Coil device

Abstract

The present invention provides a coil device that can compactly arrange these components when the coil device is mounted on a circuit board or the like together with other electronic components such as an IC chip. The coil device comprises: a coil portion (70) composed of a plurality of conductive wires (72) connected to a plurality of terminals (40a, 40b, 42); and a bobbin (20) having a first terminal block (24) and a second terminal block (26) formed on both sides of a barrel portion (22) forming the coil portion (70) in a winding direction. The length of the first terminal block (24) in a width direction perpendicular to the winding direction is configured to be greater than the width length of the second terminal block (26).

Description

Technical Field

[0001] The present invention relates to a coil device for use as, for example, a transformer. Background Art

[0002] For example, in the transformer shown in Patent Document 1, a plurality of terminals are mounted on a pair of terminal blocks arranged on both sides of a bobbin barrel (coil portion), and the primary winding and secondary winding wound on the bobbin barrel are led out to the plurality of terminals.

[0003] When such a transformer is mounted on a circuit board together with other electronic components such as an IC, the transformer is larger than the other electronic components. Therefore, the other electronic components are generally arranged around the large transformer.

[0004] However, as transformers carry higher currents and higher voltages, if the length of a pair of terminal blocks is increased to ensure a sufficient insulation distance, the mounting area of ​​the coil device, including other electronic components, will inevitably increase.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 2009-194336 Summary of the Invention

[0008] Problems to be solved by the invention

[0009] The present invention has been made in view of such actual circumstances, and its object is to provide a coil device that can reduce the mounting area of ​​the coil device including other electronic components when a circuit substrate and other electronic components such as an IC chip are mounted on the coil device together.

[0010] Technical solutions to solve problems

[0011] In order to achieve the above object, the present invention provides a coil device having:

[0012] a coil portion composed of a plurality of conductive wires connected to a plurality of terminals;

[0013] a bobbin having a first terminal block and a second terminal block formed on both sides of a barrel portion forming the coil portion in a winding direction,

[0014] The length of the first terminal block along a width direction perpendicular to the winding axis direction is greater than the length of the second terminal block in the width direction.

[0015] In the coil device of the present invention, since the first terminal block is longer than the second terminal block, arranging multiple terminals on the first terminal block allows a single coil device to be suitably used for applications where a small number of inputs produce a large number of outputs. Furthermore, since the first terminal block is longer than the second terminal block, multiple terminals can be arranged and mounted with greater spacing. This ensures insulation between the terminals, and even when electronic components such as IC chips are arranged side by side near the first terminal block and connected to the terminals of the first terminal block, insulation of the electronic components can be ensured.

[0016] Furthermore, by arranging larger electronic components, such as IC chips, side by side near the longer first terminal block, it is possible to free up lateral space in the shorter second terminal block. By arranging other electronic components in the freed-up lateral space of the second terminal block, the mounting area of ​​the coil device containing other electronic components, such as IC chips, can be reduced compared to a case where the two terminal blocks have the same length.

[0017] Preferably, the first terminal block has an extension portion protruding outward from the outer shape of the coil portion along the winding axis direction, and at least one terminal is mounted on the extension portion. With this configuration, the spacing between the terminals of the first terminal block can be sufficiently increased.

[0018] Preferably, a reinforcement portion is formed on the first terminal block. The reinforcement portion can prevent the first terminal block, which is long in the width direction, from bending, thereby increasing the strength of the coil device.

[0019] Furthermore, the reinforcing portion preferably includes a first wire contact portion with which a lead portion of the wire drawn from the coil portion to the terminal contacts. More preferably, the first wire contact portion changes the direction in which the lead portion of the wire is drawn.

[0020] In this way, the lead portion of the wire contacts the first wire contact portion between the coil portion and the terminal, changing its lead-out direction. This shortens the length of the free portion of the wire between the inflection points where the lead-out direction changes. This shortening of the free portion increases the resonant frequency of the lead portion of the wire. This prevents resonance between the mounting substrate and the wire, making wire breakage less likely.

[0021] Furthermore, the first terminal block preferably has a protrusion that contacts a lead portion of the wire drawn from the coil portion to the terminal. More preferably, the second wire contact portion changes the direction in which the lead portion of the wire is drawn.

[0022] In this way, the lead portion of the wire contacts the second wire contact portion between the coil portion and the terminal, changing its lead-out direction and shortening the length of the free portion of the wire. This increases the resonant frequency of the lead portion, preventing resonance between the mounting substrate and the wire, and making the wire less likely to break.

[0023] Preferably, the first wire contact portion is arranged closer to the coil portion than the second wire contact portion. In this way, by arranging the wire contact portion, the lead portion is led out in a zigzag shape, which can prevent the wire from being disconnected due to resonance of the wire.

