peripheral surface shape of the bobbin 40, 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. Figure 1 As shown, the engaging protrusion 66a on the upper side of the Z axis engages with the inner surface of the insulating wall 410 of the first terminal block setting portion 41 of the bobbin 40 or the insulating wall 420 of the second terminal block setting portion 42, and the engaging protrusion 66a on the lower side of the Z axis is engaged with the inner surface of the insulating wall 410 of the first terminal block setting portion 41 of the bobbin 40 or the insulating wall 420 of the second terminal block setting portion 42. Figure 2 Both ends of the bobbin lower flange portion 47 in the X-axis are engaged with the lower surface of the bobbin lower flange portion 47 .

[0055] As a result, the insulating plate portion 66 of the core cover 60 is combined with the insulating walls 410, 420 and the bobbin lower flange portion 47 to improve the insulation between the core 12 and the first coil portion 20 and the second coil portion 30. 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 corresponding to the outer shape of the core 12.

[0056] like Fig. 6A and Figure 6B As shown, the first electric wire 22 may be composed of a single wire or a twisted wire, preferably an insulating coated lead wire. The outer diameter d1 (not shown) of the first electric wire 22 is not particularly limited, but when a large current flows, for example, it is preferably The second electric wire 32 may be the same as the first electric wire 22 , but may also be different.

[0057] In the present embodiment, the wire diameter of the second electric wire 32 is thicker than the wire diameter of the first electric wire 22. However, the relationship between the wire diameters of the electric wires 22 and 32 is not limited thereto, and the wire diameter of the second electric wire 32 may be thinner than the wire diameter of the first electric wire 22, or may be equal to the wire diameter of the first electric wire 22. In addition, the materials of the first electric wire 22 and the second electric wire 32 may be the same, or may be different. In addition, the first coil portion 20 may be used as a secondary coil, and the second coil portion 30 may be used as a primary coil.

[0058] like Figure 3A and Figure 5B As shown, in the bobbin 40 of the present embodiment, a connection groove 49 is formed at the end of the winding partition flange 46 in the X-axis direction at the uppermost position and the end of the winding partition flange 46 in the X-axis direction at the lowermost position. The winding portion 45 is formed by α-winding the first electric wire 22 and the second electric wire 32. More specifically, the central portion of the first electric wire 22 is arranged to pass through the connection groove 49 formed in the winding partition flange 46 at the uppermost position, and the first electric wire 22 is wound on one side of the central portion, for example Fig. 6A In the winding region S1 shown, the first electric wire 22 is wound on the other side than the center portion in, for example, the winding region S2.

[0059] Similarly, the central portion of the second electric wire 32 is arranged to pass through the connection groove 49 formed in the winding wall flange 46 at the lowest position, and the second electric wire 32 is wound on the winding wall flange S3 on one side closer to the central portion, and the second electric wire 32 is wound on the winding area S4 on the other side closer to the central portion. Thus, the first coil portion 20 and the second coil portion 30 are arranged adjacent to each other along the winding axis direction thereof.

[0060] A first lead portion 22a of the first electric wire 22 wound in the winding area S1 is led out from one side of the winding area S1 in the Y-axis direction to the first terminal block 70_1, and is connected to a terminal metal fitting 92 fixed to one side of the first terminal block 70_1 in the Y-axis direction. Another first lead portion 22a of the first electric wire 22 wound in the winding area S2 is led out from the other side of the winding area S2 in the Y-axis direction to the first terminal block 70_1, and is connected to a terminal metal fitting 91 fixed to the other side of the first terminal block 70_1 in the Y-axis direction.

[0061] like Figure 3B and Fig. 6A As shown, a second lead portion 32a of the second electric wire 32 wound in the winding area S3 is led out from one side of the winding area S3 in the Y-axis direction to the second terminal block 70_2, and is connected to a terminal metal fitting 93 fixed to one side of the second terminal block 70_2 in the Y-axis direction. Another second lead portion 32a of the second electric wire 32 wound in the winding area S4 is led out from the other side of the winding area S4 in the Y-axis direction to the second terminal block 70_2, and is connected to a terminal metal fitting 94 fixed to the other side of the second terminal block 70_2 in the Y-axis direction.

[0062] like Figure 4 As shown, the first terminal block setting part 41 and the second terminal block setting part 42 are integrally formed at both ends of the flange part 48 in the X-axis direction of the bobbin. The first terminal block 70_1 is set in the first terminal block setting part 41, and the second terminal block 70_2 is set in the second terminal block setting part 42. In this embodiment, the terminal blocks 70_1 and 70_2 are mounted on the terminal block setting parts 41 and 42 so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin 40.

[0063] The first terminal block installation part 41 has a bottom part 414 having a substantially flat plate shape substantially parallel to the XY axis. The bottom part 414 is formed on an extension line of the bobbin upper flange part 48 in the X-axis direction and constitutes the bottom part of the first terminal block installation part 41.

[0064] An insulating wall 410 is formed at the inner end of the bottom 414 in the X-axis direction. The insulating wall 410 extends upward in the Z-axis direction and has a function of achieving good Figure 1The core 12 (base 13) shown has the function of insulating the terminals 91, 92 fixed to the first terminal block 70_1 or the first lead portions 22a, 22a connected thereto. In addition, in this embodiment, the "outside" is the side away from the central axis of the bobbin 40, and the "inside" is the side close to the central axis of the bobbin 40.

[0065] A slow fitting protrusion 411 is formed on the outer side surface in the X-axis direction of the insulating wall 410, which protrudes from the approximately central part in the Y-axis direction of the insulating wall 410 to the outer side in the X-axis direction. The slow fitting protrusion 411 includes a main protrusion 412, a pair of sub-protrusions 413a1, 413a1, and a pair of auxiliary sub-protrusions 413a2, 413a2. The main protrusion 412 has a substantially flat plate shape parallel to the XZ axis, and protrudes from the approximately central part in the Y-axis direction of the insulating wall 410 to the outer side in the X-axis direction. The main protrusion 412 is formed in the approximately central part of the Z-axis of the insulating wall 410, and has a predetermined length in the Z-axis direction.

[0066] The sub-protrusions 413a1, 413a1 and the auxiliary sub-protrusions 413a2, 413a2 are formed on both sides of the main protrusion 412 in the Y-axis direction, and are arranged at a position separated by a predetermined height in the Z-axis direction from the bottom 414. The sub-protrusions 413a1, 413a1 and the auxiliary sub-protrusions 413a2, 413a2 mainly have the function of limiting the movement width of the first terminal block 70_1 to one side in the X-axis direction and the movement width to the other side, and play the role of a stopper. In addition, the main protrusion 412 also plays the same role as it.

