Coil arrangement

Abstract

Provided is a coil device in which various elements having different functions can be easily integrated and magnetic saturation can be easily avoided. A coil device (1) has a first core (10) and a second core (20). A convex portion (24) that connects with an outer leg portion (12) of the first core (10) is formed on a back surface (23a) of a base portion (23) of the second core (20) in which an outer leg portion (22) is provided, in correspondence with the outer leg portion (12) of the first core (10).

Description

TECHNICAL FIELD

[0001] The present application relates to a coil device that integrates a plurality of elements having different functions. BACKGROUND

[0002] As a coil device that integrates a plurality of elements having different functions, for example, a coil device shown in Patent Literature 1 is known. In Patent Literature 1, three cores of E-shape are combined so that a single coil device has a plurality of functions.

[0003] However, it has been found that the structure in which magnetic saturation is difficult to avoid is inevitable in such a conventional coil device.

[0004] Patent Literature 1: Japanese Patent Application Publication No. 2012-54549 SUMMARY

[0005] PROBLEMS TO BE SOLVED BY THE INVENTION

[0006] The present application has been achieved in view of such a situation, and an object thereof is to provide a coil device in which a plurality of elements having different functions are easily integrated, and in which magnetic saturation is easily avoided.

[0007] MEANS FOR SOLVING THE PROBLEMS

[0008] To achieve the above object, the present application provides a coil device having a first core and a second core, in which

[0009] A protrusion that connects a front end surface of an outer leg portion of the first core (a front end surface in a direction of flight / the same below) is formed on a back surface of a base portion in which the outer leg portion of the second core is disposed, in correspondence with the outer leg portion of the first core.

[0010] By so configuring, the first coil element that contains the first core as a part and the second coil element that contains the second core as a part can have different functions. Also, the second core can be used as a part of the first coil element. Therefore, miniaturization of the entire coil device having two or more functions can be achieved.

[0011] In addition, the protrusion that connects the front end surface of the outer leg portion of the first core is formed in correspondence with the outer leg portion of the first core, and thus the connecting surface of the first core and the second core can be distanced from the back surface of the second core. As a result, a portion where magnetic flux is easily concentrated can be distanced from the back surface of the second core, and a structure in which magnetic saturation is difficult to occur can be achieved.

[0012] Further, in the coil device of the present application, by polishing only the front end surface of the protruding portion, the adhesion when the front end surface of the outer leg portion of the first core is connected is improved, and the magnetic coupling is improved. In addition, the front end surface of the outer leg portion of the first core can be polished, and in this case, the front end surface of the middle leg portion of the first core can be polished at the same time, and the gap between the front end surface of the middle leg portion of the first core and the back surface of the second core can be easily adjusted.

[0013] Preferably, a cross corner portion where the protruding portion protrudes from the back surface of the base portion of the second core is formed with an R portion or a chamfer portion that smoothly connects between the inner surface of the protruding portion and the back surface of the base portion of the second core. By being formed in such a structure, the coil device of the present application becomes a structure that is more difficult to be magnetically saturated.

[0014] Preferably, the front end surface of the outer leg portion of the first core and the front end surface of the middle leg portion of the first core are located on substantially the same plane. By being thus constituted, by adjusting only the protruding height of the protruding portion formed on the back surface of the second core, the gap between the front end surface of the middle leg portion of the first core and the back surface of the second core can be easily adjusted.

[0015] Preferably, the protruding height of the protruding portion from the back surface of the second core is smaller than the thickness of the second core. The protruding height of the protruding portion from the back surface of the second core is sufficient to form an R portion or a chamfer portion at a cross corner portion between the protruding portion and the back surface. The smaller the protruding height of the protruding portion from the back surface of the second core, the easier it is to form the front end surface of the protruding portion into a flat surface, and the easier it is to make the magnetic connection with the front end surface of the outer leg portion of the first core good.

[0016] Preferably, a gap of a prescribed width is formed between the front end surface of the middle leg portion of the first core and the back surface of the base portion of the second core. By forming the gap, the characteristics of the first coil element including the first core can be controlled.