[0024] Preferably, the resonant frequency of the lead portion of the conductive wire is 2000 Hz or higher.

[0025] Preferably, the lead portion of the wire extending from the coil portion to the terminal is divided into a plurality of free portions, the longest of which is 15 mm or less. This configuration prevents the lead portion of the wire from resonating with the mounting substrate and reduces the risk of wire breakage. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic perspective view of a transformer according to one embodiment of the present invention.

[0027] Figure 2 yes Figure 1 Exploded perspective view of the transformer shown.

[0028] Figure 3 yes Figure 1 The bottom side perspective view of the transformer is shown.

[0029] Figure 4 yes Figure 1 Bottom view of the transformer shown.

[0030] Figure 5 yes Figure 4 A partial enlarged view of the bottom view of the transformer is shown.

[0031] Figure 6 It is along Figure 4 Cross-sectional view of the transformer along line VI-VI.

[0032] Figure 7 Yes Figure 5 Schematic diagram of the lead-out direction of the lead portion of the wire shown. DETAILED DESCRIPTION

[0033] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0034] like Figure 1As shown, a transformer 10 as a coil device according to one embodiment of the present invention includes a bobbin 20 , a core 50 , and a cover plate 80 .

[0035] like Figure 2 As shown, the bobbin 20 includes a barrel portion 22 around which a plurality of conductive wires 72 constituting the coil portion 70 are insulated and wound. A first terminal block 24 and a second terminal block 26 are integrally formed at both ends of the barrel portion 22 in the Y-axis direction. In this embodiment, these terminal blocks 24 and 26 are elongated in the X-axis direction and are integrally formed with the lower portions of flanges 28a and 28b, respectively, formed at both ends of the barrel portion 22 in the Y-axis direction, so as not to block the through-hole 23 of the barrel portion 22 in the Z-axis direction.

[0036] In addition, in the drawings of this embodiment, the X-axis, Y-axis and Z-axis are perpendicular to each other, the Y-axis is parallel to the direction of the winding axis of the coil portion 70, the X-axis is parallel to the width direction of the terminal blocks 24 and 26, and the Z-axis is parallel to the height direction from the mounting surface toward the counter-mounting surface.

[0037] like Figure 2 As shown in FIG. 1 , a single or multiple flange portions 28c may be formed integrally with the barrel portion 22 at a midway position of the barrel portion 22 between the flange portion 28a and the flange portion 28b. The flange portion 28c may also be discontinuous along the circumferential direction, and a cutout 28d may be formed in the upper direction of the Z axis at a midway position of the flange portion 28c in the circumferential direction, as shown in FIG. Figure 4 As shown, three or more cutouts 28d may be formed at the lower position in the Z-axis direction.

[0038] like Figure 2 As shown, an engaging projection 29a and a pair of clamping projections 29b located on either side of the flanges 28a and 28b in the X-axis direction are integrally formed at the upper ends in the Z-axis direction of the flanges 28a and 28b, which are integrally formed with the respective ends in the Y-axis direction of the cylindrical portion 22. These projections 29a and 29b are formed so as to protrude in the Y-axis direction from the Y-axis end surfaces of the flanges 28a and 28b.

[0039] The engaging protrusions 29a detachably engage with the engaging holes 84 of the mounting rings 82 formed on both sides of the cover plate 80 in the Y-axis direction. These mounting rings 82 are formed so as to protrude downward from the cover plate 80 in the Z-axis direction. When the engaging protrusions are fitted into the engaging holes 84 of the mounting rings 82, the clamping protrusions 29b clamp the mounting rings 82 from both sides in the X-axis direction. As long as no significant force is applied to the mounting rings 82, the cover plate 80 will not fall off the spool 20.

[0040] The upper surface of the cover plate 80 is flat and can be sucked onto the tip of a nozzle for moving the finished product transformer 10. The cover plate 80 and the bobbin 20 are preferably each made of an insulating member, but do not necessarily need to be made of the same material.

[0041] The bobbin 20 is formed by, for example, injection molding. Its material is not particularly limited, and may be made of, for example, PBT, PET, LCP, PA, or, from the perspective of heat resistance, a phenolic resin. The cover plate 80 may be made of the same material as the bobbin 20, but due to its simple shape, it may be made of an insulating material other than resin, such as ceramic or paper. The bobbin 20 may be made of an insulating material other than resin, as long as it can be molded.

[0042] Terminals 40a, 40b, and 42 described below are insert-molded in the bobbin 20. However, these terminals 40a, 40b, and 42 may not be insert-molded together with the bobbin 20 but may be fixed to the formed bobbin by press-fitting or bonding.