[0067] One auxiliary convex portion 413a1 protrudes from a surface on one side in the Y-axis direction of the main convex portion 412 in the normal direction thereof and extends to one side in the Y-axis direction. Another auxiliary convex portion 413a1 protrudes from a surface on the other side in the Y-axis direction of the main convex portion 412 in the normal direction thereof and extends to the other side in the Y-axis direction. With respect to the Y-axis direction, the auxiliary convex portions 413a1, 413a1 extend to opposite sides to each other.

[0068] One auxiliary sub-convex portion 413a2 is integrally formed with the end of one side of the sub-convex portion 413a1 in the Y-axis direction, and extends inwardly in the X-axis direction. The inner end of the one auxiliary sub-convex portion 413a2 in the X-axis direction is connected to the outer side surface of the insulating wall 410 in the X-axis direction. Another auxiliary sub-convex portion 413a2 is integrally formed with the end of the other side of the other sub-convex portion 413a1 in the Y-axis direction, and extends inwardly in the X-axis direction in a direction substantially parallel to the one auxiliary sub-convex portion 413a2. The inner end of the other auxiliary sub-convex portion 413a2 in the X-axis direction is connected to the outer side surface of the insulating wall 410 in the X-axis direction.

[0069] A pair of anti-slip holes 419, 419, which are formed of through holes, are formed on both sides of the main protrusion 412 in the Y-axis direction. One anti-slip hole 419 is formed in an area surrounded by the main protrusion 412, a sub-protrusion 413a1, an auxiliary sub-protrusion 413a2, and the insulating wall 410. The other anti-slip hole 419 is formed in an area surrounded by the main protrusion 412, the other sub-protrusion 413a1, the other auxiliary sub-protrusion 413a2, and the insulating wall 410. The stopper protrusions 72c2, 72c2 of the first terminal block 70_1 described later are movably engaged with the anti-slip holes 419, 419, thereby preventing the first terminal block 70_1 from being detached from the first terminal block setting portion 41.

[0070] A pair of limiting wall portions 415, 415 are formed at both ends of the bottom 414 in the Y-axis direction. The limiting wall portions 415, 415 are respectively formed on both sides of the Y-axis direction of the slow-fitting protrusion 411. One limiting wall portion 415 protrudes from the bottom 414 toward the upper side of the Z-axis at an end portion on one side of the bottom 414 in the Y-axis direction, and has a predetermined length on one side of the Y-axis direction. The other limiting wall portion 415 protrudes from the bottom 414 toward the Z-axis at an end portion on the other side of the bottom 414 in the Y-axis direction, and has a predetermined length on the other side of the Y-axis direction. The limiting wall portions 415, 415 respectively have the function of limiting the movement width of the first terminal block 70_1 toward one side of the X-axis direction and the movement width toward the other side, and play the role of a stopper.

[0071] Step portions 416, 416 are formed on the outer side surfaces of the limiting wall portions 415, 415 in the X-axis direction. The step portion 416 formed on one limiting wall portion 415 is formed in an area closer to the Y-axis side than the approximate center portion thereof in the Y-axis direction, forming a step recessed inwardly in the X-axis direction. The step portion 416 formed on the other limiting wall portion 415 is formed in an area closer to the other side of the Y-axis direction than the approximate center portion thereof in the Y-axis direction, forming a step recessed inwardly in the X-axis direction. A predetermined gap is formed between the limiting wall portion 415 and the slow-fitting protrusion 411 (the auxiliary protrusion 413a1 and the auxiliary auxiliary protrusion 413a2), and the Y-axis width of the gap corresponds to the movement width of the first terminal block 41 to one side or the other side in the Y-axis direction.

[0072] The bobbin-side guides 417, 417 are integrally formed on the outer side surfaces in the X-axis direction of the limiting walls 415, 415. The bobbin-side guides 417, 417 guide the first lead parts 22a, 22a toward the terminal metal fitting 91 (92) so as to form a predetermined gap between the ends E1, E1 in the Y-axis direction of the first terminal block 70_1 and the first lead parts 22a, 22a.

[0073] Each bobbin-side guide portion 417 has a pair of protrusions 417a1 and 417a2 protruding outward in the X-axis direction. The protrusions 417a1 and 417a2 are arranged adjacent to each other at a predetermined interval in the Y-axis direction. The protrusion 417a1 is formed at a position close to the slow-fitting protrusion 411, and the protrusion 417a2 is arranged at a position where the step portion 416 is formed in the limiting wall portion 415. The protrusions 417a1 and 417a2 have a predetermined thickness in the Z-axis direction, and the thickness of the protrusion 417a1 in the Z-axis direction is larger than the thickness of the protrusion 417a2 in the Z-axis direction, and is smaller than the thickness of the limiting wall portion 415 in the Z-axis direction. In addition, the protrusion width of the protrusion 417a2 to the outside in the X-axis direction is smaller than the protrusion width of the protrusion 417a1 to the outside in the X-axis direction.

[0074] A lead wire insertion passage 418 through which the first lead wire portion 22a is inserted is formed between each of the pair of protrusions 417a1 and 417a2. By inserting the first lead wire portion 22a into the lead wire insertion passage 418, the first lead wire portion 22a can be guided toward the terminal metal fitting 91 (92) by the bobbin side guide portion 417 (see Figure 3A ).

[0075] The lead wire insertion passage 418 extends along the Z-axis direction and has a predetermined depth in the X-axis direction. The Y-axis width of the lead wire insertion passage 418 is equal to or greater than the diameter of the first lead wire portion 22a. The X-axis depth of the lead wire insertion passage 418 is a depth to the extent that the first lead wire portion 22a inserted therein does not fall off to the outside of the lead wire insertion passage 418, and is preferably equal to or greater than the diameter of the first lead wire portion 22a.

[0076] like Figure 7 As shown, the first lead portion 22a is led out along the Z-axis direction inside the lead insertion passage 418. Compared with being led out obliquely from the winding portion of the first coil portion 20 to the terminal 91 (or 92), the first lead portion 22a stands up approximately vertically above the Z-axis from the winding portion of the first coil portion 20 (near the end portion of the first terminal block setting portion 41 in the Y-axis direction), and is led out to the outside in the Y-axis direction while being bent from the Z-axis direction to the Y-axis direction.