[0017] Preferably, the coil device of the present application further has a third core, and the front end surface of the outer leg portion of the third core is connected to the front end surface of the outer leg portion of the second core. A second coil element such as a transformer or the like can be constituted by the second core and the third core.

[0018] Preferably, the length along the winding axis of the third core is different from the length along the winding axis of the first core, and the length along the winding axis of the first core is different from the length along the winding axis of the second core. By being thus constituted, a coil device having a plurality of elements with various characteristics different from each other can be realized.

[0019] A gap of a prescribed width can be formed between the middle leg portion of the second core and the middle leg portion of the third core, or no gap can be formed.

[0020] It is preferable that a winding portion of the first electric wire is arranged around the middle leg portion of the first core, and a winding portion of the second electric wire is arranged around the middle leg portion of the second core. The winding portion of the first electric wire constitutes a part of the first coil element, and the winding portion of the second electric wire constitutes a part of the second coil element.

[0021] It is preferable that the coil device of the present application has:

[0022] a first bobbin covering the middle leg portion of the first core, and the first electric wire is wound on the first bobbin;

[0023] a second bobbin covering the middle leg portion of the second core, and the second electric wire is wound on the second bobbin,

[0024] the first bobbin and the second bobbin are fitted on the side of the base portion of the second core.

[0025] By sandwiching the bobbins between the electric wires and the cores, the cores can be mounted on the bobbins after the electric wires are wound on the bobbins, and it is easy to arrange the winding portions of the electric wires around the middle leg portions of the cores. In addition, the insulation of the electric wires and the cores is easy. Furthermore, by fitting the first bobbin and the second bobbin on the side of the base portion of the second core, the integration of these bobbins with each other is easy, and the wiring of the lead portions of the electric wires is also easy.

[0026] It is preferable that the lead portion of the first electric wire is connected to a first terminal mounted on the second bobbin, and the lead portion of the second electric wire is connected to a second terminal mounted on the first bobbin. By being configured in this way, it is easy to mount the lead portions of the electric wires on the terminals while ensuring insulation.

[0027] It is preferable that the coil device of the present application has elements with multiple different functions. Elements with multiple functions can be mounted on a single coil device, and compared to manufacturing these elements separately, it is possible to reduce materials and achieve a reduction in manufacturing costs.

[0028] In addition, it is preferable that the first core functions as a part of an inductor, and the second core functions as a part of a transformer. Such a coil device can be applied to, for example, a charger mounted on an automobile or the like.

[0029] The coil device according to another aspect of the present application has a first core, a second core, and a third core,

[0030] A convex portion connected to the front end surface of the outer leg portion of the first core is formed on the back surface of the base portion of the second core to which the outer leg portion of the third core is connected, in correspondence with the outer leg portion of the first core.

[0031] In this coil device, as with the above-described coil device, miniaturization of the coil device can be achieved, and at the same time, various elements having different functions can be easily integrated, and a coil device in which magnetic saturation can be easily avoided can be achieved. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 is an overall perspective view of a coil device according to an embodiment of the present application.

[0033] Figure 2 is a partial exploded perspective view of the coil device shown in Figure 1

[0034] Figure 3A is an enlarged perspective view of the core portion shown in Figure 2

[0035] Figure 3B is an enlarged perspective view of the core portion according to another embodiment of the coil device shown in Figure 1

[0036] Figure 4 is a sectional view of the core portion along the line IV-IV shown in Figure 3A

[0037] Figure 5A is a sectional view of the coil device along the line VA-VA shown in Figure 1

[0038] Figure 5B is a sectional view of another embodiment of the coil device shown in Figure 5A

[0039] Figure 5C is a sectional view of another other embodiment of the coil device shown in Figure 5A