[0043] The center legs 54a and 54b of the core 50 are inserted from both sides in the Y-axis direction into the through-hole 23 formed in the cylindrical portion 22 of the bobbin 20. In this embodiment, the core 50 is composed of a first split core 50a and a second split core 50b. The first split core 50a includes a plate-shaped portion 52a parallel to a plane containing the X-axis and the Z-axis, and a center leg 54a that protrudes from the approximately center portion of the plate-shaped portion 52a in the Y-axis direction. Outer legs 56a protrude from the center leg 54a in the Y-axis direction at predetermined intervals on both sides of the center leg 54a in the X-axis direction and at both ends of the plate-shaped portion 52a in the X-axis direction. The protrusion height of the center leg 54a from the plate-shaped portion 52a and the protrusion height of the outer legs 56a from the plate-shaped portion 52a are approximately the same.

[0044] A notch 53a is formed at the center of the plate portion 52a in the X-axis direction and at the upper end in the Z-axis direction. The notch 53a extends to near the base of the middle leg portion 54a. The notch 53a is provided so that the mounting ring 82 of the cover plate 80 does not interfere with the core 50a.

[0045] The second split core 50b includes a plate-shaped portion 52b parallel to a plane including the X-axis and the Z-axis, and a center leg portion 54b protruding from the approximately center portion of the plate-shaped portion 52b in the Y-axis direction. Outer legs 56b protrude from the center leg 54b in the Y-axis direction at predetermined intervals on either side of the center leg 54b in the X-axis direction and at both ends of the plate-shaped portion 52b in the X-axis direction. The protrusion height of the center leg 54b from the plate-shaped portion 52b and the protrusion height of the outer legs 56b from the plate-shaped portion 52b are approximately the same.

[0046] A notch 53b is formed at the center of the plate portion 52b in the X-axis direction and at the upper end in the Z-axis direction. The notch 53b is formed to near the base of the middle leg portion 54b. The notch 53b is provided so that the mounting ring 82 of the cover plate 80 does not interfere with the core 50b.

[0047] As described above, the center legs 54a, 54b of each core 50a, 50b are inserted into the through-hole 23 of the barrel 22 of the bobbin 20 from both sides in the Y-axis direction, with the tips of the center legs 54a, 54b butted against each other. Furthermore, to adjust the performance of the core 50, a gap may be provided between the tips of the center legs 54a, 54b. Furthermore, in this embodiment, the tips of the outer legs 56a, 56b of each core 50a, 50b are butted against each other in a manner that surrounds the coil portion 70, i.e., both sides of the flanges 28a-28c in the X-axis direction. The cores 50a, 50b may also be bonded to the cover plate 80 and the bobbin 20 using adhesive 86.

[0048] There is no particular limitation on the cores 50a and 50b, and each is a magnetic body composed of a ferrite composition, a metal composition, or a composite composition of these and a resin, and is manufactured by sintering after compression molding, sintering after injection molding, or general powder pressing.

[0049] like Figure 4 As shown, the first terminal block main body 30 of the first terminal block 24 is long in the X-axis direction, which intersects the Y-axis parallel to the winding axis of the coil unit 70, and has a length L1 in the X-axis direction. The main body 30 has a central portion 30a located within the outer shape of the coil unit 70 along its longitudinal direction, and extended portions 30b that protrude from the outer shape of the coil unit 70 toward both sides in the X-axis direction along its longitudinal direction.

[0050] like Figure 1 As shown in FIG. 1 , the central terminal mounting portion 36a is arranged at a predetermined interval along the X axis at a position close to the central portion 30a on the lower side in the Z axis direction. Figure 1 In the embodiment, the central first terminals 40a protrude in the Z-axis direction from the mounting surfaces 24a of the four central terminal mounting portions 36a, and are bent and fixed in the Y-axis direction.

[0051] exist Figure 1 In the figure, the extension side terminal mounting portion 36b is arranged at a predetermined interval along the X axis on the lower side of the left extension portion 30b in the Z axis direction. In the figure, the extension side first terminal 40a protrudes from the mounting surface 24a of the two respective extension side terminal mounting portions 36b in the Z axis direction and is bent and fixed in the Y axis direction. In addition, Figure 1 In the embodiment, the extension side terminal mounting portions 36b are arranged at predetermined intervals along the X axis on the lower side of the right extension portion 30b in the Z axis direction. In the figure, the extension side first terminals 40a protrude from the mounting surfaces 24a of the two respective extension side terminal mounting portions 36b in the Z axis direction and are bent and fixed in the Y axis direction.