[0077] A predetermined gap G1, G1 is formed between the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction and the first lead parts 22a, 22a. In the present embodiment, the bobbin-side guide parts 417, 417 are provided at positions away from the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction so as to form the gaps G1, G1. Therefore, when the first lead parts 22a, 22a are inserted into the lead insertion passages 418, 418, the first lead parts 22a, 22a can be arranged at positions forcibly away from the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction. The length (distance) W1 of the gaps G1, G1 is the same as or greater than the movable distance of the first terminal block 70_1 in the Y-axis direction. Alternatively, the distance of the gaps G1, G1 is the same as or greater than the wire diameter of the first electric wire 22.

[0078] The bobbin side guides 417, 417 are formed at the end of one side of the bobbin upper flange 48 in the X-axis direction outside the Y-axis direction of the movable range A1 of the first terminal block 70_1. Therefore, when the first terminal block 70_1 moves to one side or the other side in the Y-axis direction, a part of the end E1 in the Y-axis direction of the first terminal block 70_1 (particularly the lower end of the first terminal block 70_1) does not contact the bobbin side guides 417, 417 (particularly the protrusions 417a1, 417a1) and the first lead parts 22a, 22a inserted through the lead wire insertion passages 418, 418. Therefore, the first terminal block 70_1 can move in the Y-axis direction without interfering with the bobbin side guides 417, 417 or the first lead parts 22a, 22a. The movable range A1 of the first terminal block 70_1 in the Y-axis direction corresponds to a range between a maximum movement position of the first terminal block 70_1 to one side and a maximum movement position to the other side in the Y-axis direction.

[0079] like Figure 5B As shown, the structure of the second terminal block setting portion 42 is partially identical to the structure of the first terminal block setting portion 41, and the structures of the insulating wall 420, the buffer-fitting protrusion 421, the main protrusion 422, the sub-protrusions 423a1, 423a1, the auxiliary sub-protrusions 423a2, 423a2, the bottom 424, the limiting wall portions 425, 425, the step portions 426, 426 and the anti-slip holes 429, 429 are identical to the structures of the above-mentioned insulating wall 410, the buffer-fitting protrusion 411, the main protrusion 412, the sub-protrusions 413a1, 413a1, the auxiliary sub-protrusions 413a2, 413a2, the bottom 414, the limiting wall portions 415, 415, the step portions 416, 416 and the anti-slip holes 429, 429, and their detailed description is omitted.

[0080] In addition, the insulating wall 420, the sub-protrusions 423a1, 423a1 and the auxiliary sub-protrusions 423a2, 423a2, the limiting wall portions 425, 425 and the anti-slip holes 429, 429 respectively perform the same functions with respect to the second terminal block 70_2 as the insulating wall 410, the sub-protrusions 413a1, 413a1 and the auxiliary sub-protrusions 413a2, 413a2, the limiting wall portions 415, 415 and the anti-slip holes 419, 419 perform with respect to the first terminal block 70_1.

[0081] Insertion parts 427, 427 are formed on the outer side surfaces in the X-axis direction of the limiting wall parts 425, 425. Insertion holes 427a, 427a having a predetermined depth in the X-axis direction are formed in the insertion parts 427, 427. Insertion pieces 52, 52 of the insulation cover 50 described later are inserted into the insertion holes 427a, 427a, thereby fixing the insulation cover 50 to the second terminal block installation part 42.

[0082] like Figure 5A As shown in FIG. 1 , terminal metal parts (terminals) 91 and 92 are mounted on the first terminal block 70_1. Figure 5B As shown, terminal metal fittings (terminals) 93 and 94 are mounted on the second terminal block 70_2. The terminal metal fittings 91 and 92 have shapes that are linearly symmetrical to each other on the X-axis and the Z-axis, and the terminal metal fittings 93 and 94 have shapes that are linearly symmetrical to each other on the X-axis and the Z-axis. The terminal metal fittings 91 and the terminal metal fittings 93 are composed of the same shape, and the terminal metal fittings 92 and the terminal metal fittings 94 are composed of the same shape. The terminal metal fittings 91 to 94 can be formed by stamping a conductive plate material such as a metal plate.

[0083] 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 22a of the first wire 22. 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 and 74 formed in the first terminal block 70_1 so as to be freely movable in the Z-axis direction.

[0084] 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 toward the lower side in the Z-axis direction, and the lower front ends of the hook portions 91b and 92b are formed into a hook shape. Insertion holes 91d and 92d are formed in the central portions of the mounting portions 91c and 92c, respectively. The insertion holes 91d and 92d are roughly aligned with the bolt holes of the nuts 306 mounted in the mounting holes 76 provided in the first terminal block 70_1, and each terminal metal fitting 91 and 92 is mounted on the first terminal block 70_1. In these insertion holes 91d and 92d, the mounting Figure 1The terminal metal fittings 91 and 92 can be positioned and mounted on the circuit board 300 via fasteners such as bolts or screws 304 shown.

[0085] 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 have a portion that is a plane flush with the plane of the mounting parts 91c, 92c, and a stepped bent portion that is bent downward substantially perpendicularly to the portion. 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.

[0086] Insertion protrusions 91f and 92f are formed at the ends of the mounting parts 91c and 92c on the opposite sides from the hook parts 91b and 92b. The insertion protrusions 91f and 92f are inserted into the fitting grooves 75 and 75 formed on the upper surface of the two ends of the first terminal block 70_1 in the Y-axis direction.

[0087] The terminal metal fittings 93 and 94 have the same structure as the terminal metal fittings 91 and 92, and the wire connecting parts 93a and 94a, hook parts 93b and 94b, mounting parts 93c and 94c, insertion holes 93d and 94d, connecting parts 93e and 94e, and insertion holes 93f and 94f have the same structure as the wire connecting parts 91a and 92a, hook parts 91b and 92b, mounting parts 91c and 92c, insertion holes 91d and 92d, connecting parts 91e and 92e, and insertion holes 91f and 92f, respectively. The lead parts 32a and 32a of the second wire 32 are connected to the terminal metal fittings 93 and 94, respectively.

[0088] In the present embodiment, the first terminal block 70_1 and the second terminal block 70_2 are formed separately from the bobbin 40. The structure of the second terminal block 70_2 is the same as that of the first terminal block 70_1, so its detailed description is omitted. As the material constituting the first terminal block 70_1 and the second terminal block 70_2, for example, a resin different from the bobbin 40 can be selected, for example, a resin with better formability than the bobbin 40 or a resin with good heat dissipation can be selected. Specifically, for example, resin materials such as PET, PBK or PPS can be cited.

