Coil arrangement

Abstract

The present application provides a coil device in which positioning with respect to a connection object is easy, and in which manufacture and assembly of components are easy. The coil device (10) has: a core (40) having a winding portion (43) in which coils (20, 30) are arranged on the outer periphery; terminals (71-74) to which lead portions (22a, 32a) that are end portions of the coils (20, 30) are connected; a housing (80) in which the core (40) is accommodated; and terminal stages (50, 60) to which the terminals (71-74) are mounted and which are mounted to the housing (80). The terminal stages (50, 60) are movable in both the X-axis direction and the Y-axis direction of the housing (80).

Description

Technical Field

[0001] The present invention relates to coil devices, for example, that can be suitably used as transformers, etc. Background Technology

[0002] For example, as a coil device for transformers, etc., a coil device described in Patent Document 1 is known. The coil device described in Patent Document 1 has a frame, a winding wound around its outer periphery, and terminals to which the lead portion of the winding is connected. A terminal block is formed on the frame, and the terminals can be fitted and fixed to the terminal block.

[0003] In such coil devices, there is a requirement that the terminals must be directly connected to the connecting object when connecting to a circuit board or connector (hereinafter, the connecting object). However, because the connection position of the connecting object and the position of the terminal must be aligned with high precision, this type of connection is not easy. In addition, because the manufacturing and assembly of the components constituting the coil device require high precision, there is a technical problem of increased manufacturing costs.

[0004] Existing technical documents

[0005] Patent documents

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

[0007] The present invention was developed in view of this actual situation, and its object is to provide a coil device that is easy to position with the connected object and easy to manufacture and assemble the components.

[0008] To achieve the above objectives, the coil device according to the first aspect of the present invention comprises:

[0009] The core has a wound portion with coils arranged on its outer periphery;

[0010] Terminals, which are connected to the end of the coil;

[0011] A housing containing the core;

[0012] A terminal block, on which the terminals are mounted, is installed in the housing.

[0013] The terminal is movable freely in both the first and second axial directions of the housing.

[0014] The coil device of the first aspect of the present invention includes a core having a winding portion with coils arranged on its outer periphery. That is, unlike the prior art, the coil device of the first aspect of the present invention does not employ a structure in which the coils are arranged on a frame, but has a so-called frameless structure. Therefore, this structure is simple and can achieve miniaturization of the overall shape. Furthermore, by being frameless, sufficient space can be ensured for arranging the coils, and good characteristics can be obtained by increasing the number of coil turns or thickening the wire diameter of the windings constituting the coils.

[0015] Furthermore, the coil device of the first aspect of the present invention has a terminal block on which terminals are mounted and mounted on a housing. The terminals are freely movable in both a first axial direction and a second axial direction of the housing. Therefore, after roughly positioning the connecting object and the coil device, the terminals and the connecting object can be correctly positioned and connected simply by moving the terminals relative to the housing. Additionally, when the terminals move, the ends of the coil connected to the terminals also move in a following manner. However, in the frameless structure, the undesirable situation where the movement of the coil ends is hindered by the frame does not occur, thus ensuring sufficient movable area of ​​the coil ends. Therefore, the movable area of ​​the terminals is also sufficiently ensured, guaranteeing a very high level of freedom in terminal positioning, enabling accurate and easy positioning of the terminals and the connecting object.

[0016] In addition, the structure of mounting the terminal block in the housing allows for easy changes to the mounting position of the terminal block relative to the housing, increasing the user's design freedom.

[0017] Furthermore, in the coil device of the first aspect of the present invention, as described above, during the connection stage with the connected object, the connection position of the terminal relative to the connected object can be positioned with high precision. Therefore, during this manufacturing stage, it is not necessary to manufacture and assemble each component with high precision as in the prior art in order to correctly align the connection position of the terminal relative to the connected object, which helps to simplify manufacturing and reduce manufacturing costs.

[0018] To achieve the above objectives, the coil device according to the second aspect of the present invention comprises:

[0019] The core has a wound portion with coils arranged on its outer periphery;

[0020] Terminals, which are connected to the end of the coil;

[0021] A housing containing the core;

[0022] A terminal block, on which the terminals are mounted, is installed in the housing.

[0023] The terminal block is freely movable in both the first and second axial directions of the housing.

[0024] The coil device of the second aspect of the present invention is the same as the coil device of the first aspect, being frameless, thus achieving the same effects as the coil device of the first aspect. In particular, the coil device of the second aspect of the present invention has a terminal block on which terminals are mounted and is installed in the housing. The terminal block is freely movable in both the first and second axial directions of the housing. Therefore, after the connecting object and the coil device are roughly positioned, by simply moving the terminal block relative to the housing, the terminals mounted on the terminal block move relative to the housing, enabling accurate positioning and connection of the terminals and the connecting object. Furthermore, because it is frameless, the movable area of ​​the coil ends is sufficiently ensured, as are the movable areas of the terminals and the terminal block on which the terminals are mounted. This ensures a very high degree of freedom in terminal positioning, allowing for accurate and easy positioning of the terminals and the connecting object.

[0025] Furthermore, in the coil device of the second aspect of the present invention, as described above, in this manufacturing stage, it is not necessary to manufacture and assemble the components with the high precision required in the prior art in order to correctly align the terminals with the connection positions of the connected objects, which helps to simplify manufacturing and reduce manufacturing costs.

[0026] Preferably, the interior of the housing is filled with potting resin. This structure allows heat generated by the coil to be transferred to the housing via the potting resin, improving the heat dissipation performance of the coil device. Furthermore, since the housing is frameless, the flow of the potting resin within the housing is not hindered by the frame, allowing the potting resin to be wound into all corners of the housing. Therefore, a high potting resin filling rate is ensured, improving the heat dissipation performance of the coil device and facilitating miniaturization. Moreover, with improved heat dissipation performance, coil devices suitable for high-current applications can be realized.

[0027] Preferably, the terminal is movably mounted on the terminal block in the third axis direction of the housing. This configuration facilitates fine-tuning of the mounting positions of the terminal and the connected object in the third axis direction. Therefore, in this coil device, during the connection phase with the connected object, the connection position of the terminal relative to the connected object can be precisely positioned in the third axis direction. During this manufacturing phase, it is not necessary to precisely manufacture and assemble individual components to ensure correct alignment of the terminal relative to the connected object in the third axis direction, which also contributes to ease of manufacturing and reduces manufacturing costs.

[0028] The terminal block can also move freely in the third axis direction of the housing. When the terminal block is moved relative to the housing in the third axis direction, the terminals mounted on the terminal block move in the same direction. Therefore, the connection position of the terminals and the connected objects can be freely adjusted in the third axis direction, and the terminals and the connected objects can be correctly positioned and connected even in the third axis direction.

[0029] Preferably, a protrusion is formed at the upper end of the side wall of the housing, protruding upward toward the housing. At least a portion of the terminal block is disposed on the protrusion, and the end of the coil extends outward toward the outside of the housing through the side of the protrusion. By disposing at least a portion of the terminal block on the protrusion, the height position of the terminal block can be shifted upward toward the housing. Furthermore, by shifting the height position of the terminal block upward toward the housing in this way, when the end of the coil is extended outward toward the outside of the housing through the side of the protrusion, the position of the coil end and the position of the terminal mounted on the terminal block can be aligned, facilitating the connection between the end of the coil and the terminal.

[0030] Alternatively, the coil can be composed of a first coil and a second coil, arranged side-by-side inside the housing in a direction parallel to the bottom surface of the housing. This structure allows for a thinner coil assembly compared to arranging the first and second coils overlapping in the winding axis direction.

[0031] Preferably, a soft-fitting protrusion protruding in the first axial direction is formed on either the housing or the terminal block, and a soft-fitting recess into which the soft-fitting protrusion enters is formed on the other. The soft-fitting protrusion is movably inserted into the soft-fitting recess within a predetermined range in both the first axial direction and the second axial direction. With this structure, the terminal block with the terminals mounted can be freely mounted on the housing in both the first axial direction and the second axial direction.

[0032] Alternatively, the terminal block can be freely movable in the third axis direction of the housing, and the terminal is integrally formed with the terminal block. With this structure, the process of embedding the terminal into the terminal block can be omitted after the terminal block is formed, making the manufacturing of the coil device easier. Attached Figure Description

[0033] Figure 1 This is a perspective view of the coil device according to the first embodiment of the present invention.

[0034] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0035] Figure 3 yes Figure 1 An enlarged perspective view of the terminal block and terminals shown.

[0036] Figure 4 It means to Figure 3 The diagram shows a magnified perspective view of the main part of the terminal block when it is installed in the housing.

[0037] Figure 5 yes Figure 1 Side view of the coil assembly shown.

[0038] Figure 6 This is a perspective view of the coil device according to the second embodiment of the present invention.

[0039] Figure 7 yes Figure 6 An exploded perspective view of the coil device shown.

[0040] Figure 8 yes Figure 6 The coil assembly shown is a cross-sectional view along line VIII-VIII.

[0041] Figure 9 This is a perspective view of the main parts of the coil device according to the third embodiment of the present invention.

[0042] Figure 10 yes Figure 9 A top view of the main parts of the coil assembly shown.

[0043] Figure 11 This is a perspective view of the main parts of the coil device according to the fourth embodiment of the present invention.

[0044] Figure 12 yes Figure 11 A side view of the main parts of the coil assembly shown.

[0045] Figure 13A It means Figure 11 A three-dimensional view of a modified example of the skeleton shown.

[0046] Figure 13B It means Figure 11 Three-dimensional views of other variations of the skeleton shown.

[0047] Figure 14 This is a perspective view of the main parts of the coil device according to the fifth embodiment of the present invention.

[0048] Figure 15 yes Figure 14 A side view of the main parts of the coil assembly shown.

[0049] Figure 16 This is a perspective view of the main parts of the coil device according to the sixth embodiment of the present invention.

[0050] Figure 17 yes Figure 16 A side view of the main parts of the coil assembly shown.