[0052] Each central-side first terminal 40a is electrically connected at its upper portion in the Z-axis direction to a central-side first terminal connecting piece 41a that protrudes from the outer surface 24c of the first terminal block 24 in the Y-axis direction. In this embodiment, each central-side first terminal 40a is formed of a generally U-shaped metal terminal piece, etc., integrally formed with the central-side first terminal connecting piece 41a. The generally U-shaped metal terminal piece is insert-molded near the mounting surface 24a of the central-side terminal mounting portion 36a near the central portion 30a, thereby securing multiple pairs of central-side first terminals 40a and central-side first terminal connecting pieces 41a to the central-side terminal mounting portion 36a of the central portion 30a.

[0053] Each extended-side first terminal 40b is electrically connected at its upper portion in the Z-axis direction to an extended-side first terminal connecting piece 41b that protrudes from the outer side surface 24c of the first terminal block 24 in the Y-axis direction. In this embodiment, each extended-side first terminal 40b is formed of a generally U-shaped metal terminal piece, etc., integrally formed with the extended-side first terminal connecting piece 41b. The generally U-shaped metal terminal piece is insert-molded near the mounting surface 24a of the extended-side terminal mounting portion 36b near each extended portion 30b, thereby securing multiple pairs of extended-side first terminals 40b and extended-side first terminal connecting pieces 41b to the extended-side terminal mounting portion 36b of the extended portion 30b.

[0054] like Figure 4 As shown, the second terminal block main body 32 of the second terminal block 26 is long in the X-axis direction intersecting the Y-axis parallel to the winding axis of the coil portion 70, and the length in the X-axis direction is L2. Figure 3 As shown, a second terminal mounting portion 44 is arranged on the lower side of the second terminal block in the Z-axis direction. In the figure, the second terminal 42 protrudes from the mounting surfaces 26a of six respective second terminal mounting portions 44 in the Z-axis direction and is bent and fixed in the Y-axis direction.

[0055] Each second terminal 42 is electrically connected at its upper portion in the Z-axis direction to a second terminal connecting piece 43 that protrudes from the outer side surface 26c of the second terminal base 26 in the Y-axis direction. In this embodiment, each second terminal 42 is formed of a substantially U-shaped metal terminal piece, etc., integrally formed with the second terminal connecting piece 43. The plurality of pairs of second terminals 42 and second terminal connecting pieces 43 are secured to the second terminal mounting portion 44 by insert-molding the substantially U-shaped metal terminal piece near the mounting surface 26a of the second terminal mounting portion 44.

[0056] like Figure 6 As shown, the mounting surface 24a ( Figure 3 The same also applies to the mounting surface 26a shown) from the terminal 40a ( Figure 1The terminals 40b and 42 shown in the figure are also the same) are higher than the height H1. In addition, the coil portion 70 is higher than the terminal 40a ( Figure 1 The terminals 40b, 42 are also shown as being higher than a height H2.

[0057] In this embodiment, these Figure 1 The terminals 40a, 40b, and 42 including the connecting pieces 41a, 41b, and 43 are not particularly limited and may be made of, for example, copper, a copper alloy, iron, an iron alloy, or CP wire. When the bobbin 20 is formed by injection molding, these terminals 40a, 40b, and 42 can be integrated with the bobbin 20 by insert molding or the like, but may also be attached to the bobbin 20 by other methods.

[0058] The conductive wire 72 that constitutes the coil portion 70 and connects to the connecting pieces 41a, 41b, and 43 of the terminals 40a, 40b, and 42 is not particularly limited. For example, conductive conductive wires such as copper, copper alloy, iron, iron alloy, and CP wire with insulation coatings can be used. The insulating material constituting the insulation coating is not particularly limited, and urethane, polyamide-imide, ETFE, and the like can be used.

[0059] like Figures 3 to 5 As shown, the lead wire 72 has a lead portion 72a extending from the coil portion 70 to the connecting pieces 41a, 41b, and 43. Figure 7 As shown, the lead portion 72 a arranged on the lower side of the first terminal block 24 in the Z-axis direction is bent in contact with the first terminal block 24 and has several free portions 72 a 1 .

[0060] like Figure 4 As shown, a central terminal mounting portion 36a is formed near the central portion 30a of the second bottom surface 24f located on the lower side in the Z-axis direction of the first terminal block 24, into which the central first terminal 40a is embedded. A lead groove 37 is formed between adjacent central terminal mounting portions 36a. Each lead groove 37 guides the lead portion 72a to the outer side surface 24c of the first terminal block 24. The lead portion 72a guided to the outer side surface 24c by each lead groove 37 is aligned with the lead portion 72a located on the outer side along the Y-axis of the lead groove 37. Figure 3 The central first terminal connecting piece 41a is connected. The connection method is not particularly limited, and examples thereof include welding, laser welding, arc welding, thermocompression welding, and resistance welding.