[0089] like Figure 4 and Figure 5A As shown, the first terminal block 70_1 has a block body 71. A through hole 72 is formed on the block body 71, and the through hole 72 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 306 can be respectively installed in each mounting hole 76.

[0090] Terminal grooves 74 and 74 are formed at the boundaries between the terminal mounting parts 73 and 73 and the stage body 71, and the hook parts 91b and 92b of the terminal metal fittings 91 and 92 are respectively inserted into the terminal grooves 74 and 74 so as to be freely movable in the Z-axis direction. In addition, fitting grooves 75 and 75 are formed on the upper surfaces of the ends of the terminal mounting parts 73 and 73 in the Y-axis direction, and the insertion protrusions 91f and 92f of the terminal metal fittings 91 and 92 are respectively inserted into the fitting grooves. As a result, the movement of the terminal metal fittings 91 and 92 in the X-axis and Y-axis directions relative to the first terminal stage 70_1 is restricted, and the movement of each terminal metal fitting 91 and 92 in the Z-axis direction is only allowed relative to the first terminal stage 70_1.

[0091] The wire connecting parts 91a and 92a of the terminal metal fittings 91 and 92 are located outside along the Y-axis direction from both ends of the first terminal block 70_1, and the upper surfaces of the wire connecting parts 91a and 92a are located below the upper surfaces of the mounting parts 91c and 92c on the Z axis.

[0092] A slow-fitting recess 72a into which the slow-fitting protrusion 411 formed on the first terminal block setting portion 41 enters is formed on the side of the through hole 72 formed on the table body 71 facing the bobbin 40. In the present embodiment, a portion of the inner wall constituting the slow-fitting recess 72 is composed of a support piece 72c1 having a width in the Z-axis direction that can be elastically deformed into an opening entrance that can open the slow-fitting recess 72. A pair of stop protrusions 72c2, 72c2 are formed on the front end side of the support piece 72c1. The stop protrusions 72c2, 72c2 engage with a pair of anti-slip holes 419, 419 and function as anti-slip parts. The stop protrusions 72c2, 72c2 are formed at a predetermined interval in the Y-axis direction. In order to elastically deform the support piece 72c1 into a cantilever shape, slits are respectively formed on both sides of the support piece 72c1 in the Y-axis direction.

[0093] When the stopper protrusions 72c2, 72c2 are engaged with the stopper holes 419, 419, gaps are formed in the X-axis direction and the Y-axis direction between the stopper holes 419 and the stopper protrusions 72c2. Therefore, the first terminal block 70_1 can freely slide (slide) in the X-axis direction and the Y-axis direction relative to the first terminal block setting portion 41 within the range of the gap.

[0094] The slow fitting recess 72a includes a main recess 72a1, a sub-recess 72a2, and an auxiliary sub-recess 72a3. When viewed from the X-axis direction, these recesses are generally T-shaped, the main recess 72a1 constitutes a portion extending in the Z-axis direction, and the sub-recess 72a2 and the auxiliary sub-recess 72a3 constitute a portion extending in the Y-axis direction. The sub-recess 72a2 and the auxiliary sub-recess 72a3 are respectively connected in the X-axis direction, and the auxiliary sub-recess 72a3 is located on the inner side of the sub-recess 72a2 in the X-axis direction. The sub-recess 72a2 and the auxiliary sub-recess 72a3 are respectively connected to the lower end of the main recess 72a1 in the Z-axis direction, and extend to one side and the other side of the main recess 72a1 in the Y-axis direction. The auxiliary sub-recess 72a3 is formed to be wider than the sub-recess 72a2 in the Y-axis direction.

[0095] The main protrusion 412 (more specifically, a portion of the main protrusion 412 located above the upper surface of each of the sub-protrusions 413a1, 413a1 and the auxiliary sub-protrusions 413a2, 413a2) is inserted into the main concave portion 72a1. The Y-axis width of the main concave portion 72a1 is larger than the Y-axis width of the main protrusion 412 (see Figure 7 ), so a gap is formed in the Y-axis direction between the main recess 72a1 and the main protrusion 412. Therefore, the main protrusion 412 is freely fitted with respect to the main recess 72a1 in the Y-axis direction within the range of the gap, and accordingly, the first terminal block 70_1 can slide and move in the Y-axis direction relative to the first terminal block setting portion 41 within the range of the gap. In addition, the length corresponding to the difference between the Y-axis width of the main recess 72a1 and the Y-axis width of the main protrusion 412 (for example, the length of half of the difference) becomes the movable distance of the first terminal block 70_1 in the Y-axis direction.

[0096] A pair of sub-protrusions 413a1, 413a1 are inserted into the sub-recess 72a2. When the sub-protrusions 413a1, 413a1 are inserted into the sub-recess 72a2, a gap is formed between the end of one side of the sub-protrusion 413a1 in the Y-axis direction and the one side of the sub-recess 72a2 in the Y-axis direction. In addition, a gap is formed between the end of the other side of the other sub-protrusion 413a1 in the Y-axis direction and the other side of the sub-recess 72a2 in the Y-axis direction. Therefore, the sub-protrusions 413a1, 413a1 are freely fitted with respect to the sub-recess 72a2 in the range of these gaps in the Y-axis direction, and accordingly, the first terminal block 70_1 can slide and move in the Y-axis direction relative to the first terminal block setting portion 41 in the range of these gaps.

[0097] A pair of auxiliary sub-protrusions 413a2, 413a2 are inserted into the auxiliary sub-recess 72a3. When the auxiliary sub-protrusions 413a3, 413a2 are inserted into the auxiliary sub-recess 72a3, a gap is formed between the end of one side of the auxiliary sub-protrusion 413a2 in the Y-axis direction and the one side of the auxiliary sub-recess 72a3 in the Y-axis direction. In addition, a gap is formed between the end of the other side of the other auxiliary sub-protrusion 413a2 in the Y-axis direction and the other side of the auxiliary sub-recess 72a3 in the Y-axis direction. Therefore, the auxiliary sub-protrusions 413a2, 413a2 are freely fitted in the Y-axis direction relative to the auxiliary sub-recess 72a3 within the range of these gaps, and accordingly, the first terminal block 70_1 can slide and move in the Y-axis direction relative to the first terminal block setting portion 41 within the range of these gaps.

[0098] A mounting recess 72b is formed on the side of the through hole 72 opposite to the side facing the bobbin 40. The mounting recess 72b is connected to the outer side of the auxiliary recess 72a2 in the X-axis direction. The inner cover 78 is mounted on the mounting recess 72b.