[0040] KEY

[0041] 1... coil device

[0042] 10, 110... first core

[0043] 11... first middle leg portion

[0044] 11a... front end surface

[0045] 11b... flat surface

[0046] 12... first outer leg portion

[0047] 12a... front end surface

[0048] 12b... inner side surface

[0049] 12c... outer side surface​​​​​​​

[0050] 13 first base

[0051] 13a back surface

[0052] 13b inner surface

[0053] 13c outer lateral surface

[0054] 20, 120 second core

[0055] 21 second middle leg portion

[0056] 21a front end surface

[0057] 21b flat surface

[0058] 22 second outer leg portion

[0059] 22a front end surface

[0060] 22b inner lateral surface

[0061] 22c outer lateral surface

[0062] 23 second base

[0063] 23a back surface

[0064] 23b inner surface

[0065] 23c outer lateral surface

[0066] 24 protrusion

[0067] 24a front end surface

[0068] 24b inner lateral surface

[0069] 30, 130 third core

[0070] 31 third middle leg portion

[0071] 31a front end surface

[0072] 31b flat surface

[0073] 32 third outer leg portion

[0074] 32a front end surface

[0075] 32b inner surface

[0076] 32c outer lateral surface

[0077] 33 third base

[0078] 33a back surface

[0079] 33b …… inner surface

[0080] 33c …… outer surface

[0081] 40 …… first bobbin

[0082] 41, 42 …… first end wall flange

[0083] 43 …… first terminal platform

[0084] 44 …… first locking plate

[0085] 45 …… fitting protrusion

[0086] 46 …… insulating protrusion

[0087] 47 …… first bobbin main body

[0088] 48 …… first through hole

[0089] 50 …… second bobbin

[0090] 51, 52 …… second end wall flange

[0091] 53 …… second terminal platform

[0092] 53a, 53b …… terminal mounting portion

[0093] 54 …… second locking plate

[0094] 55 …… fitting recess

[0095] 56a, 56b, 56c, 56d …… lead slot

[0096] 57a, 57b, 157, 257a-257h …… second bobbin main body

[0097] 58 …… second through hole

[0098] 59, 259a-259g …… intermediate flange

[0099] 60a, 60b …… first terminal

[0100] 70a, 70b …… second terminal

[0101] 70a1, 70b1 …… rivet piece

[0102] 80a, 80b …… third terminal

[0103] 80a1, 80b1 …… rivet piece

[0104] 90 …… first electric wire

[0105] 91a, 91b... first lead portion

[0106] 92... second electric wire

[0107] 93a, 93b... second lead portion

[0108] 94... third electric wire

[0109] 95a, 95b... third lead portion DETAILED DESCRIPTION

[0110] Hereinafter, the present application will be described based on the embodiment shown in the drawings.

[0111] First embodiment

[0112] As shown in Figure 1 , the coil device 1 of the present embodiment is used as, for example, a coil device for an on-vehicle charger or the like, a transformer and an inductor are integrated. The coil device 1 has a first core 10, a second core 20, a third core 30, a first electric wire 90, a second electric wire 92 and a third electric wire 94.

[0113] As shown in Figure 5A , in the present embodiment, the first electric wire 90 is wound on the first bobbin 40, and the second electric wire 92 and the third electric wire 94 are wound on the second bobbin 50, respectively. In addition, in the drawings, the X-axis direction coincides with the winding direction of each electric wire 90, 92, 93, and the X-axis, the Y-axis and the Z-axis are orthogonal to each other. Further, in the present embodiment, the Z-axis coincides with the height direction of the coil device 1.

[0114] As shown in Figure 4 , the first core 10, the second core 20 and the third core 40 have a substantially E-shaped cross section, respectively, and are called so-called E-type cores. The first core 10 and the third core 30 are like a general E-type core as shown in Figure 5A , the length in the X-axis direction is different from that of a general E-type core. In the present embodiment, the second core 20 is different from a general E-type core. Details will be described later.

[0115] As shown in Figure 2 and Figure 3A , the first core 10 has a rectangular flat plate-shaped first base 13 parallel to the Y-axis and the Z-axis. The first core 10 has a first outer leg portion 12 at each of both ends of the first base 13 in the Y-axis direction, and these first outer leg portions 12 project at a substantially right angle along the X-axis from the inner surface 13b of the base 13.

[0116] Further, the first core 10 has a first middle leg portion 11 at a substantially intermediate position of the pair of first outer leg portions 12 in the Y-axis direction, which projects from the inner surface 13b of the base 13 along the X-axis in the same direction as the outer leg portions 12. As shown in Figure 4As shown, the first outer leg 12 protrudes from the inner surface 13b of the first base 13 in the X-axis direction with a protrusion height H1. In this embodiment, the first middle leg 11 is the same as the first outer leg 12, protruding in the X-axis direction with a protrusion height H1. As a result, the front end face 12a of the first outer leg 12 and the front end face 11a of the first middle leg 11 are located on the same plane.