[0061] like Figure 4As shown, an extension side terminal mounting portion 36b is formed on the second bottom surface 24f of the extension portion 30b of the first terminal block 24, into which the extension side first side terminal 40b is embedded. A lead groove 37 is formed between adjacent extension side terminal mounting portions 36b. Each lead groove 37 guides the lead portion 72a to the outer side surface 24c of the first terminal block 24. The lead portion 72a guided to the outer side surface 24c by each lead groove 37 is aligned with the lead portion 72a located on the outer side along the X axis. Figure 3 The method for connecting is as described above.

[0062] A reinforcement portion 33 is formed midway along the second bottom surface 24f, located between the extended-side terminal mounting portion 36b and the central-side terminal mounting portion 36a. The reinforcement portion 33 is thicker than the first terminal block main body 30 in the Z-axis direction. Lead grooves 37 are also formed between the reinforcement portion 33 and the extended-side terminal mounting portion 36b. Each lead groove 37 guides the lead portion 72a to the outer side surface 24c of the first terminal block 24. The lead portion 72a, guided to the outer side surface 24c by each lead groove 37, is connected to the extended-side first terminal connecting piece 41b adjacent to the reinforcement portion 33. The connection method is as described above.

[0063] A boundary wall 34 is formed along the inner side surface 24d at the center of the first terminal block 24 in the Y-axis direction. The boundary wall 34 protrudes in the Z-axis direction from the first terminal block main body 30. The protrusion height of the boundary wall 34 along the Z-axis is approximately the same as the protrusion height of the mounting portions 36a, 36b and the reinforcement portion 33 from the main body 30.

[0064] A guide groove is formed between the boundary wall 34 and the mounting portion 36a for passing the lead portion 72a of the terminal connection piece 41b located at the X-axis end of the first terminal block 24. Furthermore, a guide notch is formed in the boundary wall 34 for passing the lead portion 72a from the coil portion 70 toward each of the terminal connection pieces 41a and 41b. In this embodiment, protrusions 35 are formed on both sides of the boundary wall 34 along the X-axis, projecting outward along the Y-axis.

[0065] like Figure 6 As shown, the bottom surface of the terminal block body 30 has a first bottom surface 24e and a second bottom surface 24f with different heights. The height H3 from the first bottom surface 24e to the mounting surface 24a is greater than the height H4 from the second bottom surface 24f to the mounting surface 24a.

[0066] like Figure 4As shown, the bottom surface of the second terminal block 26, located on the lower side in the Z-axis direction, has a first bottom surface 26e and a second bottom surface 26f, which have different heights in a stepped manner, similar to the bottom surface of the first terminal block 24. On the second bottom surface 26f, second terminal mounting portions 44, into which the second terminals 42 are embedded, are formed at predetermined intervals in the X-axis direction.

[0067] A lead groove 37 is formed between adjacent second terminal mounting portions 44. The lead groove 37 guides the lead portion 72a of the wire 72 drawn out from the coil portion 70 to the outer side surface 26c of the second terminal base 26. Figure 3 As shown, the lead portion 72a of the wire 72 guided to the outer side surface 26c through the lead groove 37 is connected to the second terminal connection piece 43 located near the lead groove 37. The method for connection is as described above.

[0068] like Figure 3 As shown, a boundary wall 34 is formed along the inner side surface 26d of the second terminal block 26 on the second terminal block body 32. Similar to the boundary wall 34 of the first terminal block 24, the boundary wall 34 protrudes from the second terminal block body 32 in the Z-axis direction. The protrusion height of the boundary wall 34 along the Z-axis is approximately the same as the protrusion height of the mounting portion 44 from the body 32. A guide notch is formed in the boundary wall 34 for passing the lead wires 72a from the coil portion 70 toward each terminal connection piece 43.

[0069] like Figure 5 As shown, a protrusion 35 and a reinforcement portion 33 are provided on the bottom surfaces 24e and 24f of each extension portion 30b of the first terminal block 24, which guide the lead portion 72a from the center toward the outside along the X-axis. A wire contact portion 35a is formed at the protruding tip of the protrusion 35, which protrudes from the end of the boundary wall 34 along the X-axis toward the outside along the Y-axis (the side of the coil portion 70 farther from the center along the X-axis or Y-axis) and contacts the middle of the lead portion 72a.

[0070] Furthermore, a wire contact portion 33a is formed on the reinforcement portion 33. The wire contact portion 33a protrudes from the reinforcement portion 33 toward the inner side along the Y axis (the side toward the center of the coil portion 70 along the X axis or the Y axis) and contacts the middle of the lead portion 72a. These wire contact portions 33a and 35a are offset in the X axis direction and protrude in opposite directions along the Y axis. When viewed from the X axis direction, they overlap with a predetermined width w1.