[0099] The inner cover 78 is installed in the mounting recess 72b of the first terminal block 70_1 after the hook portions 91b and 92b of the terminal metal fittings 91 and 92 are respectively inserted into the terminal grooves 74 and 74 of the first terminal block 70_1. Thus, the terminal metal fittings 91 and 92 can be prevented from being separated from the first terminal block 70_1, and the Z-axis movement range of the terminal metal fittings 91 and 92 relative to the first terminal block 70_1 can be limited.

[0100] Install on the outside of the inner cover 78 Figure 3A and Figure 3B The outer cover 79 shown. The outer cover 79 covers the first terminal block 70_1 with the inner cover 78 installed, together with the terminal metal fittings 91 and 92, from the outside of the X-axis and the Y-axis. The outer cover 79 also covers the lower side of the first terminal block 70_1 in the Z-axis, but does not cover the upper side of the Z-axis. When the outer cover 79 is installed on the first terminal block 70_1, it is configured to be relatively movable in the same direction relative to the bobbin 40 in a manner that follows the relative movement of the first terminal block 70_1 in the X-axis and Y-axis directions.

[0101] like Figure 5B As shown, the insulating cover 50 includes: a cover body 51, a pair of insertion pieces 52, 52, a lower fixing piece 53, and a pair of cover side guides 54, 54. The insulating cover 50 is detachably mounted on the end portion of the bobbin 40 in the X-axis direction (the side where the second terminal block setting portion 42 is arranged), and has a function of insulating the first coil portion 20 wound on the winding portion 45 of the bobbin 40 from the second lead portions 32a, 32a of the second coil portion 30 led out from the end portion of the bobbin 40 in the X-axis direction to the terminals 93, 94.

[0102] The cover body 51 has a shape corresponding to the curved shape of the end portion of the bobbin 40 in the X-axis direction, and is arranged outside the first coil portion 20 formed in the winding portion 45. A pair of insertion pieces 52, 52 are formed integrally with the upper end portion of the cover body 51, and are respectively formed at both ends of the cover body 51 in the Y-axis direction. The insertion pieces 52, 52 have a substantially flat plate shape parallel to the XY axis, and protrude inward in the X-axis direction. The insertion pieces 52, 52 are inserted into the insertion holes 427a, 427a of the second terminal block setting portion 42.

[0103] The lower fixing piece 53 is integrally formed with the lower end of the cover body 51 and has a substantially flat plate shape parallel to the XY axis. The lower fixing piece 53 is arranged to be substantially parallel to the insertion pieces 52, 52. The lower fixing piece 53 protrudes inward in the X-axis direction and is fixed to the Fig. 6A The lower surface of the winding partition wall flange 46 between the winding area S2 and the winding area S3 is shown.

[0104] The cover side guides 54, 54 are integrally formed with the outer side surface of the cover body 51 in the X-axis direction, and are arranged at both ends of the cover body 51 in the Y-axis direction. The cover side guides 54, 54 have the same function as the bobbin side guides 417, 417, such as Figure 3B As shown, the second lead portion 32a is guided toward the terminal metal fitting 93 (94) in such a manner that a predetermined gap G2 is formed between the end E2 of the second terminal block 70_2 in the Y-axis direction and the second lead portion 32a. In the present embodiment, at the end on one side of the bobbin 40 in the X-axis direction (the side where the first terminal block 70_1 is arranged), the bobbin side guide portions 417, 417 are formed integrally with the bobbin 40, and at the end on the other side of the bobbin 40 in the X-axis direction (the side where the second terminal block 70_2 is arranged), the cover side guide portions 54, 54 are formed integrally with the insulating cover 50 that is formed separately from the bobbin 40.

[0105] like Figure 3B and Figure 5B As shown, the cover side guides 54, 54 respectively have a pair of protrusions 54a1, 54a2 protruding outward in the X-axis direction. The protrusions 54a1, 54a2 are respectively arranged adjacent to each other at a predetermined interval in the Y-axis direction. The protrusions 54a1, 54a2 have a predetermined length in the Z-axis direction, and the protrusion length of the protrusion 54a2 in the X-axis direction is greater than the protrusion length of the protrusion 54a1 in the X-axis direction.

[0106] A lead wire insertion passage 55 through which the second lead wire portion 32a is inserted is formed between the pair of protrusions 54a1 and 54a2. By inserting the second lead wire portion 32a into the lead wire insertion passage 55, the cover-side guide portion 54 can guide the second lead wire portion 32a toward the terminal fitting 93 (94).

[0107] The lead wire insertion passage 55 extends in the Z-axis direction and has a predetermined depth in the X-axis direction. The Y-axis width of the lead wire insertion passage 55 is equal to or greater than the diameter of the second lead wire portion 32a. The X-axis depth of the lead wire insertion passage 55 is a depth to the extent that the second lead wire portion 32a inserted therein does not fall out of the lead wire insertion passage 55, and is preferably equal to or greater than the diameter of the second lead wire portion 32a.

[0108] The second lead portion 32a is led out along the Z-axis direction inside the lead insertion passage 55. Compared with being led out obliquely from the winding portion of the second coil portion 30 toward the terminal 93 (or 94), the second lead portion 32a stands up approximately vertically above the Z-axis from the winding portion of the second coil portion 30 (near the end portion in the Y-axis direction of the second terminal block setting portion 42), and is led out to the outside in the Y-axis direction while being bent from the Z-axis direction to the Y-axis direction.

[0109] A predetermined gap G2, G2 is formed between the end E2, E2 of the second terminal block 70_2 in the Y-axis direction and the second lead parts 32a, 32a. In the present embodiment, the cover-side guide parts 54, 54 are arranged at a position away from the end E2, E2 of the second terminal block 70_2 in the Y-axis direction so as to form the gaps G2, G2. Therefore, when the second lead parts 32a, 32a are inserted into the lead insertion passages 55, 55, the second lead parts 32a, 32a can be arranged at a position forcibly away from the end E2, E2 of the second terminal block 70_2 in the Y-axis direction. The length (distance) of the gaps G2, G2 is the same as or greater than the movable distance of the second terminal block 70_2 in the Y-axis direction. Alternatively, the distance of the gaps G2, G2 is the same as or greater than the wire diameter of the second electric wire 32.