[0051] Explanation of symbols

[0052] 10, 10A~10E… Coil Device

[0053] 20…First coil

[0054] 22…First winding

[0055] 22a…First lead section

[0056] 30…Second coil

[0057] 32…Second winding

[0058] 32a…Second lead section

[0059] 40, 40A…core

[0060] 41…base

[0061] 42…outer foot

[0062] 43… Winding section

[0063] 44…Middle foot

[0064] Terminal blocks 50, 50B, 50C, 50E, 60, 60B, 60C, 60E…

[0065] 51, 51B, 51C, 51E, 61, 61B, 61C, 61E… Main body of the platform

[0066] 52, 52C, 62, 62C… Through holes

[0067] 52a, 52aC, 62a, 62aC… Slow-fitting recesses

[0068] 52a1, 62a1…main concave portion

[0069] 52a2, 62a2…sub-concave

[0070] 62a3… Support sheet

[0071] 62a4…stop protrusion

[0072] 52b, 62b... Mounting recess

[0073] 53, 63… Terminal mounting section

[0074] 54, 54B, 64, 64B… terminal slots

[0075] 540…clamping section

[0076] 55, 55B, 65, 65B… Fitting grooves

[0077] 56, 66… mounting holes

[0078] 57, 67... nuts

[0079] 58, 68... Inner cover

[0080] 71~74… Terminal metal parts (terminals)

[0081] 71a~74a… Winding connection section

[0082] 71b~74b… Hook section

[0083] 71c~74c… Installation Section

[0084] 71d~74d… through holes

[0085] 71e~74e… Connecting parts

[0086] 71f~74f… Insertion of protrusion

[0087] 80, 80B, 80C, 80C', 80C”, 80D, 80E… casing

[0088] 81…Bottom

[0089] 82…sidewall

[0090] 82a_1, 82a_2... Terminal block setting section

[0091] 82a1…Extension

[0092] 83a, 83aC, 83aC', 83aC”, 83aD… Slow-fitting protrusions

[0093] 83a1…Main Convex

[0094] 83a2…Secondary convex part

[0095] 84… Anti-detachment groove

[0096] 85… Through hole

[0097] 90…stopping wall section

[0098] 91…wall section

[0099] 92…Chimerization Department

[0100] 100…Circuit board

[0101] 102… Mounting Hole

[0102] 104… screws

[0103] 110…resin. Detailed Implementation

[0104] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0105] First Implementation Method

[0106] like Figure 1 As shown, the coil device 10 of the first embodiment of the present invention is used, for example, as a transformer and is mounted on a circuit board 100 or a connector (not shown). The coil device 10 is mounted relative to these mounting objects with the upper surface of the coil device 10 in the Z-axis direction as the mounting surface. The coil device 10 includes a first coil 20, a second coil 30, two cores 40, a first terminal block 50, a second terminal block 60, terminal metal parts 71 to 74, and a housing 80, etc.

[0107] like Figure 2 As shown, the two cores 40 each have a symmetrical shape (the same shape), and are composed of cores with a roughly U-shaped or roughly C-shaped longitudinal cross-section (including the cut surfaces along the Y and Z axes). The cores 40 form a magnetic circuit through which the magnetic flux generated by the first coil 20 and the second coil 30 passes. The cores 40 are made of a soft magnetic material such as ferrite or metallic magnetic material, and have a flat base 41 extending in the Y-axis direction and a pair of legs 42, 42 protruding from both ends of the base 41 in the Y-axis direction in the Z-axis direction.

[0108] One core 40 and another core 40 are respectively arranged vertically in the Z-axis direction. The two cores 40 are combined in the Z-axis direction with the front ends of the outer legs 42, 42 of one core 40 and the front ends of the outer legs 42, 42 of the other core 40 aligned in the Z-axis direction. The two cores 40 can be bonded together using adhesive in their vertically combined state, or they can be fixed by wrapping a strip around their outer periphery. Alternatively, the front ends of the outer legs 42, 42 of one core 40 and the front ends of the outer legs 42, 42 of the other core 40 can be spaced apart at a predetermined interval without contacting each other.

[0109] In each core 40, a first coil 20 is arranged (or wound) around the outer periphery of one pair of outer legs 42 in the Y-axis direction, and a second coil 30 is arranged (or wound) around the outer periphery of the other pair of outer legs 42 in the Y-axis direction. That is, one pair of outer legs 42 functions as winding portions 43. The coil device 10 in this embodiment has a frameless structure without a frame, and the first coil 20 and the second coil 30 are directly arranged in the winding portions 43. The first coil 20 and the second coil 30 are arranged in the space between the base 41 of one core 40 and the base 41 of the other core 40 when the two cores 40 are combined. Alternatively, the first coil 20 and the second coil 30 may be placed on the base 41 of these cores 40.

[0110] One pair of legs 42, 42 has an approximately elliptical shape in cross-section (including the cross-section of the X and Y axes), but this shape is not particularly limited and can be appropriately modified, such as being circular. In addition, the length of one pair of legs 42, 42 in the Z-axis direction can also be appropriately modified according to the number of layers in the Z-axis direction of the first coil 20 or the second coil 30 wound.

[0111] The first coil 20 is formed by a first winding 22, and the second coil 30 is formed by a second winding 32. The first coil 20 can be formed by an air-core coil, or it can be formed by winding the first winding 22 around the winding portion 43 of the core 40. The second coil 30 is formed in the same way. The first coil 20 and the second coil 30 are arranged side by side inside the housing 80 in a direction parallel to the bottom surface 81 of the housing 80 (Y-axis direction). As a winding method for the windings 22 and 32, examples include arranged winding or α-winding. Arranged winding is a common winding method where the winding is wound from one end of the winding shaft to the other.

[0112] When using an air-core coil as the first coil 20 or the second coil 30, a self-fusing wire with a fusion layer formed on the outermost layer can also be used as the first winding 22 or the second winding 32. As the self-fusing wire, a conductor with an insulation layer formed on the outside of the conductor and a fusion layer formed on the outside of the insulation layer can be used. By fusing the self-fusing wire while it is wound into a coil shape, and connecting each turn integrally via the fusion layer, an air-core coil with a stable winding shape can be formed. Furthermore, as the fusion layer, resins such as polyamide-based or polyimide-based resins can be used, for example. Alternatively, a general winding without a fusion layer, i.e., a winding consisting of a conductor and an insulation layer, can also be used.

[0113] The first coil 20, for example, constitutes a primary coil, and the second coil 30, for example, constitutes a secondary coil. Their relationship can also be reversed. The windings 22 and 32 can be made of single wires or stranded wires. Furthermore, the materials of the first winding 22 and the second winding 32 can be the same or different.

[0114] Preferably, the windings 22 and 32 are made of insulated wire. The outer diameter d1 (not shown in the figure) of the first winding 22 is not particularly limited, but when carrying a large current, it is preferably φ1.0 to φ3.0 mm. The diameter of the second winding 32 is larger than that of the first winding 22, but the relationship between the two can be reversed or the same.

[0115] The two cores 40, with the first coil 20 and the second coil 30 wound around them, are housed (placed) inside the housing 80. Figure 1 Furthermore, inside the housing 80, with the core 40 and the like housed therein, a resin 90 with high thermal conductivity, such as a filling resin, is filled, thereby improving the heat dissipation of heat generated by the coils 20, 30, etc. The resin 90 fills approximately 80% of the height of the housing 80. With the housing 80 filled with resin 90, the upper part of the core 40 protrudes from the top of the resin 90. In this embodiment, because it is a frameless structure, a relatively wide gap (the gap between the outer peripheral surfaces of the two cores 40 and the inner surface of the sidewall 82) is formed around the two cores 40 inside the housing 80, allowing a sufficient amount of resin 90 to be filled within this gap.

[0116] The housing 80 has a bottom surface 81 and side walls 82. The bottom surface 81 has a rectangular shape, but this shape is not particularly limited and can also be square or other shapes. The side walls 82 extend upward from the periphery of the bottom surface 81, surrounding the four sides of the bottom surface 81. Terminal blocks 50 and 60 are mounted on the side walls 82.

[0117] The sidewall 82 has: a first surface 821 located on the negative X-axis side and parallel to the YZ plane; a second surface 822 located on the positive Y-axis side and parallel to the XZ plane; a third surface 823 located on the positive X-axis side and parallel to the YZ plane; and a fourth surface 824 located on the negative Y-axis side and parallel to the XZ plane. A terminal block mounting portion 82a_1 is formed on the first surface 821 of the sidewall 82, and a terminal block mounting portion 82a_2 is formed on the third surface 823.

[0118] Terminal block mounting portions 82a_1 and 82a_2 are respectively formed at the upper ends of the first surface 821 and the third surface 823, and are constituted by protrusions protruding upward toward the housing 80. Terminal block mounting portion 82a_1 is formed at the end of the first surface 821 on the positive Y-axis side, and terminal block mounting portion 82a_2 is formed at the end of the third surface 823 on the negative Y-axis side. That is, terminal block mounting portions 82a_1 and 82a_2 are arranged diagonally relative to the housing 80. At least a portion of terminal block 50 is disposed in terminal block mounting portion 82a_1, and at least a portion of terminal block 60 is disposed in terminal block mounting portion 82a_2.

[0119] like Figure 1 As shown, a pair of first lead portions 22a, 22a of the first winding 22 are led out from the side of the terminal block mounting portion 82a_1 in the Y-axis direction. More specifically, one first lead portion 22a is led out from one side of the terminal block mounting portion 82a_1 in the Y-axis direction, passing through the side of the terminal block mounting portion 82a_1 and extending outward from the first surface 821. The other first lead portion 22a is led out from the other side of the terminal block mounting portion 82a_1 in the Y-axis direction, passing through the side of the terminal block mounting portion 82a_2 and extending outward from the first surface 821. These lead portions 22a, 22a extend outward from the housing 80 approximately parallel to the X-axis direction.