[0071] Therefore, the two lead portions 72a extending from the coil portion 70 and toward the first extension-side terminal 40b abut at least both of the wire abutment portions 33a and 35a, forming a zigzag shape. The width w0 of the first terminal block 24 in the Y-axis direction is smaller than w1. The ratio w0 is preferably 0 to 1 / 2, and more preferably 1 / 20 to 1 / 5.

[0072] In this embodiment, the two lead portions 72a extending from the coil portion 70 and directed toward the first extension-side terminal 40b abut not only the wire abutting portions 33a and 35a but also abut the wire abutting portion 34a corresponding to the cutout of the boundary wall 34 near the coil portion 70. Furthermore, the lead portions 72a also abut the first extension-side terminal mounting portion 36b near the terminal 40b.

[0073] like Figure 7 As shown, each lead portion 72 abuts against the wire abutment portions 34a, 33a, 35a and other abutment portions, so that the lead-out direction has an inflection point P where the lead-out direction changes at, for example, an angle θ. That is, each lead portion 72a extending to the first extension-side terminal 40b changes its lead-out direction at the inflection point P, which includes the lead-out start point S and the lead-out end point E, and connects from the coil portion 70 to the connection portion 41b1 of the first extension-side terminal 40b.

[0074] The free portion 72a1 of the lead portion 72a is formed between the inflection point P and the inflection point P, which include the lead start point S and the lead end point E. In this way, the lead portion 72a is divided into a plurality of free portions 72a1 on both sides of the inflection point P.

[0075] In this embodiment, the angle θ of the direction change is 180° or less, more preferably 90°≤θ<180°. In particular, in the wire contact portions 33a and 35a, the angle θ of the inflection point P is preferably 90°≤θ≤175°.

[0076] In this embodiment, if Figure 1 As shown, since the first terminal block 24 is longer than the second terminal block 26, by arranging multiple terminals 40a and 40b on the first terminal block 24, a single transformer 10 can be suitably used for applications where a large number of outputs are obtained from a small number of inputs. For example, the transformer 10 of this embodiment is used in inverter circuits for driving motors and compressors, and can be used in automobiles, industrial equipment, household appliances, and housing equipment.

[0077] Furthermore, multiple terminals 40a, 40b can be arranged and mounted at large intervals on a first terminal block 24 that is longer than the second terminal block 26. For example, the pitch distance L3 between each pair of terminals 40a, 40b can be determined based on the distance required to maintain a minimum insulation distance, and the pitch distance L4 between the central first terminal 40a and the extended first terminal 40b can be set longer. Furthermore, the pitch distance between a pair of identical central first terminals 40a can be set to the same length as the pitch distance L4.

[0078] For example, the pitch distance L3 is preferably 2.5 mm to 5 mm, and the pitch distance L4 can be preferably extended to 8 mm or more. Thus, insulation between the paired terminals 40 a or 40 b can be ensured, and even when electronic components such as IC chips are arranged side by side near the first terminal block 24 and connected to the terminals 40 a and 40 b of the first terminal block 24, insulation between the IC chips and the like can be ensured.

[0079] In this embodiment, four pairs of terminals 40 a and 40 b are mounted on the first terminal block 24 at a predetermined pitch interval L4 . Therefore, electronic components having a width dimension equal to or smaller than the four pitch intervals L4 can be arranged in parallel near the first terminal block 24 .

[0080] Furthermore, by arranging electronic components, such as IC chips, that are smaller than transformer 10, side by side near first terminal block 24, which is longer than second terminal block 26, space can be freed up on either side of the X-axis of the shorter second terminal block 26. By arranging other smaller electronic components in the lateral space of second terminal block 26, the mounting area for transformer 10 and related components, including IC chips and other electronic components, can be reduced compared to a case where both terminal blocks have the same length.

[0081] In this embodiment, the first terminal block 24 includes an extension portion 30b that protrudes outward along the X-axis from the outer shape of the coil portion 70. At least a pair of terminals 40b are mounted on the extension portion 30b. This configuration allows the pitch distance L4 between the terminals 40a and 40b of the first terminal block 24 to be substantially increased.

[0082] like Figure 3 As shown in FIG. 1 , in this embodiment, a total of three pairs of second terminals 42 are installed on the second terminal block 26. Figure 4 As shown, the pitch distance L5 between each pair of terminals 42 is approximately the same as the pitch distance L3 described above. The length L2 of the second terminal block 26 is less than the length L1 of the first terminal block 24. The ratio L2 / L1 is preferably 4 / 5 or less, more preferably 3 / 5 or less, and particularly preferably 1 / 2 or less. The second terminals 42 of the second terminal block 26 can be used, for example, as input terminals of the transformer 10.