[0117] Furthermore, the outer surface 13c of the upper end of the first base 13 along the Z-axis is flush with the outer surface of the upper end of the pair of first outer legs 12 along the Z-axis. The height of the first base 13 along the Z-axis is approximately the same as the height of the first outer legs 12 along the Z-axis. The first middle leg 11 has a generally circular shape in a cross-section parallel to the Y-axis and Z-axis, and the outer diameter of the first middle leg 11 is smaller than the height of the first base 13 along the Z-axis.

[0118] like Figure 2 As shown, a predetermined gap is formed between the outer peripheral surface of the first middle leg 11 and the inner surface 12b of the first outer leg 12. One end of the first winding frame 40 in the X-axis direction enters this predetermined gap. Therefore, the inner surface 12b of the first outer leg 12 corresponds to the shape of the first end wall flange 41 of the first winding frame 40 and is curved. The first middle leg 11 is cylindrical, and its outer diameter corresponds to the inner diameter of the first through hole 48 of the first winding frame 40.

[0119] The second core 20 has a rectangular flat second base 23, which has the same width along the Y-axis and Z-axis as the first base 13. Preferably, the thickness of the second base 23 along the X-axis is approximately the same as or thicker than the thickness of the first base 13 along the X-axis, but it may also be smaller.

[0120] The second base 23 has second outer legs 22 at both ends in the Y-axis direction, and these second outer legs 22 protrude approximately at right angles from the plane of the base 23 along the X-axis. Along the X-axis, the protrusion direction of the second outer legs 22 relative to the second base 23 is the same as the protrusion direction of the first outer legs 12 relative to the first base 13. In addition, the second core 20 has a second middle leg 21 at approximately the midpoint of the pair of second outer legs 22 in the Y-axis direction, protruding from the plane of the base 23 along the X-axis in the same direction as the outer legs 22.

[0121] like Figure 4As shown, the second outer leg 22 protrudes from the inner surface 23b of the second base 23 in the X-axis direction with a protrusion height H2. The protrusion height H2 can also be the same as the protrusion height H1, but is preferably greater than the protrusion height H1. In this embodiment, the second middle leg 21, like the second outer leg 22, protrudes in the X-axis direction with a protrusion height H2. As a result, the front end face 22a of the second outer leg 22 and the front end face 21a of the second middle leg 21 are located on the same plane, but since there is a gap in the front end face of the middle leg 21, the protrusion length of the middle leg 21 can also be shorter than the protrusion length of the outer leg 22.

[0122] In addition, such as Figure 2 and Figure 3A As shown, the outer surface 23c of the upper end of the second base 23 along the Z-axis is flush with the outer surface of the upper end of the pair of second outer legs 22 along the Z-axis. The height of the second base 23 along the Z-axis and the height of the second outer legs 22 along the Z-axis are approximately the same. The second middle leg 21 has a generally circular shape in a cross-section parallel to the Y-axis and Z-axis. The outer diameter of the second middle leg 21 is smaller than the height of the second base 23 along the Z-axis and is approximately the same as, but may be different from, the outer diameter of the first middle leg 11.

[0123] like Figure 2 As shown, a predetermined gap is formed between the outer peripheral surface of the second middle leg 21 and the inner surface 22b of the second outer leg 22. One end of the second winding frame 50 in the X-axis direction enters this predetermined gap. Therefore, the inner surface 22b of the second outer leg 22 corresponds to the shape of the second end wall flange 51 of the second winding frame 50 and is curved. The second middle leg 21 is cylindrical, and its outer diameter corresponds to the inner diameter of the second through hole 58 of the second winding frame 50.

[0124] like Figure 4 As shown, the back surface 23a of the second base 23 faces the front end face 11a of the first middle leg 11 of the first core 10 with a predetermined gap, and protrusions 24 are formed at both ends of the back surface 23a in the Y-axis direction. Each protrusion 24 protrudes from the back surface 23a of the second base 23 with a protrusion height H4 in opposite directions along the X-axis and the direction protruding from the second outer leg 22.