[0110] The end of the cover-side guide portions 54, 54 on the other side of the flange portion 48 on the bobbin in the X-axis direction is formed outside the movable range of the second terminal block 70_2 in the Y-axis direction. Therefore, when the second terminal block 70_2 moves to one side or the other side in the Y-axis direction, a portion of the end E2 of the second terminal block 70_2 in the Y-axis direction (especially the lower end of the second terminal block 70_2) does not contact the cover-side guide portions 54, 54 (especially the protrusion 54a1) and the second lead portions 32a, 32a inserted into the lead insertion passage 55. Therefore, the second terminal block 70_2 can move in the Y-axis direction without interfering with the cover-side guide portions 54, 54 or the second lead portion 32a. In addition, the movable range of the second terminal block 70_2 in the Y-axis direction is similar to the movable range A1 ( Figure 7 )Same.

[0111] In this embodiment, the diameter of the second electric wire 32 is larger than that of the first electric wire 22. At the end on the other side of the bobbin 40 in the X-axis direction, the second lead portion 32a of the second electric wire 32 with a larger diameter is guided toward the terminal 93 (94) by the cover side guide portions 54, 54.

[0112] An example of a method for manufacturing the coil device 10 is described below. In manufacturing the coil device 10, first, Figure 2 The bobbin 40 is shown. The material of the bobbin 40 is not particularly limited, and an insulating material such as resin may be used.

[0113] Then, in Fig. 6A At the positions of the winding regions S1 and S2 of the bobbin 40 shown in the figure, the first electric wire 22 is wound around the outer periphery of the hollow cylinder 44 to form the first coil portion 20. In addition, at the positions of the winding regions S3 and S4 of the bobbin 40, the second electric wire 32 is wound around the outer periphery of the hollow cylinder 44 to form the second coil portion 30. After the first coil portion 20 and the second coil portion 30 are formed, an insulating cover 50 is attached to the outer periphery of the bobbin 40 at the end portion in the X-axis direction of the bobbin 40. As the first electric wire 22, there is no particular limitation, and a stranded wire or the like is used appropriately. The same is true for the second electric wire 32.

[0114] Next, the first lead portions 22a, 22a are led out from the winding regions S1, S2 to opposite sides of each other in the Y-axis direction, as shown in FIG. Figure 5A As shown in the figure, the first lead wires 22a and 22a are erected in the Z-axis direction and inserted into the lead wire insertion passages 418 and 418 of the bobbin side guides 417 and 417. Thus, the first lead wires 22a and 22a can be fully led back in the Y-axis direction and the Z-axis direction through the bobbin side guides 417 and 417 and then guided to the terminals 91 and 92. After the first lead wires 22a and 22a are inserted into the lead wire insertion passages 418 and 418, these lead wires are bent in the Y-axis direction and led out to the outside in the Y-axis direction.

[0115] In addition, the second lead portions 32a, 32a are led out from the winding regions S3, S4 to the opposite sides in the Y-axis direction, as shown in FIG. Figure 5B As shown in FIG. 1 , the second lead wires 32a and 32a are erected in the Z-axis direction and inserted into the lead wire insertion passages 55 and 55 of the cover side guides 54 and 54. Thus, the second lead wires 32a and 32a can be fully led back in the Y-axis direction and the Z-axis direction through the cover side guides 54 and 54 and then guided to the terminals 93 and 94. After the second lead wires 32a and 32a are inserted into the lead wire insertion passages 55 and 55, these lead wires are bent in the Y-axis direction and led out to the outside in the Y-axis direction.

[0116] Then, if Figure 5A and Figure 5BAs shown, the first terminal block 70_1 and the second terminal block 70_2 are moved from the outside in the X-axis direction and attached to the first terminal block installation portion 41 and the second terminal block installation portion 42 of the bobbin 40, respectively.

[0117] In more detail, Figure 4 As shown, when installing the first terminal block 70_1, the main recess 72a1 is engaged with the main protrusion 412 so as to be freely movable in the X-axis direction and the Y-axis direction, the sub-recess 72a2 is engaged with the sub-protrusions 413a1, 413a1 so as to be freely movable in the X-axis direction and the Y-axis direction, and the auxiliary sub-recess 72a3 is engaged with the auxiliary sub-protrusions 413a2, 413a2 so as to be freely movable in the X-axis direction and the Y-axis direction.

[0118] In addition, if Figure 4 and Figure 5B As shown, when installing the second terminal block 70_2, the main recess 72a1 is engaged with the main protrusion 422 so as to be freely movable in the X-axis direction and the Y-axis direction, the sub-recess 72a2 is engaged with the sub-protrusions 423a1, 423a1 so as to be freely movable in the X-axis direction and the Y-axis direction, and the auxiliary sub-recess 72a3 is engaged with the auxiliary sub-protrusions 423a2, 423a2 so as to be freely movable in the X-axis direction and the Y-axis direction.

[0119] like Figure 5A and Figure 5B As shown, when the terminal metal fittings 91, 92 and the terminal metal fittings 93, 94 are respectively installed on the first terminal block 70_1 and the second terminal block 70_2, 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 welding, fusion, resistance welding, ultrasonic welding, laser welding, riveting, thermocompression bonding, thermal fusion bonding, etc.

[0120] Furthermore, before mounting the terminal blocks 70_1 and 70_2 on the terminal block installation portions 41 and 42 , the lead portions 22a and 32a may be preliminarily connected to the wire connecting portions 91a to 94a of the terminal metal fittings 91 to 94 and the terminal metal fittings 91 to 94 may be mounted on the terminal blocks 70_1 and 70_2 .

[0121] Then, inner covers 78 and 78 are installed on terminal blocks 70_1 and 70_2. Figure 2 The core covers 60, 60 shown are 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.

[0122] As described above, the coil device 10 of the present embodiment has mounting terminals 91 to 94, and is mounted on the terminal blocks 70_1 and 70_2 of the bobbin 40 so as to be freely movable in both the X-axis direction and the Y-axis direction of the bobbin 40. Therefore, after roughly positioning the positions of the mounting holes 302 of the circuit substrate 300 and the positions of the terminals 91 to 94 of the coil device 10, only the terminal blocks 70_1 and 70_2 are relatively moved relative to the bobbin 40, and the positions of the terminals 91 to 94 of the terminal blocks 70_1 and 70_2 and the mounting holes 302 of the circuit substrate 300 can be accurately positioned and connected.

[0123] In addition, in the coil device 10 of the present embodiment, during the manufacturing stage of the coil device 10, it is not necessary to precisely align the positions of the terminals 91 to 94 of the terminal blocks 70_1 and 70_2 with the mounting holes 302 of the circuit substrate 300 for manufacturing, so that the manufacturing and assembly of the various parts constituting the coil device 10 becomes easy, which helps to reduce manufacturing costs.