[0120] A pair of second lead portions 32a, 32a extend from the side of the second winding 32 in the Y-axis direction of the terminal block mounting portion 82a_2. More specifically, one second lead portion 32a extends from one side of the terminal block mounting portion 82a_2 in the Y-axis direction, passing through the side of the terminal block mounting portion 82a_2 and extending outward to the outside of the third surface 823. The other second lead portion 32a extends from the other side of the terminal block mounting portion 82a_2 in the Y-axis direction, passing through the side of the terminal block mounting portion 82a_2 and extending outward to the outside of the third surface 823. These lead portions 32a, 32a extend outward to the outside of the housing 80 approximately parallel to the X-axis direction.

[0121] The first lead portions 22a, 22a and the second lead portions 32a, 32a preferably extend upwards from the upper end (upper edge) of the sidewall 82 and outwards from the outer side of the housing 80, forming a gap of a predetermined length between the first lead portions 22a, 22a and the second lead portions 32a, 32a and the upper end of the sidewall 82. As described later, in this embodiment, the terminals 71 to 74 are movably configured in the Z-axis direction, and the first lead portions 22a, 22a or the second lead portions 32a, 32a connected to the terminals 71 to 74 move in the Z-axis direction with this movement, but this is to prevent the first lead portions 22a, 22a or the second lead portions 32a, 32a from contacting the upper end of the sidewall 82. Preferably, the first lead portions 22a, 22a and the second lead portions 32a, 32a are positioned below the upper surface of the core 40 (base 41) disposed above it and above the upper end of the sidewall 82, facing outward from the housing 80.

[0122] A pair of first lead portions 22a, 22a are located on the side of the terminal block 50 in the Y-axis direction and are connected to a pair of terminal metal parts 71, 72 mounted on the terminal block 50. In addition, a pair of second lead portions 32a, 32a are located on the side of the terminal block 60 in the Y-axis direction and are connected to a pair of terminal metal parts 73, 74 mounted on the terminal block 60.

[0123] like Figure 2As shown, a soft-fitting protrusion 83a is formed in the terminal block mounting portion 82a-1, and a soft-fitting protrusion 83a is also formed in the terminal block mounting portion 82a-2. The soft-fitting protrusion 83a is used for mounting the terminal block 50 or 60 relative to the housing 80, and serves as a support for the terminal block 50 or 60. The terminal block 50 or 60 is mounted relative to the housing 80 by inserting the soft-fitting protrusion 83a into the soft-fitting recess 52a or 62a of the terminal block 50 or 60.

[0124] The engagement protrusion 83a has a main protrusion 83a1 and a pair of secondary protrusions 83a2, 83a2. The main protrusion 83a1 has a surface parallel to the XZ plane, protrudes outward from the first surface 821 of the sidewall 82 toward the X-axis direction, and has a predetermined length along the Z-axis direction. When the terminal block 50 or 60 is supported by the main protrusion 83a1 and the secondary protrusions 83a2, 83a2, the main protrusion 83a has the effect of, for example, reinforcing the support of the terminal block 50 or 60 provided by the secondary protrusions 83a2, 83a2. A portion of the main protrusion 83a is formed in the terminal block mounting portion 82a_1 or 82a_2, located above the upper end of the sidewall 82 (wherein, the portion where the terminal block mounting portion 82a_1 or 82a_2 is not formed).

[0125] A pair of secondary protrusions 83a2 and 83a2 each have a surface parallel to the XY plane, protruding outward from the first surface 821 of the sidewall 82 toward the X-axis, and having a predetermined length along the Y-axis. The protrusion length of the secondary protrusion 83a2 toward the X-axis is longer than that of the main protrusion 83a1 toward the X-axis. The secondary protrusions 83a2 and 83a2 are formed below the terminal block mounting portion 82a_1 or 82a_2.

[0126] A pair of secondary protrusions 83a2 and 83a1 are integrally connected to the main protrusion 83a1 at its lower end. One secondary protrusion 83a2 protrudes from one side of the main protrusion 83a1 in the Y-axis direction toward the other side, and the other secondary protrusion 83a2 protrudes from the other side of the main protrusion 83a1 in the Y-axis direction toward the other side.

[0127] Anti-detachment grooves 84 and 84 are formed on the bottom surfaces of the sub-protrusions 83a2 and 83a2, respectively. The anti-detachment grooves 84 and 84 have a predetermined width in the Y-axis direction and a predetermined length in the X-axis direction. Furthermore, the anti-detachment grooves 84 and 84 have a predetermined depth in the Z-axis direction extending from the bottom surface of the sub-protrusions 83a2 and 83a2. Details will be described later, but the stop protrusion of the terminal block 50 or 60 engages with the anti-detachment holes 84 and 84.

[0128] The position of the soft-fitting protrusion 83a is not limited to the position shown in the figure, and can be appropriately changed in the X-axis, Y-axis, and Z-axis directions. For example, when changing the Y-axis position of the soft-fitting protrusion 83a, it is preferable to change the Y-axis position of the terminal block mounting portions 82a_1 or 82a_2 accordingly. When changing the Z-axis position of the soft-fitting protrusion 83a, the main protrusion 83a1 is preferably configured to span across the terminal block mounting portions 82a_1 or 82a_2.

[0129] Terminal block 50 is mounted on side wall 82 at position 1 of terminal block mounting section 82a, and terminal block 60 is mounted on side wall 82 at position 2 of terminal block mounting section 82a. The mounting position of terminal block 50 relative to side wall 82 corresponds to the lead-out position of the first lead portion 22a, 22a of the first coil 20, and the mounting position of terminal block 60 relative to side wall 82 corresponds to the lead-out position of the second lead portion 32a, 32a of the second coil 30. Figure 1 ).

[0130] A pair of terminal metal parts 71 and 72 are installed on terminal block 50, and a pair of terminal metal parts 73 and 74 are installed on terminal block 60. For example... Figure 3 As shown, terminal block 50 includes a main body 51, a through hole 52, a terminal mounting part 53, a terminal groove 54, a fitting groove 55, and a mounting hole 56. Terminal block 60 includes a main body 61, a through hole 62, a terminal mounting part 63, a terminal groove 64, a fitting groove 65, and a mounting hole 66. Details of the above-mentioned parts constituting terminal blocks 50 and 60 will be described later. Hereinafter, the structure of the terminal metal parts 71 to 74 will be described.

[0131] Terminal metal parts (terminals) 71 to 74 are formed, for example, by stamping conductive sheet metal such as a metal plate. A pair of terminal metal parts 71 and 72 have shapes that are mutually symmetrical along the X-axis and Z-axis, and a pair of terminal metal parts 73 and 74 have shapes that are mutually symmetrical along the X-axis and Z-axis.

[0132] Terminal metal parts 71 and 72 each have a first lead portion 22a for clamping the first winding 22. Figure 1 The winding connection portions 71a and 72a are joined together. The winding connection portions 71a and 72a are formed to extend outward in the Y-axis direction from both ends of the terminal block 50. In addition, the terminal metal members 71 and 72 each have hook portions 71b and 72b formed at different positions than the winding connection portions 71a and 72a. The hook portions 71b and 72b are respectively movable in the Z-axis direction and can be inserted into the terminal slots 54 and 54 formed in the terminal block 50.

[0133] Hooks 71b and 72b are respectively formed to protrude downwards in the Z-axis direction from the Y-axis end of the planar mounting portions 71c and 72c, with the lower front end of hooks 71b and 72b shaped like hooks. Through holes 71d and 72d are respectively formed in the central portion of the mounting portions 71c and 72c. With the terminal metal parts 71 and 72 mounted on the terminal block 50, the positions of the through holes 71d and 72b and the nuts 57 and 57 (which are fitted into the mounting holes 56 and 56 of the terminal block 50) are... Figure 2 The bolt holes of 56 are roughly aligned. The inner diameter of mounting hole 56 can also be sufficiently larger than the inner diameter of bolt hole 57. Insertion holes 71d and 72d are used for mounting... Figure 1 The screws 104 and other fasteners shown can be used to position the terminal metal parts 71 and 72 and install them on the circuit board 100.

[0134] Mounting portions 71c and 72c and winding connection portions 71a and 72a are integrally connected via connecting portions 71e and 72e, respectively. Stepped bends are formed in the connecting portions 71e and 72e, and the height of the winding connection portions 71a and 72a in the Z-axis direction is configured to be lower than the plane of the mounting portions 71c and 72c. The width of the connecting portions 71e and 72e in the X-axis direction is narrower than the width of the mounting portions 71c and 72c in the X-axis direction.

[0135] Insertion protrusions 71f and 72f are formed at the ends of the mounting portions 71c and 72c located on opposite sides of the hook portions 71b and 72b in the Y-axis direction. The insertion protrusions 71f and 72f protrude downwards from the plane of the mounting portions 71c and 72c in the Z-axis direction. The insertion protrusions 71f and 72f are respectively inserted into the fitting grooves 55 and 55 formed on the upper surfaces of the two ends of the terminal block 50 in the Y-axis direction.

[0136] Terminal metal parts 73 and 74 have winding connection portions 73a and 74a, hook portions 73b and 74b, mounting portions 73c and 74c, through holes 73d and 74d, connecting portions 73e and 74e, and insertion protrusions 73f and 74f. The structure of terminal metal part 73 is the same as that of terminal metal part 71, and the structure of terminal metal part 74 is the same as that of terminal metal part 72. Therefore, the description of the structure of each corresponding part of terminal metal parts 71 and 72 is also directly applicable to the structure of each of the above-mentioned parts of terminal metal parts 73 and 74, and therefore, their description is omitted. Furthermore, the connection objects of the winding connection portions 73a and 74a are the second lead portions 32a and 32a of the second winding 32, and the mounting objects of terminal metal parts 73 and 74 are the terminal block 60.

[0137] Next, the structures of terminal blocks 50 and 60 will be described. Terminal blocks 50 and 60 have the same structure. Therefore, to avoid repetition, the descriptions of the components of terminal blocks 50 and 60 will sometimes be based on either terminal block 50 or terminal block 60 as an example.