[0125] As a result, in this embodiment, a gap W1 corresponding to the protrusion height H4 is formed between the front end face 11a of the first middle leg portion 11 of the first core 10 and approximately the center portion of the back surface 23a of the second base portion 23. The protrusion height H4 of each protrusion 24 is preferably 1.5 times or less the thickness of the base portion 23 in the X-axis direction, and more preferably less than or equal to the thickness of the base portion 23. Furthermore, the protrusion height H4 of each protrusion 24 is preferably 0.1 mm to 5 mm.

[0126] An R portion or a chamfer portion that smoothly links between the inner side surface 24b of the protrusion and the back surface 23a of the base portion 23 is formed at the intersecting corner portion where the protrusion 24 protrudes from the back surface 23a of the base portion 23 of the second core 20. In the present embodiment, the radius of curvature of the R portion or the length of the chamfer portion in the X-axis direction corresponds to the protrusion height H4 of the protrusion.

[0127] As shown in FIG. 1, at least a portion of the inner side surface 24b of the protrusion 24 is curved in accordance with the outer shape of the first end wall flange 42 provided at the other end of the X-axis direction of the first bobbin 40. The shapes of the front end surfaces 24a, 12a are preferably the same as each other, so that the front end surface 24a of each protrusion 24 along the X-axis is connected to the front end surface 12a of each outer leg portion 12 of the first core 10. Figure 2

[0128] As shown in FIG. 1, the third core 30 has a third base portion 33 that is a rectangular flat plate having the same width along the Y-axis and the Z-axis as the first base portion 13. The thickness of the third base portion 33 along the X-axis is preferably substantially the same as the thickness of the first base portion 13 along the X-axis, but can be different. Figure 3A The third core 30 has a third outer leg portion 32 at each of the Y-axis direction ends of the third base portion 33, and these third outer leg portions 32 protrude at substantially right angles along the X-axis from the inner surface 33b of the base portion 33. The protruding direction of the third outer leg portion 32 with respect to the third base portion 33 is opposite to the protruding direction of the second outer leg portion 22 with respect to the second base portion 23 in the X-axis direction. In addition, the third core 30 has a third middle leg portion 31 that protrudes along the X-axis in the same direction as the outer leg portion 32 from the inner surface 33b of the base portion 33 at a substantially intermediate position in the Y-axis direction of the pair of third outer leg portions 32.

[0129] As shown in FIG. 1, the third outer leg portion 32 protrudes from the inner surface 33b of the third base portion 33 in the X-axis direction at a protrusion height H3. The protrusion height H3 can be the same as the protrusion height H2, but can be greater than the protrusion height H2 and can be smaller than the protrusion height H2. In the present embodiment, the third middle leg portion 31 protrudes in the X-axis direction at the protrusion height H3, like the third outer leg portion 32.

[0130] Figure 4 As a result, the front end surface 32a of the third outer leg portion 32 and the front end surface 31a of the third middle leg portion 31 are located on the same plane, but since the gap is provided at the front end surface 31a of the middle leg portion 31, the protrusion length of the middle leg portion 31 can be shorter than the protrusion length of the outer leg portion 32. That is, the front end surface 31a of the middle leg portion 31 can be connected in contact with the front end surface 21a of the middle leg portion 21, or can face apart with a prescribed gap.

[0131] As a result, the front end surface 32a of the third outer leg portion 32 and the front end surface 31a of the third middle leg portion 31 are located on the same plane, but since the gap is provided at the front end surface 31a of the middle leg portion 31, the protrusion length of the middle leg portion 31 can be shorter than the protrusion length of the outer leg portion 32. That is, the front end surface 31a of the middle leg portion 31 can be connected in contact with the front end surface 21a of the middle leg portion 21, or can face apart with a prescribed gap.