[0124] In particular, the coil device 10 of the present embodiment has bobbin-side guides 417, 417, which guide the first lead portions 22a, 22a in a manner that forms a predetermined gap G1, G1 between the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction and the first lead portions 22a, 22a. In this way, by having the bobbin-side guides 417, 417, as shown below, the first terminal block 70_1 can be smoothly moved in the Y-axis direction.

[0125] When the first lead parts 22a, 22a are connected to the terminals 91, 92 by thermal compression or the like, the first lead parts 22a, 22a may be hardened and difficult to bend due to the influence of the heat at the portion where the thermal compression or the like is performed. In this case, the first terminal block 70_1 connected to the first lead parts 22a, 22a via the terminals 91, 92 may be difficult to move in the Y-axis direction. Therefore, by providing the bobbin side guide parts 417, 417 on the coil device 10, the first lead parts 22a, 22a are led back to the terminals 91, 92 along the path guided by the bobbin side guide parts 417, 417, so that the first lead parts 22a, 22a can have a sufficient length of wire length. When the first lead parts 22a, 22a are connected to the terminals 91, 92 by thermal compression or the like, the proportion of the portion hardened by the influence of the heat can be reduced, and the bendability of the first lead parts 22a, 22a can be fully maintained. Therefore, the movement of the first terminal block 70_1 in the Y-axis direction can be prevented from being hindered by the hardened parts of the first lead parts 22a, 22a, and the first terminal block 70_1 can be smoothly moved in the Y-axis direction, which significantly improves the positioning accuracy of the terminals 91, 92 of the first terminal block 70_1 and the circuit substrate 300.

[0126] In addition, the first terminal block 70_1 can move freely within the range of the above-mentioned gaps G1, G1 without interfering with the bobbin-side guides 417, 417 or the first lead portions 22a, 22a guided by the guides, so that when moving in the Y-axis direction, the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction can be prevented from contacting the bobbin-side guides 417, 417 or the first lead portions 22a, 22a guided by the guides. Therefore, in this regard, the first terminal block 70_1 can also be smoothly moved in the Y-axis direction, and the above-mentioned effect can be obtained.

[0127] In addition, in the present embodiment, the bobbin side guides 417, 417 are disposed at positions away from the ends E1, E1 in the Y-axis direction of the first terminal block 70_1 at a distance equal to or greater than the movable distance of the first terminal block 70_1 in the Y-axis direction. Thus, the bobbin side guides 417, 417 are disposed outside the movable range of the first terminal block 70_1 in the Y-axis direction, thereby effectively preventing the terminal block from contacting the guide or the lead portion guided by the guide, and effectively achieving smooth movement of the terminal block in the first axis direction.

[0128] In addition, in the present embodiment, the bobbin-side guides 417, 417 have a pair of protrusions 417a1, 417a2 protruding outward in the X-axis direction, and lead wire insertion passages 418, 418 through which the first lead wires 22a, 22a are inserted are formed between the pair of protrusions 417a1, 417a2, respectively. By inserting the first lead wire 22a into each lead wire insertion passage 418, the first lead wire 22a can be prevented from being displaced in the Y-axis direction by the pair of protrusions 417a1, 417a2, thereby preventing the first lead wire 22a from entering the moving path of the first terminal block 70_1 in the Y-axis direction, and effectively achieving smooth movement of the first terminal block 70_1 in the Y-axis direction.

[0129] In addition, in the present embodiment, the bobbin 40 has a bobbin upper flange portion 48, and the bobbin side guide portions 417, 417 are formed at the ends of the bobbin upper flange portion 48 in the X-axis direction outside the movable range A1 of the first terminal block 70_1 in the Y-axis direction. By forming the bobbin side guide portions 417, 417 integrally with the bobbin upper flange portion 48, it is possible to prevent the coil device 10 from being enlarged due to the formation of the bobbin side guide portions 417, 417. In addition, by forming the bobbin side guide portions 417, 417 in the above-mentioned area, the first lead portions 22a, 22a can be led to the terminals 91, 92 in a manner that bypasses the ends E1, E1 in the Y-axis direction of the first terminal block 70_1, and a sufficient length of wire can be given to the first lead portions 22a, 22a, and the proportion of the portion hardened due to the heat effect of thermocompression bonding is reduced, and the bendability of the first lead portions 22a, 22a is fully maintained.

[0130] In addition, in the present embodiment, the first coil portion 20 and the second coil portion 30 are respectively arranged adjacent to each other along the winding axis direction. Therefore, compared with, for example, the first coil portion 20 is arranged on the periphery of the bobbin 40, and the second coil portion 30 is arranged on the outside thereof, the number of parts can be reduced, and the miniaturization of the coil device 10 can be achieved.

[0131] In addition, in the present embodiment, the insulating cover 50 for insulating the first coil portion 20 from the second lead portion 32 of the second coil portion 30 is mounted on the end portion in the X-axis direction of the bobbin 40, and the cover side guide portions 54, 54 are provided on the insulating cover 50. The cover side guide portions 54, 54 guide the second lead portions 32a, 32a in a manner that a predetermined gap G2, G2 is formed between the end portions E2, E2 in the Y-axis direction of the second terminal block 70_2 and the second lead portions 32a, 32a. Therefore, based on the cover side guide portions 54, 54, the same effect as the above-mentioned effect described for the bobbin side guide portion 417 is obtained.

[0132] Insulation cover 50 can be used to satisfactorily insulate first coil portion 20 and second coil portion 30. In addition, by forming cover-side guides 54, 54 integrally with insulation cover 50, increase in size of coil device 10 due to formation of cover-side guides 54, 54 can be prevented.

[0133] In addition, in the present embodiment, the diameter of the second electric wire 32 is larger than that of the first electric wire 22, and the second lead portion 32a of the second electric wire 32 having a larger diameter is guided by the cover side guide portion 54. The second electric wire 32 having a larger diameter is originally highly rigid and difficult to bend, and therefore, when the second lead portion 32a of the second electric wire 32 having a larger diameter is hardened due to the influence of heat such as thermocompression bonding, the bendability of the second lead portion 32a is particularly easily damaged. Therefore, by guiding the second lead portion 32a of the second electric wire 32 having a larger diameter back along the lead insertion passage 55 guided by the cover side guide portion 54, the proportion of the hardened portion of the second lead portion 32a can be reduced, and the bendability can be maintained as much as possible, which can effectively avoid the problem of hindering the movement of the second terminal block 70_2 in the Y-axis direction.