[0138] As the material constituting the terminal blocks 50 and 60, a resin with good formability or good heat dissipation can be selected. Examples of such resins include PET, PBK, or PPS.

[0139] The terminal block 50 has a main body 51. A through hole 52 extending in the X-axis direction is formed in the main body 51. Terminal mounting portions 53, 53 are integrally formed on both sides of the main body 51 in the Y-axis direction. Hereinafter, the main body 51 will sometimes include the terminal mounting portions 53, 53. Mounting holes 56, 56 are formed approximately at the center of the upper surface of the terminal mounting portions 53, 53, respectively, through which nuts 57, 57 (…) can be fitted. Figure 2 ).

[0140] Terminal slots 54 are formed at the boundaries of terminal mounting portions 53 and 54 and the main body 51, respectively. Hooks 71b and 72b of terminal metal pieces 71 and 72 are movably inserted into each terminal slot 54 and 54 in the Z-axis direction. Each terminal slot 54 is formed between a pair of clamping portions 540 and 540 having a plate surface parallel to the XZ plane. Fitting grooves 55 and 55 are formed on the upper surface of the Y-axis ends of the terminal mounting portions 53 and 53, and insertion protrusions 71f and 72f of terminal metal pieces 71 and 72 are inserted into the fitting grooves 55 and 55. As a result, the movement of terminal metal pieces 71 and 72 relative to the terminal block 50 in the X and Y axes is restricted, allowing only movement of terminal metal pieces 71 and 72 relative to the terminal block 50 in the Z-axis direction.

[0141] A soft-fitting recess 52a is formed on the inner side of the through hole 52 formed in the main body 51 (the side facing the housing 40) into which the soft-fitting protrusion 83a of the housing 80 enters. Additionally, a mounting recess 52b is formed on the outer side of the through hole 52. A mounting recess 52b is installed in the mounting recess 52b. Figure 2 The inner cover 58 is shown.

[0142] The inner cover 58 is installed in the mounting recess 52b with the hooks 71b and 72b of the terminal metal parts 71 and 72 respectively inserted into the slots 54 and 54. As a result, the hook-shaped hooks 71b and 72b at the front ends of the terminal metal parts 71 and 72 engage with the inner cover 58, which can prevent the terminal metal parts 71 and 72 from being pulled out of the terminal block 50 and limit the range of Z-axis movement of the terminal metal parts 71 and 72 relative to the terminal block 50.

[0143] The gradually fitting recess 52a, which serves as an opening of the through hole 52, has a main recess 52a1 located at the center in the Y-axis direction and a pair of secondary recesses 52a2, 52a2 located on both sides in the Y-axis direction. The width of the secondary recesses 52a2 in the Z-axis direction is narrower than the width of the main recess 52a1 in the Z-axis direction.

[0144] Figure 2 The secondary protrusions 83a2 and 83a2 of the housing 80 shown can be freely fitted into the secondary recesses 52a2 and 52a2 in the X and Y axis directions. Figure 2 The main protrusion 83a1 shown is movable into the main recess 52a1 in the X and Y axis directions. The inner surface of the secondary recess 52a2, which is substantially parallel to the X and Y axes, becomes a guide surface (sliding surface) for the secondary protrusion 83a2. The terminal block 50 is held movable relative to the housing 80 in the X and Y axis directions along the guide surfaces that contact the secondary protrusion 83a2 and the secondary recess 52a2.

[0145] On the terminal block 60, a portion of the inner wall constituting the soft-fit recess 62a is formed by a support piece 62a3 of Z-axis width that is elastically deformable and capable of opening the entrance of the soft-fit recess 62a. A pair of stop protrusions 62a4, 62a4 are formed on the front end side of the support piece 62a3, and a pair of anti-disengagement holes 84, 84( ) are formed with the soft-fit protrusion 83a. Figure 2 The terminal block 62a3 is designed to be locked in place to prevent detachment. To allow the support plate 62a3 to elastically deform into a cantilever beam shape, slits are formed on both sides of the support plate 62a3 along the Y-axis. Furthermore, the locking mechanism of a pair of stop protrusions 62a4, 62a4 and a pair of anti-detachment holes 84, 84 secures the terminal block 60 relative to the housing 80, while allowing free sliding movement of the terminal block 60 relative to the housing 80 along the X and Y axes.

[0146] also, Figure 3 In the diagram of terminal block 50, the support piece and the stop protrusion are omitted, but these structures on terminal block 50 are the same as the structures of support piece 62a3 and stop protrusions 62a4 and 62a4 on terminal block 60.

[0147] In this embodiment, the terminal blocks 50 and 60 are configured to move freely in both the X-axis and Y-axis directions of the housing 80. Hereinafter, reference will be made to... Figures 2-4 The detailed structure of the terminal blocks 50 and 60 that make them possible is described below.

[0148] like Figure 2 and Figure 3As shown, in this embodiment, the width of the main protrusion 83a1 of the gradual engagement protrusion 83a in the Y-axis direction is smaller than the width of the main recess 52a1 of the gradual engagement recess 52a in the Y-axis direction. Therefore, when the gradual engagement recess 52a and the gradual engagement protrusion 83a are engaged, a gap is formed between the main protrusion 83a1 and the main recess 52a1. Figure 4 The gap G1 is shown. More specifically, with the main protrusion 83a1 disposed at the center of the main recess 52a1 in the Y-axis direction, the gap G1 is formed between the side surface of the main protrusion 83a1 in the Y-axis direction and the inner wall of the main recess 52a1 in the Y-axis direction, and is also formed between the side surface of the main protrusion 83a1 in the Y-axis direction and the inner wall of the main recess 52a1 in the Y-axis direction.

[0149] Furthermore, in this embodiment, the Y-axis width (length from the Y-axis end of one secondary protrusion 83a2 to the Y-axis end of the other secondary protrusion 83a2) of the soft-fit protrusion 83a is smaller than the Y-axis width (length from the Y-axis end of one secondary protrusion 83a2 to the Y-axis end of the other secondary protrusion 83a2) of the soft-fit recess 52a. Therefore, when the soft-fit recess 52a and the soft-fit protrusion 83a are engaged, a gap is formed between the secondary protrusion 83a2 and the secondary recess 52a2. Figure 5 The gap G2 is shown. More specifically, the gap G2 is formed between the inner walls of the sub-protrusion 82a2 on one side of the Y-axis direction and the sub-recess 52a2 on the other side of the Y-axis direction, and is also formed between the inner walls of the sub-protrusion 82a2 on the other side of the Y-axis direction and the sub-recess 52a2 on the other side of the Y-axis direction.

[0150] Therefore, the main protrusion 83a1 can move freely axially within the gap G1 inside the main recess 52a1. Additionally, the secondary protrusion 83a2 can move freely along the Y-axis within the gap G2 inside the secondary recess 52a2. This structure is also provided on the terminal block 60, and the terminal blocks 50 and 60 can move freely in the Y-axis direction of the housing 80.

[0151] Furthermore, as described above, the stop protrusions 62a4, 62a4 of the terminal block 60 and the anti-detachment grooves 84, 84 formed on the bottom surfaces of the sub-protrusions 83a2, 83a2 Figure 2The stop protrusions 62a4 and 62a4 are engaged, but in this engaged state, they can move freely in the X-axis direction within the anti-disengagement grooves 84 and 84. That is, the X-axis width of the stop protrusions 62a4 and 62a4 is smaller than the X-axis width of the anti-disengagement grooves 84 and 84. When they are engaged, a gap is formed in the X-axis direction between the stop protrusions 62a4 and 62a4 and the inner walls of the anti-disengagement grooves 84 and 84. Therefore, the stop protrusions 62a4 and 62a4 can move freely in the X-axis direction within the anti-disengagement grooves 84 and 84, within the range of this gap, enabling the terminal blocks 50 and 60 to move freely in the X-axis direction toward the housing 80.

[0152] As described above, in this embodiment, the terminal blocks 50 and 60 are freely movable in both the X-axis and Y-axis directions of the housing 80. Furthermore, when the stop protrusions 62a4 and 62a4 and the anti-disengagement grooves 84 and 84 are engaged, a gap is also formed between the inner walls of the stop protrusions 62a4 and 62a4 and the anti-disengagement grooves 84 and 84 in the Y-axis direction. The stop protrusions 62a4 and 62a4 (terminal blocks 60) are inside the anti-disengagement grooves 84 and 84, and within the range of this gap, they are also freely movable in the Y-axis direction of the housing 80.

[0153] Figure 5 In this context, the widths of gaps G1 and G2 in the Y-axis direction can be different or the same. The widths of gaps G1 and G2 in the Y-axis direction can be appropriately determined based on the predetermined amount of movement of the terminal metal parts 71-74 relative to the housing 80 in the Y-axis direction. The gaps formed between the inner walls of the stop protrusions 62a4, 62a4 and the anti-detachment grooves 84, 84 in the X-axis direction are also the same, and can be appropriately determined based on the predetermined amount of movement of the terminal metal parts 71-74 relative to the housing 80 in the X-axis direction.

[0154] Next, refer to Figures 1-3 The manufacturing method of the coil device 10 will be explained. First, prepare... Figure 2 The components shown are then installed. Next, terminal blocks 50 and 60 are installed onto the housing 80. The terminal block 50 is installed onto the housing 80 by engaging the soft-fit recesses 52a (main recesses 52a1 and secondary recesses 52a2) of the terminal block 50 with the soft-fit protrusions 83a (main protrusions 83a1 and secondary protrusions 83a2) of the housing 80. The same procedure is performed when installing the terminal block 60 onto the housing 80. With the soft-fit protrusions 83a and 62a2 engaged, the stop protrusions 62a4 and 62a4 (…) are… Figure 3 ) and anti-detachment groove 84, 84 ( Figure 2 ) card.