[0132] In addition, as shown in FIG. 1, the third core 30 has a third protrusion 34 that protrudes from the inner surface 33b of the third base portion 33 in the X-axis direction at a protrusion height H4. The protrusion height H4 is preferably substantially the same as the protrusion height H2 of the second core 20, but can be different. Figure 2 and​​Figure 3A As shown, the outer surface 33c of the upper end of the third base 33 along the Z-axis is flush with the outer surface of the upper end of the pair of third outer legs 32 along the Z-axis. The height of the third base 33 along the Z-axis and the height of the third outer legs 32 along the Z-axis are approximately the same. The third middle leg 31 has a generally circular shape in a cross-section parallel to the Y-axis and Z-axis. Preferably, the outer diameter of the third middle leg 31 is smaller than the height of the third base 33 along the Z-axis and is approximately the same as the outer diameter of the second middle leg 21.

[0133] like Figure 2 As shown, a predetermined gap is formed between the outer peripheral surface of the third middle leg 31 and the inner surface 32b of the third outer leg 32. The other end of the second winding frame 50 in the X-axis direction enters this predetermined gap. Therefore, the inner surface 32b of the third outer leg 32 corresponds to the shape of the second end wall flange 52 of the second winding frame 50 and becomes a curved surface. The third middle leg 31 is cylindrical, and its outer diameter corresponds to the inner diameter of the second through hole 58 of the second winding frame 50.

[0134] like Figure 4 As shown, the back surface 33a of the third base 33 is preferably a flat surface without any protrusions, but it may also have a protrusion similar to the protrusion 24 formed on the back surface 13a of the second core 20. Furthermore, in this embodiment, the back surface 13a of the base 13 is preferably a flat surface without any protrusions, but it may also have a protrusion similar to the protrusion 24 formed on the back surface 13a of the second core 20.

[0135] like Figure 2 As shown, the first winding frame 40 has a first winding frame body 47, on which a first through hole 48 is formed. Figure 5A As shown, the length of the first winding frame body 47 in the X-axis direction is configured to be greater than that of the first winding frame body 47. Figure 4 The amount of the protrusion height H1 and the length of the gap W1 of the first outer foot 12 shown. Figure 2 The inner diameter of the first through hole 48 shown corresponds to the outer diameter of the first middle foot 11, and is designed so that the first middle foot 11 is inserted into the first through hole 48.

[0136] like Figure 2 As shown, the first winding frame body 47 has first end wall flanges 41 and 42 at both ends along the X-axis. A first terminal block 43 extending along the Y-axis is integrally formed on one (upper) end of the first end wall flange 41 in the Z-axis direction. The length of the first terminal block 43 in the Y-axis direction corresponds to the length of the first base 13 in the Y-axis direction. The first terminal block 43 can also be fixed to the outer surface 13c of the first base 13 by adhesive or the like.

[0137] A first locking plate 44 extending along the Y axis is formed on the Z axis direction side (upper end) of the first end wall flange 42. A fitting protrusion 45 is formed in the center of the first locking plate 44. The length of the first locking plate 44 in the Y axis direction corresponds to the length of the second base 23 in the Y axis direction. The first locking plate 44 can also be fixed to the outer side surface 23c of the second base 23 by an adhesive or the like.

[0138] As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 1 As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively.

[0139] An insulating protrusion 46 insulating the second lead portion 93b and the third lead portion 95a is formed between the second terminal 70b and the third terminal 80a adjacent to each other. The second terminals 70a, 70b have an external connection portion protruding in the Z axis direction and a lead mounting portion protruding in the X axis direction. The lead mounting portion is plate-shaped and has a rivet piece 70a1, 70b1 that locks the lead portion of the electric wire. The second terminals 70a, 70b and the third terminals 80a, 80b each have a shape and a configuration that are axially symmetrical about the X axis.

[0140] As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 2 As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively.

[0141] Figure 5A As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 4 As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 2 As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively.

[0142] As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 2 As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively. Figure 5A As shown in FIG. 1, a pair of electrically conductive second terminals 70a, 70b and a pair of electrically conductive third terminals 80a, 80b are provided on the first terminal platform 43, respectively.

[0143] Furthermore, the second winding frame body 57a has a second end wall flange 51 at one end on the side of the second core 20. The second winding frame body 57b has a second end wall flange 52 at one end on the side of the third core 30. A second locking plate 54 extending along the Y-axis is formed at the upper end of the second end wall flange 52 in the Z-axis direction. The length of the second locking plate 54 in the Y-axis direction corresponds to the length of the third base 33 in the Y-axis direction. The second locking plate 54 can also be fixed to the outer surface 33c of the third base 33 by adhesive or the like.