[0083] like Figure 3 As shown, a reinforcement portion 33 is formed on the first terminal block 24. The reinforcement portion 33 prevents the first terminal block 24, which is long in the X-axis direction (width direction), from bending, thereby increasing the strength of the transformer 10. In particular, Figure 4 The longer the pitch interval L4 shown, the better the reinforcing effect achieved by the reinforcing portion 33 .

[0084] Furthermore, when the pitch interval L4 is long, multiple reinforcement portions 33 may be arranged at predetermined intervals along the X-axis. In this embodiment, reinforcement portions 33 are formed so as to protrude from the bottom surface of the terminal block body 30 approximately in the center of each pitch interval L4 located on both sides of the terminal block 24.

[0085] like Figure 5 As shown, the reinforcement portion 33 has a wire abutment portion 33a with which the lead portion 72a of the wire extending from the coil portion 70 to the two extended side first terminals 40b contacts, and the wire abutment portion 33a changes the direction in which the lead portion 72a is extended. In addition, the first terminal block 24 has a protrusion 35 located between the reinforcement portion 33 and the coil portion 70 and projecting outward from a position outside along the X-axis of the boundary wall 34 along the axis (Y-axis) of the coil portion 70.

[0086] Similar to the reinforcement portion 33, the boundary wall 34 and the protrusion 35 also have a reinforcing effect on the first terminal block 24. The protrusion 35 is formed to protrude from the inner side surface 24d in a direction opposite to the direction in which the wire contact portion 33a of the reinforcement portion 33 protrudes inward from the outer side surface 24c of the terminal block 24 along the Y-axis. A wire contact portion 35a is formed at the protruding tip of the protrusion 35. This wire contact portion 35a contacts the lead portion 72a of the wire directed toward the terminal 40b. By contacting the wire, the wire contact portion 35a changes the direction in which the lead portion 72a is drawn from the coil portion 70 toward the wire contact portion 33a of the reinforcement portion 33.

[0087] Thus, the lead portion 72a of the wire contacts at least the wire contact portions 35a and 33a when being led out from the coil portion 70 to the terminal 40b, thereby changing the direction of the lead. Figure 7 As shown, the length L6 of the free portion 72a1 of the lead portion 72a between the inflection points P where the lead direction changes can be shortened. Reducing the length L6 of the free portion 72a1 increases the resonant frequency of the lead portion 72a of the conductor. This prevents resonance between the mounting substrate (circuit board) (not shown) and the lead portion 72a of the conductor, making it less likely for the lead portion 72a of the conductor to break.

[0088] Furthermore, the wire contact portion 35a of the protrusion 35 is arranged closer to the coil portion 70 than the wire contact portion 33a of the reinforcement 33. Thus, by arranging the wire contact portions 35a and 33a, the lead portion 72a is led out in a zigzag shape, thereby preventing the wire from being disconnected due to resonance of the lead portion 72a.

[0089] In this embodiment, Figure 7The longest length L6 of the free portion 72a1 of the lead portion 72a is preferably 10 mm or less. This configuration effectively prevents vibration and resonance of the lead portion 72a of the conductor during use of the transformer 10, and the lead portion 72a is less likely to break.

[0090] In addition, if Figure 7 As shown, in this embodiment, the length L6 of the free portion 72a1 between the inflection point P of the lead portion 72a contacting the terminal mounting portion 36b adjacent to the reinforcement portion 33 and the inflection point P of the lead portion 72a contacting the wire contact portion 33a is the longest free portion 72a1. The position of the longest free portion 72a1 can be changed by changing the position of the inflection point P and the direction change angle θ.

[0091] In this embodiment, the corners of the portion of the wire 72 that contacts the first wire contact portion 33a, the second wire contact portion 34a, the third wire contact portion 35a, and the mounting portion are curved. This structure reduces the pressure applied to the wire 72 even when the wire 72 vibrates, making it less likely to break.

[0092] In this embodiment, the resonant frequency of the lead portion 72a of the wire 72 is preferably 2000 Hz or higher. More preferably, the resonant frequency of the wire 72 is 3000 Hz or higher. Even more preferably, the resonant frequency of the lead portion 72a of the wire 72 is 4000 Hz or higher. This configuration effectively prevents vibration and resonance of the lead portion 72a of the wire during use of the transformer 10, making the lead portion 72a less susceptible to breakage.

[0093] 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.

[0094] For example, in this embodiment, Figure 7 As shown, the lead portion 72a is specifically divided into five or six free portions 72a1. However, by changing the number of protrusions 35, including the reinforcement portion 33, or the shape of the terminal mounting portion, increasing the inflection point P, it is possible to increase the number of free portions 72a1. This increases the number of free portions, shortening the length of the free portions 72a1. Furthermore, the first terminal block 24 can be made longer along the X-axis.