[0155] Next, terminal metal parts 71 and 72 are installed on terminal block 50, and terminal metal parts 73 and 74 are installed on terminal block 60. By... Figure 3The hooks 71b and 72b shown are inserted into the terminal slots 54 and 54, and the insertion protrusions 71f and 72f are inserted into the fitting slots 55 and 55 to install the terminal metal parts 71 and 72 onto the terminal block 50. The same procedure is performed when installing the terminal metal parts 73 and 74 onto the terminal block 60. Alternatively, the terminal metal parts 71 to 74 can be installed onto the terminal blocks 50 and 60 before they are installed onto the housing 80.

[0156] After installing the terminal metal parts 71 and 72 onto the terminal block 50, install the inner cover 58 ( Figure 2 The inner cover 68 is installed in the mounting recess 52b. After the terminal metal parts 73 and 74 are installed on the terminal block 60, the inner cover 68 is installed in the mounting recess 62b. By installing the inner covers 58 and 68, the terminal metal parts 71 to 74 can be prevented from detaching relative to the terminal blocks 50 and 60. Furthermore, the movement of the terminal metal parts 71 to 74 relative to the terminal blocks 50 and 60 in the Z-axis direction can also be restricted.

[0157] Next, as Figure 2 As shown, in one pair of outer legs 42, 42 (winding portions 43, 43) of a core 40, a first coil 20 is disposed on one outer leg 42, and a second coil 30 is disposed on the other outer leg 42. In this embodiment, an air-core coil is used as the first coil 20 and the second coil 30.

[0158] Next, the other core 40 is combined with the coils 20 and 30 in the winding section 43 and 43. More specifically, by combining the front ends of the outer legs 42 and 42 of the one core 40 with the front ends of the outer legs 42 and 42 of the other core 40, the one core 40 and the other core 40 can be combined vertically while the first coil 20 and the second coil 30 are in place.

[0159] Alternatively, instead of arranging coils 20 and 30 (air coils) on the outer feet 42, 42 (winding portions 43, 43) of each of the two cores 40, coils 20 and 30 can be formed by winding the wires 22 and 32 around the respective winding portions 43, 43 while one core 40 and the other core 40 are combined.

[0160] Next, the assembly of the two cores 40, including coils 20 and 30, is housed inside the housing 80. At this time, the first lead portions 22a, 22a of the first winding 22 are led out from the outside of the side wall 82 of the housing 80 in the Y-axis direction of the terminal block mounting portion 82a-1. In addition, the second lead portions 32a, 32a of the second winding 32 are led out from the outside of the side wall 82 of the housing 80 in the Y-axis direction of the terminal block mounting portion 82a-2.

[0161] Next, a first lead portion 22a is connected to the winding connection portion 71a of the terminal metal member 71, and another first lead portion 22a is connected to the winding connection portion 72a of the terminal metal member 72. Additionally, a second lead portion 32a is connected to the winding connection portion 73a of the terminal metal member 73, and another second lead portion 32a is connected to the winding connection portion 74a of the terminal metal member 74. The method for connecting the lead portions 22a, 22a and the lead portions 32a, 32a to the winding connection portions 71a to 74a is not particularly limited, and examples include welding, fusion welding, resistance welding, ultrasonic welding, laser welding, riveting, thermoforming, and thermal fusion welding.

[0162] Alternatively, a pair of lead wires 22a and 22a may be pre-connected to the winding connection portions 71a and 72a of the terminal metal parts 71 and 72, respectively. Similarly, a pair of lead wires 32a and 32a may be pre-connected to the winding connection portions 73a and 74a of the terminal metal parts 73 and 74, respectively.

[0163] Next, resin 90 is filled inside the housing 80. The filling of resin 90 is preferably performed after the core 40 or the like is housed inside the housing 80, but it can also be performed before the core 40 or the like is housed inside the housing 80. By performing the above steps, the coil device 10 can be obtained.

[0164] like Figure 1 As shown, the coil device 10 of this embodiment includes a core 40 having a winding portion 43 on the outer periphery where a first coil 20 or a second coil 30 is arranged. That is, unlike the prior art, the coil device 10 does not employ a structure where the coils 20 and 30 are arranged on a frame, but has a so-called frameless structure. Therefore, this structure is simple and can achieve miniaturization of the overall shape. Furthermore, by being frameless, sufficient space can be ensured for arranging the coils 20 and 30, and good characteristics can be obtained by increasing the number of turns of the coils 20 and 30, or by thickening the wire diameter of the windings 22 and 32 constituting the coils 20 and 30.

[0165] Furthermore, in the coil device 10 of this embodiment, the terminal blocks 50 and 60 are freely movable in both the X-axis and Y-axis directions of the housing 80. Therefore, after the circuit board 100 and the coil device 10 are roughly positioned, by simply moving the terminal blocks 50 and 60 relative to the housing 80 in the X-axis and / or Y-axis directions, the terminal metal parts 71 to 74 mounted on the terminal blocks 50 and 60 will move relative to the housing 80 in the same direction, thereby enabling the terminal metal parts 71 to 74 and the circuit board 100 to be correctly positioned and connected.

[0166] Furthermore, when the terminal metal parts 71 to 74 move, the ends (lead portions 22a and 32a) of the coils 20 and 30 connected to the terminal metal parts 71 to 74 also move in a following manner. However, in the frameless structure, the undesirable situation of the movement of the lead portions 22a and 32a being hindered by the frame does not occur, and the movable area of ​​the lead portions 22a and 32a can be fully ensured. Therefore, the movable area of ​​the terminal metal parts 71 to 74 is also fully ensured, and the degree of freedom of positioning of the terminals 71 to 74 is ensured at an extremely high level, enabling accurate and easy positioning of the terminal metal parts 71 to 74 and the circuit board 100.

[0167] Furthermore, in the structure where terminal blocks 50 and 60 are mounted on the housing 80, the mounting positions of terminal blocks 50 and 60 relative to the housing 80 (positions of terminal block mounting parts 82a_1 and 82a_2) can be easily changed, increasing the user's design freedom.

[0168] Furthermore, in the coil device 10 of this embodiment, as described above, during the connection stage with the circuit board 100, the connection position or mounting position (mounting hole 102) of the terminal metal parts 71 to 74 relative to the circuit board 100 can be positioned with high precision. Therefore, during this manufacturing stage, it is not necessary to manufacture and assemble each component with high precision as in the prior art in order to correctly align the connection position of the terminal metal parts 71 to 74 relative to the circuit board 100, which helps to simplify manufacturing and reduce manufacturing costs.

[0169] Furthermore, the interior of the housing 80 is filled with resin (filled resin) 90. Therefore, heat generated by the coils 20 and 30 can be transferred to the housing 80 via the resin 90, improving the heat dissipation performance of the coil device 10. Additionally, since the housing 80 is frameless, the flow of the resin 90 within the housing 80 is not hindered by the frame, allowing the resin 90 to be wound into all corners of the housing 80. Therefore, a high resin 90 filling rate is ensured, improving the heat dissipation performance of the coil device 10 and facilitating miniaturization. Furthermore, with improved heat dissipation performance, a coil device 10 suitable for high-current applications can be realized.

[0170] Furthermore, the terminal metal parts 71 to 74 are freely movable in the Z-axis direction of the housing 80 and mounted on the terminal blocks 50 and 60. Therefore, the mounting positions of the terminal metal parts 71 to 74 and the circuit board 100 can be easily adjusted in the Z-axis direction.

[0171] Furthermore, at least a portion of the terminal blocks 50 and 60 are disposed in the terminal block mounting portions 82a1_1 and 82a_2, and the lead portions 22a and 32a extend outward from the side of the terminal block mounting portions 82a1_1 and 82a_2. By disposing at least a portion of the terminal blocks 50 and 60 in the terminal block mounting portions 82a1_1 and 82a_2, the height position of the terminal blocks 50 and 60 can be moved upward toward the housing 80.

[0172] Furthermore, by shifting the height of the terminal blocks 50 and 60 upward toward the housing 80, when the lead wires 22a and 32a are led out toward the outside of the housing 80 through the side of the terminal block mounting portions 82a1-1 and 82a-2, the lead wire positions of the lead wires 22a and 32a can be aligned with the positions of the terminal metal pieces 71-74 mounted on the terminal blocks 50 and 60, making it easy to connect the lead wires 22a and 32a to the terminal metal pieces 71-74.

[0173] Additionally, the first coil 20 and the second coil 30 are located inside the housing 80, at the bottom surface 81 of the housing 80. Figure 2 The coils are arranged side-by-side in a parallel direction (Y-axis direction). Therefore, compared to the case where the first coil 20 and the second coil 30 are arranged overlapping in the Z-axis direction, the coil device 10 can be made thinner.

[0174] Second Implementation Method

[0175] Figures 6-8 The coil device 10A of the second embodiment shown has the same structure as the coil device 10 of the first embodiment, except for the points shown below, and performs the same function. In the drawings, the same symbols are used to mark the components that are common to the components in the coil device 10 of the first embodiment, and some of their descriptions are omitted.

[0176] like Figure 7 As shown, the coil assembly 10A has four cores 40A and a housing 80A. The cores 40A are so-called E-shaped cores, roughly E-shaped, and have a pair of outer legs 42, 42 and a middle leg 44. The middle leg 44 protrudes from the middle position of the base 41 in the Y-axis direction towards the Z-axis direction. The four cores 40A are configured to be assembled in both the X-axis and Z-axis directions. The four cores 40A can be assembled in the Z-axis direction by abutting the front ends of the middle legs 44, 44 and the front ends of the outer legs 42, 42 of the vertically arranged cores 40A together. Furthermore, there may be a gap between the front ends of the middle legs 44, 44.

[0177] In this embodiment, when the four cores 40A are combined, the first coil 20 and the second coil 30 are arranged vertically or wound around the center leg 44 of each core 40A connected in the Z-axis direction. That is, the center leg 44 of each core 40A becomes a winding portion 43 for arranging or winding the coils 20 and 30.