[0144] A second terminal block 53 extending along the Y-axis is formed at the upper end of the second end wall flange 51 in the Z-axis direction. A fitting recess 55 is formed on the lower central surface of the second terminal block 53. The fitting recess 55 has a shape and size corresponding to the fitting protrusion 45, and the fitting protrusion 45 can fit into the fitting recess 55. The length of the second terminal block 53 in the Y-axis direction corresponds to the length of the second base 23 in the Y-axis direction. The second terminal block 53 can also be fixed to the first locking plate 44 by adhesive or the like.

[0145] like Figure 1 As shown, the second terminal block 53 has a pair of conductive first terminals 60a and 60b. The first terminals 60a and 60b are embedded in the second terminal block 53, but they can also be separately provided on the second terminal block 53 by fitting or bonding.

[0146] On the second terminal block 53, a lead groove 56a for guiding the second lead portion 93a may also be formed at a position corresponding to the X-axis direction of the second terminal 70a. Additionally, on the second terminal block 53, a lead groove 56b for guiding the second lead portion 93b may also be formed at a position corresponding to the X-axis direction of the second terminal 70b.

[0147] On the second terminal block 53, a lead groove 56c for guiding the third lead portion 95a may also be formed at a position corresponding to the X-axis direction of the third terminal 80a. On the second terminal block 53, a lead groove 56d for guiding the third lead portion 95b may also be formed at a position corresponding to the X-axis direction of the second terminal 80b.

[0148] The first terminals 60a and 60b are L-shaped metal terminals consisting of an external connecting portion protruding in the Z-axis direction and a lead wire connecting portion protruding in the X-axis direction. The terminal mounting portion 53a of the second terminal block 53 on which the first terminal 60a is mounted protrudes toward the side of the first terminal block 43 that is closer to the first terminal block 43 than the terminal mounting portion 53b on which the first terminal 60b is mounted. The first terminal 60a is positioned on the side of the first terminal block 43 that is closer to the first terminal block 43 than the first terminal 60b.

[0149] like Figure 5AAs shown, the first electric wire 90 is wound around the first bobbin main body 47 of the first bobbin 40 to form a winding portion of the first electric wire, thereby constituting a first coil element (e.g., an inductor). The first lead portion 91a of the first electric wire 90 is electrically connected to the first terminal 60a. The first lead portion 91b of the first electric wire 90 is electrically connected to the first terminal 60b. The connection method is not particularly limited, and laser welding, heat staking, soldering, or the like can be used.

[0150] The second electric wire 92 is wound around the second bobbin main body 57a of the second bobbin 50 to form a winding portion of the second electric wire, thereby constituting a part of a second coil element. The second lead portion 93a of the second electric wire 92 is caught by the rivet piece 70a of the second terminal 70a and is electrically connected to the second terminal 70a. The second lead portion 93b of the second electric wire 92 is caught by the rivet piece 70b of the second terminal 70b and is electrically connected to the second terminal 70b. The connection method is the same as the above-described connection method.

[0151] The third electric wire 94 is wound around the second bobbin main body 57b of the second bobbin 50 to form a winding portion of the third electric wire, thereby constituting another part of the second coil element. As the second coil element, a transformer or the like can be exemplified. The third lead portion 95a of the third electric wire 94 is caught by the rivet piece 80a of the third terminal 80a and is electrically connected to the third terminal 80a. The third lead portion 95b of the third electric wire 94 is caught by the rivet piece 80b of the third terminal 80b and is electrically connected to the third terminal 80b. The connection method is the same as the above-described connection method.

[0152] In the present embodiment, the first core 10, the second core 20, and the third core 30 are constituted by a magnetic body such as a Ni-Zn-based ferrite, a Mn-Zn-based ferrite, or a metal magnetic body. In the present embodiment, the first core 10, the second core 20, and the third core 30 are produced by molding and sintering a magnetic powder, but can be constituted by a press powder molded body or the like of a magnetic powder and a resin binder or the like.