[0095] Furthermore, when multiple reinforcements 33 are present between pitch intervals L4, at least the reinforcement 33 closest to the terminal 40b is preferably formed so that the wire contact portion 33a protrudes in a direction opposite to the direction in which the terminal 40b protrudes from the outer side surface 24c of the terminal block 24 along the Y-axis. Reinforcements located further inward than the reinforcement 33 preferably have a wire contact portion in a direction opposite thereto. Furthermore, it is preferred that the protrusion 35 located near the coil portion 70 protrudes outward along the axis of the coil portion 70 and has a wire contact portion 35a at its protruding tip.

[0096] Furthermore, in this embodiment, Figure 5 As shown, at the end portion on the outer side 24c of the extended first terminal mounting portion 36b, the lead portion 72a of the wire 72 is bent and connected to the connecting portion 41b1 of the extended first terminal 40b. This shortens the length of the free portion of the lead portion 72a. Of course, the lead portion 72a can also be connected to the connecting portion 41b1 without being bent at this portion.

[0097] Explanation of symbols

[0098] 10...Coil device

[0099] 20... spools

[0100] 22...Cylinder

[0101] 23...through hole

[0102] 24...First terminal block

[0103] 24a……Mounting surface

[0104] 24b...reverse mounting surface

[0105] 24c...outer side

[0106] 24d...Inside

[0107] 24e...first bottom surface

[0108] 24f...the second bottom surface

[0109] 26...Second terminal block

[0110] 26a……Mounting surface

[0111] 26b...reverse mounting surface

[0112] 26c...outer side

[0113] 26d...Inside

[0114] 26e...first bottom surface

[0115] 26f...the second bottom surface

[0116] 28a to 28c: flange portion

[0117] 29a……Engaging protrusion

[0118] 29b... Clamping protrusion

[0119] 30……First terminal block body

[0120] 30a...Central

[0121] 30b...Extension

[0122] 32...Second terminal block body

[0123] 32a...Central

[0124] 32b...Extension

[0125] 33... Strengthening Department

[0126] 33a: wire contact portion

[0127] 34...Boundary Wall

[0128] 34a: wire contact portion

[0129] 35... protrusion

[0130] 35a: wire contact portion

[0131] 36a: Center side first terminal mounting portion

[0132] 36b: Extended side first terminal mounting portion

[0133] 37...lead duct

[0134] 40a……Central side first terminal

[0135] 40b……Extended side first terminal

[0136] 41a……Central first terminal connecting piece

[0137] 41b……Extended side first terminal connecting piece

[0138] 41a1, 41b1...connection

[0139] 42……Second terminal

[0140] 43...Second terminal connecting piece

[0141] 44……Second terminal mounting portion

[0142] 50...core

[0143] 50a……first split core

[0144] 50b...second split core

[0145] 52a, 52b...base

[0146] 54a, 54b...mid-foot

[0147] 56a, 56b...outer foot

[0148] 70...coil part

[0149] 72...wire

[0150] 72a……lead portion

[0151] 80...cover plate

[0152] 82...Mounting ring

[0153] 84...locking hole

[0154] 86...adhesive

Claims

1. A coil device, wherein: have: a coil portion composed of a plurality of conductive wires connected to a plurality of terminals; and a bobbin having a first terminal block and a second terminal block formed on both sides of a barrel portion having the coil portion formed thereon in a winding direction, The length of the first terminal block along the width direction perpendicular to the winding axis direction is greater than the length of the second terminal block in the width direction. The first terminal block has an extension portion protruding outward from the outer shape of the coil portion along the width direction. At least one terminal is installed on the extension portion. The terminal includes a central terminal provided on the extension portion and an extension terminal provided on the extension portion located further outward than the central terminal in the width direction. The central side terminal and the extension side terminal are installed on the outer side surface of the extension portion, The extension portion located between the central terminal and the extension terminal has a first protrusion. The first protrusion protrudes inward from the outer surface of the first terminal block along the winding axis direction. The first protrusion has a first contact portion that changes the direction in which the lead portion of the lead wire is drawn out.

2. The coil device according to claim 1, wherein The first protrusion also serves as a reinforcement portion of the first terminal block.

3. The coil device according to claim 1 or 2, wherein: The extension portion has a second protrusion portion between the first protrusion portion and the coil portion, The second protrusion has a second lead wire contact portion with which a lead wire portion of the lead wire drawn out from the coil portion to the terminal contacts.

4. The coil device according to claim 3, wherein The second wire contact portion changes the lead-out direction of the lead portion of the wire.

5. The coil device according to claim 1, wherein The resonant frequency of the lead portion of the conductive wire is 2000 Hz or higher. The coil device according to claim 1 , wherein: The lead portion of the wire led out from the coil portion to the terminal is divided into a plurality of free portions, The longest length of the free portion is 10 mm or less.

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