[0178] like Figure 8 As shown, the first coil 20 and the second coil 30 are arranged at predetermined intervals in the Z-axis direction around the center feet 44 of each core 40A. In the illustrated example, among the four cores 40A, the first coil 20 is arranged around the center feet 44, 44 of the two upper cores 40A, and the second coil 30 is arranged around the center feet 44, 44 of the two lower cores 40A. However, the positions of the coils 20 and 30 are not limited to the illustrated example and can be appropriately varied. For example, the second coil 30 can also be placed on the base 41 of the two lower cores 40A.

[0179] Four cores 40A are disposed inside the housing 80A with the first coil 20 and the second coil 30 arranged in the respective winding portions 43. The first coil 20 and the second coil 30 are housed inside the housing 80A and are completely covered by resin 90 filling the interior of the housing 80A. In addition, the two cores 40A disposed at the top partially protrude from above the resin 90.

[0180] like Figure 7 As shown, the housing 80A differs from the housing 80 of the first embodiment in that the terminal block mounting portions 82a_1 and 82a_2 are formed on the second surface 822 and the fourth surface 824 of the side wall 82. The terminal block mounting portions 82a_1 and 82a_2 are arranged opposite to each other in the X-axis direction, as shown... Figure 6 As shown, the terminal blocks 50 and 60 located at these positions are also arranged relative to each other in the X-axis direction.

[0181] A pair of first lead portions 22a, 22a of the first winding 22 extend from one side of the housing 80 in the X-axis direction and connect to the winding connection portions 71a, 72a of the terminal metal parts 71, 72 mounted on the terminal block 50. A pair of second lead portions 32a, 32a of the second winding 32 extend from the other side of the housing 80 in the X-axis direction and connect to the winding connection portions 73a, 74a of the terminal metal parts 73, 74 mounted on the terminal block 60.

[0182] In this embodiment, the terminal blocks 50 and 60 can also move freely in both the X-axis and Y-axis directions of the housing 80, achieving the same effect as in the first embodiment. Furthermore, in this embodiment, because the first coil 20 and the second coil 30 are arranged vertically, the width of the coil device 10A in the X-axis direction can be reduced compared to the coil device 10 in the first embodiment, thus enabling miniaturization of the coil device 10A.

[0183] Third Implementation Method

[0184] Figure 9 and Figure 10 The coil device 10B of the third embodiment shown has the same structure and performs the same function as the coil device 10A of the second embodiment, except for the points shown below. In the drawings, components common to the components in the coil device 10A of the second embodiment are labeled with the same symbols, and some of their descriptions are omitted. In addition, various components housed inside the housing 80B are not shown in the drawings.

[0185] like Figure 9 As shown, the coil device 10B has a housing 80B. The housing 80B differs from the housing 80A of the second embodiment in that it includes terminal blocks 50B and 60B. That is, in the second embodiment, the terminal blocks 50 and 60 are separately formed from the housing 80A, while in this embodiment, the terminal blocks 50B and 60B are integrally formed with the housing 80B. As shown below, in this embodiment, instead of fixing the terminal blocks 50B and 60B, the terminal metal parts 71 to 74 mounted on the terminal blocks 50B and 60B are freely movable in the X-axis, Y-axis, and Z-axis directions.

[0186] Terminal block 50B is formed on one side of the side wall 82 in the X-axis direction (second surface 822), and terminal block 60B is formed on the other side of the side wall 82 in the X-axis direction (fourth surface 824). In the example shown, terminal blocks 50B and 60B are formed at the upper end of the side wall 82, but the formation position (height) of terminal blocks 50B and 60B can also be changed appropriately.

[0187] Terminal blocks 50B and 60B protrude outwards along the X-axis with a predetermined length and have a predetermined width along the Y-axis. Terminal block 50B has a main body 51B, terminal mounting portions 53, 53, terminal slots 54B, 54B, fitting slots 55B, 55B, and mounting holes 56, 56, but does not have a structure equivalent to a through hole 52. Similarly, terminal block 60B has a main body 61B, terminal mounting portions 63, 63, terminal slots 64B, 64B, fitting slots 65B, 65B, and mounting holes 66, 66, but does not have a structure equivalent to a through hole 62. Because terminal blocks 50B and 60B have the same structure, only the structure of terminal block 50B will be described below to avoid repetition.

[0188] In addition, the portion of the hook portion 71b to 74b of the terminal metal parts 71 to 74 that extends downward in the Z-axis direction and narrows in the X-axis direction is referred to as the narrow portion 71b1 to 74b1, and the portion that extends outward in the X-axis direction and widens in the X-axis direction is referred to as the wide portion 71b2 to 74b2.

[0189] Terminal slots 54B, 54B and terminal slots 54, 54 (in the first embodiment) Figure 3 Unlike the terminal slots 54B and 54B in the first embodiment, these slots are enclosed (surrounded) by the inner wall in both the X-axis and Y-axis directions. Figure 3 Compared to the previous method, the width of the slots in the X and Y axes is increased. The X-axis width of the terminal slots 54B and 54B is larger than the X-axis width of the hook portions 71b and 72b (narrow portions 71b1 and 72b1) of the terminal metal parts 71 and 72, and the Y-axis width of the terminal slots 54B and 54B is larger than the Y-axis width (plate thickness of terminal metal parts 71 and 72) of the hook portions 71b and 72b (narrow portions 71b1 and 72b1) of the terminal metal parts 71 and 72. Therefore, when the hook portions 71b and 72b are inserted into the terminal slots 54B and 54B, as... Figure 10 As shown, a gap G3 is formed between the inner walls of the hook portions 71b and 72b and the terminal slots 54B and 54B.

[0190] In addition, the fitting grooves 55B, 55B and the fitting grooves 55, 55( of the first embodiment) Figure 3 Compared to the previous method, the width of the grooves formed in both the X and Y axes becomes larger. For example... Figure 9As shown, the X-axis width of the fitting grooves 55B and 55B is larger than the X-axis width of the insertion protrusions 71f and 72f of the terminal metal parts 71 and 72, and the Y-axis width of the fitting grooves 55B and 55B is larger than the Y-axis width (plate thickness of the terminal metal parts 71 and 72) of the insertion protrusions 71f and 72f of the terminal metal parts 71 and 72. Therefore, when the insertion protrusions 71f and 72f are inserted into the fitting grooves 55B and 55B, as... Figure 10 As shown, a gap G4 is formed between the inner walls of the insertion protrusions 71f and 72f and the fitting grooves 55B and 55B.

[0191] Inside the terminal slots 54B, 54B, the hooks 71b, 72b can move freely in both the X-axis and Y-axis directions within the gap G3. Furthermore, inside the fitting slots 55B, 55B, the insertion protrusions 71f, 72f can move freely in both the X-axis and Y-axis directions within the gap G4. As a result, in this embodiment, the terminal metal members 71, 72 can move freely in both the X-axis and Y-axis directions of the housing 80B. Additionally, similar to the first embodiment, the terminal metal members 71, 72 can also move freely in the Z-axis direction of the housing 80B.

[0192] Furthermore, the width of the wide portions 71b2 and 72b2 of the hook portions 71b and 72b in the X-axis direction is larger than the width of the terminal slots 54B and 54B in the X-axis direction, thereby preventing the hook portions 71b and 72b from being pulled out of the terminal slots 54B and 54B. A portion of the wide portions 71b2 and 72b2 is disposed inside a slot (not shown) formed inside the terminal block 50B, allowing the interior of the slot to move freely along the XYZ axes. In addition, the anti-disengagement mechanism of the terminal metal parts 71 and 72 relative to the terminal block 50B can be provided on the insertion protrusions 71f and 72f, or it can be provided on both the hook portions 71b and 72b and the insertion protrusions 71f and 72f.

[0193] In the illustrated example, the widths of gaps G3 and G4 in the X-axis direction are the same, but they can also be different. Similarly, the widths of gaps G3 and G4 in the Y-axis direction are the same, but they can also be different. The widths of gaps G3 and G4 in the X-axis and Y-axis directions can be appropriately determined based on the predetermined amounts of movement of the terminal metal parts 71 and 72 relative to the housing 80B in the X-axis and Y-axis directions, respectively.

[0194] The structure described above is also provided in the terminal block 60B. Inside the terminal slots 64B and 64B, the hooks 73b and 74b can move freely in both the X-axis and Y-axis directions within the gap G3. Furthermore, inside the fitting slots 65B and 65B, the insertion protrusions 73f and 74f can move freely in both the X-axis and Y-axis directions within the gap G4. As a result, in this embodiment, the terminal metal members 73 and 74 can also move freely in both the X-axis and Y-axis directions of the housing 80B. Additionally, similar to the first embodiment, the terminal metal members 73 and 74 can also move freely in the Z-axis direction of the housing 80B.

[0195] This embodiment also achieves the same effects as the second embodiment. Specifically, in this embodiment, the terminal blocks 50B and 60B are integrally formed with the housing 80B; therefore, they do not move relative to the housing 80B in the X-axis and Y-axis directions, but the terminal metal parts 71-74 themselves can move freely relative to the housing 80B in the X-axis and Y-axis directions. Therefore, when... Figure 1 After the circuit board 100 and other substrates and the coil device 10B are roughly positioned, the insertion holes 71d to 74 of the terminal metal parts 71 to 74 and the mounting holes 102 of the circuit board 100 can be correctly positioned by simply moving the terminal metal parts 71 to 74 relative to the housing 80B. Therefore, the circuit pattern of the circuit board 100 and each terminal metal part 71 to 74 can be easily and correctly positioned and connected using fasteners such as screws 104.

[0196] Fourth Implementation Method

[0197] Figures 11 to 13B The coil device 10C of the fourth embodiment shown has the same structure as the coil device 10A of the second embodiment, except for the points shown below, and performs the same function. In the drawings, the same symbols are used to mark the components that are common to the components in the coil device 10A of the second embodiment, and some of their descriptions are omitted.