[0134] The present invention is not limited to the above-mentioned embodiments, and various changes can be made within the scope of the present invention. Fig. 6A The first coil portion 20 and the second coil portion 30 are shown in reverse arrangement. Alternatively, the first coil portion 20 may be used as a secondary coil, and the diameter of the first electric wire 22 may be larger than the diameter of the second electric wire 32 .

[0135] In addition, the winding method of the first electric wire 22 is not limited to α winding, and can also be arranged in a straight line. Even in the straight line winding, the effect of the present invention can be expected. The same is true for the second electric wire 32. 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.

[0136] In the above-mentioned embodiment, the application example of the present invention to a transformer is shown, but the present invention can also be applied to other coil devices. For example, the coil device of the present invention can also be used for a reactor or the like.

[0137] In the above embodiment, the arrangement of the slow fitting protrusions 411 and 421 and the slow fitting recess 72 a may be reversed. That is, the slow fitting protrusions 411 and 421 may be formed on the first terminal block 70_1 or the second terminal block 70_2 and the slow fitting recess 72 a may be formed on the bobbin 40 .

[0138] In addition, the winding method of the first electric wire 22 and the second electric wire 32 wound inside the coil device 10 is not limited to the above-mentioned embodiment. For example, the first coil portion 20 can also be formed on the outer periphery of the bobbin 40 (winding portion 45), the bobbin cover is installed on the outer side of the first coil portion 20, and the second coil portion 30 is formed on the outer periphery of the bobbin cover. In this case, the first coil portion 20 can be arranged on the inner side, and the second coil portion 30 can be arranged on the outer side, and the first coil portion 20 and the second coil portion 30 can be arranged in double layers.

[0139] In the above embodiment, the terminal blocks 70_1 and 70_2 are formed on both sides of the bobbin 40 in the X-axis direction, but either the terminal blocks 70_1 or 70_2 may be formed only on one side in the X-axis direction.

[0140] Explanation of symbols

[0141] 10…Coil device

[0142] 20…First coil

[0143] 22…First Wire

[0144] 22a: first lead portion

[0145] 30…Second coil

[0146] 32…Second wire

[0147] 32a...second lead portion

[0148] 40…Spool

[0149] 41…First terminal block installation portion

[0150] 410…Insulation wall

[0151] 411…Slow fitting convex part

[0152] 412…Main convex part

[0153] 413a1, 413a1…auxiliary convex part

[0154] 413a2, 413a2 ... auxiliary convex portion

[0155] 414…Bottom

[0156] 415…Restriction wall

[0157] 416…Steps

[0158] 417…Bobbin side guide

[0159] 417a1, 417a2 ... protrusion

[0160] 418…Wire insertion channel

[0161] 419…Anti-loosening hole

[0162] 42…Second terminal block installation portion

[0163] 420…Insulation wall

[0164] 421…Gently fitting convex part

[0165] 422…Main convex part

[0166] 423a1, 423a1…auxiliary convex part

[0167] 423a2, 423a2 ... auxiliary convex portion

[0168] 424…Bottom

[0169] 425…Restriction wall

[0170] 426…Steps

[0171] 427…Insertion

[0172] 427a…Insert hole

[0173] 429…Anti-loosening hole

[0174] 45…Winding section

[0175] 50…Insulation cover

[0176] 51…Hood body

[0177] 52…Insert piece

[0178] 53…Lower fixing plate

[0179] 54…Hood side guide

[0180] 54a1, 54a2 ... protrusion

[0181] 55…Wire insertion channel

[0182] 70_1, 70_2…Terminal block

[0183] 71… Main body

[0184] 72…Through hole

[0185] 72a ... slow fitting recess

[0186] 72a1…Main recess

[0187] 72a2…Secondary recess

[0188] 72a3 ... auxiliary concave portion

[0189] 72b…Mounting recess

[0190] 72c1…Supporting sheet

[0191] 72c2…Stop protrusion

[0192] 73…Terminal mounting part

[0193] 74…Terminal slot

[0194] 75…fitting groove

[0195] 76…Mounting holes

[0196] 91~94…Terminal metal parts (terminal)

[0197] 91a~94a…Wire connection part

[0198] 91b~94b…Hook part

[0199] 91c~94c…Installation part

[0200] 91d~94d…Through hole

[0201] 91e~94e…Connection

[0202] 91f~94f…Insertion convex part

[0203] 300…Circuit board

Claims

1. A coil device, comprising: a bobbin having a winding portion for winding the electric wire around its outer circumference; A terminal connected to a lead portion of the electric wire; A terminal block, on which the terminal is mounted, and which is mounted on the bobbin so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin; A guide portion guides the lead portion so as to form a predetermined gap between an end portion of the terminal block in the Y-axis direction and the lead portion.

2. The coil device according to claim 1, wherein: The guide portion is provided at a position away from an end portion of the terminal block in the Y-axis direction by a distance equal to or greater than a movable distance of the terminal block in the Y-axis direction.

3. The coil device according to claim 1 or 2, wherein: The guide portion has a pair of protrusions protruding outwards. A lead wire insertion passage through which the lead wire portion is inserted is formed between each of the pair of protruding portions.

4. The coil device according to claim 1 or 2, wherein: The bobbin has a flange portion formed on the outer periphery of the winding portion, The guide portion is formed at an end portion of the flange portion in the X-axis direction outside a movable range of the terminal block in the Y-axis direction.

5. The coil device according to claim 3, wherein: The bobbin has a flange portion formed on the outer periphery of the winding portion, The guide portion is formed at an end portion of the flange portion in the X-axis direction outside a movable range of the terminal block in the Y-axis direction.

6. The coil device according to claim 1 or 2, wherein: The electric wire is composed of a first electric wire and a second electric wire, A first coil portion formed by winding the first electric wire and a second coil portion formed by winding the second electric wire are formed on the bobbin.

7. The coil device according to claim 6, wherein: The first coil portion and the second coil portion are disposed adjacent to each other along a winding axis direction thereof.

8. The coil device according to claim 6, wherein: An insulating cover is mounted on the end of the bobbin in the X-axis direction to insulate one of the first coil portion and the second coil portion from the lead portion of the other of the first coil portion and the second coil portion led out from the end of the bobbin in the X-axis direction to the terminal. The guide portion is disposed on the insulating cover.

9. The coil device according to claim 6, wherein: The diameter of one of the first electric wire and the second electric wire is larger than the diameter of the other electric wire. The lead portion of the electric wire having a larger diameter is guided by the guide portion.

10. The coil device according to claim 8, wherein: The diameter of one of the first electric wire and the second electric wire is larger than the diameter of the other electric wire. The lead portion of the electric wire having a larger diameter is guided by the guide portion.

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