[0198] like Figure 11 As shown, the coil device 10C includes a housing 80C and terminal blocks 50C and 60C. The housing 80C differs from the housing 80A of the second embodiment in that it has a soft-fitting protrusion 83aC. The soft-fitting protrusion 83aC has a convex shape formed by a generally prismatic shape, protruding outward from the terminal block mounting portions 82a-1 and 82a-2 in the X-axis direction. The soft-fitting protrusion 83aC of this embodiment differs from the soft-fitting protrusion 83a of the second embodiment in that it is not composed of two parts, a main protrusion 83a1 and a secondary protrusion 83a2, but rather is composed of a single protrusion.

[0199] Terminal metal parts 71 to 74 are pressed into or inserted into terminal blocks 50C and 60C. The hook portions 71b to 74b and the insertion protrusions 71f to 74f of the terminal metal parts 71 to 74 are embedded in the interior of the terminal blocks 50C and 60C, and the terminal metal parts 71 to 74 are integrated with the terminal blocks 50C and 60C.

[0200] Terminal blocks 50C and 60C differ from terminal blocks 50 and 60 of the second embodiment in that they have through holes 52C and 62C with soft-fit recesses 52aC and 62aC. Figure 12 As shown, the width of the recessed portion 52aC in the Y-axis direction is larger than the width of the protruding portion 83aC in the Y-axis direction. Furthermore, the width of the recessed portion 52aC in the Z-axis direction is larger than the width of the protruding portion 83aC in the Z-axis direction. Therefore, when the protruding portion 83aC is installed in the recessed portion 52aC, a gap G5 is formed between the inner walls of the protruding portion 83aC and the recessed portion 52aC, surrounding the protruding portion 83aC. Thus, inside the recessed portion 52aC, the protruding portion 83aC is movably inserted within the gap G5 in both the Y-axis and Z-axis directions, allowing the terminal block 50C to move freely within the housing 80C in both the Y-axis and Z-axis directions. This is also the case in the terminal block 60C.

[0201] In addition, detailed illustrations are omitted, but similar to the first embodiment, a single anti-detachment groove is formed on the bottom surface of the soft-fitting protrusion 83aC (see reference). Figure 2 (Anti-detachment groove 84), Figure 11 The stop protrusion 62a4 of the terminal block 60 shown engages with the anti-disengagement groove. The width of the anti-disengagement groove in the X-axis direction is larger than the width of the stop protrusion 62a4 in the X-axis direction. When they are engaged, a gap is formed between the inner wall of the anti-disengagement groove and the stop protrusion 62a4 in the X-axis direction. Therefore, when the stop protrusion 62a4 is engaged with the anti-disengagement groove, the stop protrusion 62a4 (terminal block 60) can move freely in the X-axis direction of the housing 80C within this gap. This is also the case in the terminal block 50C.

[0202] In addition, Figure 12 In the example shown, the soft-fitting protrusion 83aC is fixed in a floating state without contacting its inner wall in the internal space of the soft-fitting recess 52aC, but the soft-fitting protrusion 83aC can also be fixed in a state of contact with the inner wall (upper inner wall or lower inner wall) of the soft-fitting recess 52aC.

[0203] In this embodiment, the same effect as in the second embodiment can be obtained. Specifically, in this embodiment, the terminal blocks 50C and 60C are freely movable in the Z-axis direction of the housing 80C. Therefore, when the terminal blocks 50C and 60C are moved relative to the housing 80C in the Z-axis direction, the terminal metal parts 71-74 mounted on the terminal blocks 50C and 60C move in the same direction, enabling the terminal metal parts 71-74 (through holes 71d-74d) and... Figure 1 The connection position (mounting hole 102) of the circuit board 100 shown can be freely adjusted in the Z-axis direction. Therefore, the terminal metal parts 71 to 74 and the circuit board 100 can be correctly positioned and connected in the Z-axis direction.

[0204] Furthermore, in this embodiment, the terminal metal parts 71 to 74 are integrally formed with the terminal blocks 50C and 60C. Therefore, after the terminal blocks 50C and 60C are formed, the process of embedding the terminal metal parts 71 to 74 into the terminal blocks 50C and 60C can be omitted, making the manufacture of the coil device 10C easier.

[0205] In addition, Figure 11 In the example shown, the soft-fitting protrusion 83aC protrudes outward in the X-axis direction, but the protrusion direction of the soft-fitting protrusion 83aC is not limited to this and can be appropriately changed. For example, in Figure 13A The housing 80C' shown has a soft-fitting protrusion 83aC' that protrudes outward in the Z-axis direction. The soft-fitting protrusion 83aC' and the terminal block mounting portion 82a_1 or 82a_2 are connected by an extension portion 82a1, and the soft-fitting protrusion 83aC' extends from the upper surface of the extension portion 82a1 along the Z-axis direction. When the soft-fitting protrusion 83aC' is inserted into the soft-fitting recess 52aC of the terminal block 50C, the terminal block 50C can be mounted on the extension portion 82a1.

[0206] Detailed illustrations are omitted, but a soft-fit recess 52aC (62aC) extending in the Z-axis direction is formed on the terminal block 50C (60C). By inserting the soft-fit protrusion 83aC' into the interior of the soft-fit recess 52aC (62aC), the terminal block 50C (60C) can be freely mounted to the housing 80C' along the Z-axis direction. In addition, by making the width of the soft-fit recess 52aC (62aC) in the X-axis direction and the width in the Y-axis direction larger than the width of the soft-fit protrusion 83aC' in the X-axis direction and the Y-axis direction, the terminal block 50C (60C) can be freely mounted to the housing 80C' in both the X-axis direction and the Y-axis direction.

[0207] In addition, Figure 13BThe housing 80C shown has a soft-fitting protrusion 83aC protruding outward in the Y-axis direction. The soft-fitting protrusion 83aC has a portion extending a predetermined length in the X-axis direction and a portion extending in a direction substantially perpendicular to that portion.

[0208] Detailed illustrations are omitted, but a soft-fit recess 52a (62a) extending in the Y-axis direction is formed on the terminal block 50C (60C). By inserting the soft-fit protrusion 83aC” into the interior of the soft-fit recess 52a (62a), the terminal block 50C (60C) can be freely mounted to the housing 80C along the Y-axis direction. In addition, by making the width of the soft-fit recess 52a (62a) in the X-axis direction and the width in the Z-axis direction larger than the width of the soft-fit protrusion 83aC” in the X-axis direction and the Z-axis direction, the terminal block 50C (60C) can be freely mounted to the housing 80C in both the X-axis direction and the Z-axis direction.

[0209] Fifth Implementation Method

[0210] Figure 14 and Figure 15 The coil device 10D of the fifth embodiment shown has the same structure as the coil device 10C of the fourth embodiment, except for the points shown below, and performs the same function. In the drawings, the same symbols are used to mark the components that are common to the components in the coil device 10C of the fourth embodiment, and some of their descriptions are omitted.

[0211] like Figure 14 As shown, the coil device 10D has a housing 80D and a stop wall portion 90. In the coil device 10D of this embodiment, the stop wall portion 90 prevents the terminal blocks 50C and 60C from detaching from the housing 80D.

[0212] The housing 80D differs from the housing 80C of the fourth embodiment in that it has a soft-fitting protrusion 83aD. An insertion hole 85 is formed inside the soft-fitting protrusion 83aD. The insertion hole 85 extends along the long side direction (X-axis direction) of the soft-fitting protrusion 83aD, and the length of the insertion hole 85 in the X-axis direction is longer than the length of the fitting portion 92 of the stop wall portion 90 described below. The fitting portion 92 of the stop wall portion 90 can be inserted into the insertion hole 85.

[0213] The stop wall portion 90 is installed inside the soft-fit protrusion 83aD that enters the soft-fit recess 52C, and functions as an anti-dislodgement part for the terminal block 50C relative to the housing 80D. The stop wall portion 90 has a wall portion 91 and a fitting portion 92. The wall portion 91 has a generally flat shape, and the area of ​​each surface of the wall portion 91 in the X-axis direction is larger than the opening area of ​​the mounting recess 52b of the soft-fit recess 52aD.

[0214] The fitting portion 92 is formed on the inner surface of the wall portion 91 in the X-axis direction and protrudes inward in the X-axis direction. The fitting portion 92 has a solid shape and is inserted into the interior of the insertion hole 85 when the soft fitting protrusion 83aD is disposed inside the soft fitting recess 52aC, and fits with the soft fitting protrusion 83aD.

[0215] With the engaging portion 92 engaged with the soft-fitting protrusion 83aD, the terminal block 50C is configured to be held between the terminal block mounting portion 82a_1 and the wall portion 91. The terminal block 50C can move freely in the X-axis direction within the area between the terminal block mounting portion 82a_1 and the wall portion 91. When the terminal block 50C moves a predetermined amount outward in the X-axis direction, the periphery of the mounting recess 52b of the terminal block 50C contacts the wall portion 91, preventing the terminal block 50C from moving further outward in the X-axis direction than this contact position. Therefore, the wall portion 91 prevents the terminal block 50C from being pulled outward relative to the housing 80D in the X-axis direction.

[0216] In this embodiment, the same effect as in the fourth embodiment can also be obtained. Furthermore, in this embodiment, by engaging the fitting portion 92 with the soft-fitting protrusion 83aD (through hole 85), the terminal blocks 50C and 60C can be prevented from detaching from the housing 80D by the stop wall portion 90 while the soft-fitting protrusion 83aD is freely movable relative to the soft-fitting recess 52aC in the X-axis, Y-axis, and Z-axis directions.

[0217] Alternatively, the stop wall portion 90 and the buffer engagement protrusion 83aD can be connected with resin (e.g., a paste-like filler or adhesive) instead of being connected via the engagement portion 92. In this case, the shape of the stop wall portion 90 is not particularly limited as long as it can be installed via resin into the interior of the buffer engagement protrusion 83aD, which enters the buffer engagement recess 52aC. By connecting the stop wall portion 90 and the buffer engagement protrusion 83aD with resin, the terminal blocks 50C and 60C can be prevented from detaching from the housing 80D while the buffer engagement protrusion 83aD is freely movable relative to the buffer engagement recess 52aC in the X-axis, Y-axis, and Z-axis directions.

[0218] Sixth Implementation Method

[0219] Figure 16 and Figure 17 The coil device 10E of the sixth embodiment shown has the same structure as the coil device 10C of the fourth embodiment, except for the points shown below, and performs the same function. In the drawings, the same symbols are used to mark the components that are common to the components in the coil device 10C of the fourth embodiment, and some of their descriptions are omitted.

[0220] like Figure 16 As shown, the coil device 10E includes a housing 80E, terminal blocks 50E, 50E, and terminal blocks 60E, 60E. In this embodiment, each of the four terminal metal pieces 71 to 74 is mounted relative to each of the four terminal blocks 50E, 50E, 60E, 60E, and each terminal metal piece has a terminal block.

[0221] The housing 80E differs from the housing 80C of the fourth embodiment in that it has two soft-fitting protrusions 83aC, 83aC formed in the terminal block mounting portion 82a-1 and two soft-fitting protrusions 83aC, 83aC formed in the terminal block mounting portion 82a-2. The two soft-fitting protrusions 83aC, 83aC are arranged at a predetermined interval in the Y-axis direction and extend outward from the terminal block mounting portion 82a-1 or 82a-2 in the X-axis direction in a manner that is substantially parallel to each other.

[0222] Each of the two terminal blocks 50E has a main body 51E, a through hole 52C, and a mounting hole 56. A terminal metal part 71 is integrally formed on one terminal block 50E, and a terminal metal part 72 is integrally formed on the other terminal block 50E.

[0223] Each of the two terminal blocks 60E has a main body 61E, a through hole 62C, and a mounting hole 66. A terminal metal part 73 is integrally formed on one terminal block 60E, and a terminal metal part 74 is integrally formed on the other terminal block 60E.

[0224] like Figure 17 As shown, the soft-fitting protrusion 83aC formed on one side of the terminal block mounting portion 82a_1 in the Y-axis direction enters the interior of the soft-fitting recess 52aC of the terminal block 50E disposed on the other side of the Y-axis direction. The soft-fitting protrusion 83aC formed on the other side of the terminal block mounting portion 82a_1 in the Y-axis direction enters the interior of the soft-fitting recess 52aC of the terminal block 50E disposed on the other side of the Y-axis direction. In this state, within the soft-fitting recess 52aC, the soft-fitting protrusion 83aC can move freely in both the Y-axis and Z-axis directions within the gap G5, and also moves freely in the X-axis direction. Therefore, in this embodiment, the two terminal blocks 50E, 50E can move freely in the X-axis, Y-axis, and Z-axis directions of the housing 80E, respectively. Similarly, the two terminal blocks 60E, 60E can also move freely in the X-axis, Y-axis, and Z-axis directions of the housing 80E.

[0225] In this embodiment, the same effects as in the fourth embodiment can be obtained. Furthermore, in this embodiment, each of the four terminal metal pieces 71 to 74 is mounted on one of the four terminal blocks 50E, 50E, 60E, 60E. Therefore, the terminal metal pieces 71 to 74 can be moved relative to the housing 80E independently of each terminal block 50E (60E), and the insertion holes 71d to 74d of the terminal metal pieces 71 to 74 and the mounting holes 102 of the circuit board 100 can be correctly positioned on each terminal metal piece 71 to 74. Therefore, the circuit pattern of the circuit board 100 and the terminal metal pieces 71 to 74 can be easily positioned and connected correctly using fasteners such as screws 104.

[0226] This invention is not limited to the embodiments described above, and various modifications can be made within the scope of this invention.

[0227] In the above embodiments, examples of the application of the coil device of the present invention to a transformer are shown, but the present invention can also be applied to other electronic components such as reactors.

[0228] In the first embodiment described above, such as Figure 2 As shown, the two cores 40 are each formed by a core of approximately U-shape (U-shaped core), but the shape of the core 40 is not limited to this; it can also be formed by a core of approximately E-shape or other shapes. Alternatively, one core 40 can be formed by a U-shaped core, and the other core 40 can be formed by a core of I-shape (I-shaped core), and they can be combined to form an EI-type core. The second embodiment described above is similar, and the shape of the core 40A can also be appropriately modified.

[0229] In the first embodiment described above, terminal block mounting portions 82a_1 and 82a_2 are formed on the first surface 821 and the third surface 823 of the side wall 82. However, the arrangement positions of the terminal block mounting portions 82a_1 and 82a_2 can be appropriately changed. For example, the terminal block mounting portions 82a_1 and 82a_2 can be respectively arranged on the same surface of the side wall 82 (e.g., only the first surface 821), or they can be arranged on adjacent surfaces (e.g., the first surface 821 and the second surface 822).

[0230] In the first embodiment described above, a soft-fitting protrusion 83a is formed in the housing 80, and soft-fitting recesses 52a and 62a are formed in the terminal blocks 50 and 60. However, it is also possible to form soft-fitting recesses in the housing 80 and soft-fitting protrusions in the terminal blocks 50 and 60. The same effect can be obtained in this case. The second, fourth to sixth embodiments described above are also the same.

[0231] In the second embodiment described above, the first coil portion 20 and the second coil portion 30 may also be arranged radially on the inner and outer sides, respectively.

[0232] In the first embodiment described above, two terminal blocks 50 and 60 are installed on the housing 80. However, the number of terminal blocks installed on the housing 80 is not limited to this and can be appropriately changed. For example, only one terminal block may be installed on the housing 80. The second to sixth embodiments described above are the same.

[0233] When the technology shown in the third embodiment is applied to the first, second, and fourth to sixth embodiments, in addition to the terminal blocks 50 and 60, the terminal metal parts 71 to 74 can also move freely in both the X-axis and Y-axis directions of the housing 80.

[0234] Applying the technology shown in the fourth embodiment to the first and second embodiments can also enable the terminal blocks 50 and 60 to move freely in the XYZ axes of the housing 80.

[0235] Applying the technology shown in the fifth embodiment to the first, second, fourth, and sixth embodiments, the terminal blocks 50 and 60 can also be prevented from detaching from the housing 80 by means of the stop wall portion 90.

[0236] Applying the technology shown in the sixth embodiment to the first to fifth embodiments can also enable each terminal 71 to terminal 74 to have a terminal block.

[0237] In the above embodiments, the windings 22 and 32 can also be composed of various windings such as round wires or flat wires. When using flat wire windings, either flat or plain wires can be used. Alternatively, instead of windings 22 and 32, a plate-shaped conductor, such as a copper plate, can be used.

[0238] In the above embodiments, as Figure 1 The connection object (mounting object) of the coil device 10 shown is the circuit board 100, but the coil device 10 can also be mounted to the connector or the like, for example.

[0239] In the above embodiments, it can also be achieved by... Figure 1 The threaded hole of the screw 104 shown forms a through hole 71d to 74d.

Claims

1. A coil device, wherein, have: The core has a wound portion with coils arranged on its outer periphery; Terminals, which are connected to the end of the coil; A housing containing the core; and A terminal block, on which the terminals are mounted, is mounted on the housing. The terminal is movable relative to the first axis direction and is mounted on the terminal block. A soft-fitting protrusion is provided on either the housing or the terminal block. On either the housing or the terminal block, a soft-fit recess is formed for the soft-fit protrusion to enter. The terminal block is movably mounted relative to the housing in the second axial direction. The terminal is movable relative to the housing in both the first and second axial directions, which are substantially perpendicular to each other.

2. A coil device, wherein, have: The core has a wound portion with coils arranged on its outer periphery; Terminals, which are connected to the end of the coil; A housing containing the core; and A terminal block, on which the terminals are mounted, is mounted on the housing. A soft-fitting protrusion is provided on either the housing or the terminal block. On either the housing or the terminal block, a soft-fit recess is formed for the soft-fit protrusion to enter. The terminal block is movable relative to the housing in both a first axis direction and a second axis direction that are substantially perpendicular to each other. The terminal is movably mounted on the terminal block in a third axis direction perpendicular to the first axis direction and the second axis direction.

3. The coil device according to claim 1 or 2, wherein, The interior of the housing is filled with a filling resin.

4. The coil device according to claim 1 or 2, wherein, The terminal block is movable freely in the third axis direction of the housing.

5. The coil device according to claim 1 or 2, wherein, A protrusion is formed at the upper end of the side wall of the housing, protruding upwards towards the housing. At least a portion of the terminal block is disposed on the protrusion. The end of the coil extends from the side of the protrusion toward the outside of the housing.

6. The coil device according to claim 1 or 2, wherein, The coil consists of a first coil and a second coil. The first coil and the second coil are arranged side by side inside the housing, with respect to a direction parallel to the bottom surface of the housing.

7. The coil device according to claim 1 or 2, wherein, The soft-fitting protrusion is movably inserted within the soft-fitting recess within a specified range in the first axial direction and the second axial direction.

8. The coil device according to claim 1 or 2, wherein, The terminal inserted into the terminal block has a hook portion. The inner cover is installed in the mounting recess of the terminal block. The lower hook-shaped portion of the hook engages with the inner cover.

9. A coil device, wherein, have: The core has a wound portion with coils arranged on its outer periphery; Terminals, which are connected to the end of the coil; A housing containing the core; and A terminal block, on which the terminals are mounted, is mounted on the housing. The terminal block is fixed relative to the housing. The hook portion of the terminal is inserted into the terminal slot. A portion of the hook-shaped lower end of the hook is inside the terminal slot and is freely movable in the first axial direction and the second axial direction. The width of the hook-shaped portion at the lower end of the hook in the first axial direction is wider than the width of the terminal slot in the first axial direction. The terminal is movable relative to the housing in both the first and second axial directions, which are substantially perpendicular to each other. The first axial direction and the second axial direction are perpendicular to each other.

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