[0153] In addition, the first bobbin 40 and the second bobbin 50 are constituted by a plastic such as PPS, PET, PBT, LCP, or the like, but can be constituted by another insulating member. In addition, the first bobbin 40 and the second bobbin 50 are preferably the same material, but can be different materials.

[0154] The first electric wire 90, the second electric wire 92, and the third electric wire 94 can be constituted by a single wire, a stranded wire, or an insulated covered wire. In addition, the electric wires 90, 92, 94 can be round wires or flat wires.

[0155] Furthermore, these wires 90, 92, and 94 can be made of the same material and have the same structure, or they can be different. Additionally, the materials used to construct these wires 90, 92, and 94 can be, for example, copper or copper alloys, or good conductors such as silver or nickel; there are no particular limitations as long as the material is a conductor. Figure 1 The first terminals 60a and 60b, the second terminals 70a and 70b, and the third terminals 80a and 80b shown are made of metals such as copper or copper alloys.

[0156] In the coil device 1 of this embodiment, a coil having Figure 5A The first coil element, shown with first core 10 and first wire 90, is used as an inductor. Alternatively, the second coil element, having second core 20 and second wire 92, and third core 30 and third wire, can be used as a transformer.

[0157] That is, the coil device of this embodiment can have coil elements with various functions in a single device. Moreover, the second base 23 of the second core 20, by combining with the first core 10, can also be used as part of an inductor as the first coil element. Therefore, the overall miniaturization of the coil device, which can function as a coil element with two or more functions, can be achieved.

[0158] In addition, such as Figure 4 As shown, the protrusion 24, which connects to the front end face 12a of the outer leg portion 12 of the first core 10, is formed on the back side 23a corresponding to the outer leg portion 12 of the first core 10. Therefore, the connecting surfaces (front end faces 12a, 24a) of the first core 10 and the second core 20 can be moved away from the back side 23a of the second core 20. As a result, a structure is formed where the area where magnetic flux is easily concentrated is moved away from the back side 23a of the second core 20, and magnetic saturation is difficult to achieve.

[0159] Furthermore, in the coil device 1 of this embodiment, by grinding only the front end face 24a of the protrusion 24, the tightness when connected with the front end face 12a of the outer leg portion 12 of the first core 10 is improved, and the magnetic coupling is enhanced. In addition, the front end face 12a of the outer leg portion 12 of the first core 10 can also be ground. In this case, while grinding the front end face 12a of the outer leg portion 12 of the first core 10, the front end face 11a of the middle leg portion 11 of the first core 10 can also be ground simultaneously, and the gap W1 between the front end face 11a of the middle leg portion 11 of the first core 10 and the back surface 23a of the second core 20 can be easily adjusted.

[0160] Furthermore, an R-shaped or chamfered portion is formed at the intersection of the protrusion 24 protruding from the back surface of the base 23 of the second core 20, smoothly connecting the inner side surface 24b of the protrusion 24 and the back surface 23a of the base 23 of the second core 20. By forming this structure, the coil device 1 of this embodiment becomes a structure that is more difficult to magnetically saturate.

[0161] Further, in the present embodiment, the front end surface 12a of the outer leg portion 12 of the first core 10 and the front end surface 11a of the middle leg portion 11 of the first core 10 are located on substantially the same plane. With this configuration, by adjusting the protruding height H4 of the protruding portion 24 formed on the back surface 23a of the second core 20, it is easy to adjust the gap Wl between the front end surface 11a of the middle leg portion 11 of the first core 10 and the back surface 23a of the second core 20.

[0162] Further, the front end surface 12a of the first outer leg portion 12 and the front end surface 11a of the first middle leg portion 11 can be ground at the same time, and the manufacturing process can be simplified. Therefore, the manufacturing cost of the coil device 1 can be reduced.

[0163] The protruding height H4 of the protruding portion 24 from the back surface 23a of the second core 20 is smaller than the thickness of the base portion 23 of the second core 20 along the X axis. The protruding height H4 of the protruding portion 24 from the back surface 23a of the second core 20 is sufficient to form an R portion or a chamfer portion at the intersection corner portion between the protruding portion 24 and the back surface 23a.

[0164] The smaller the protruding height H4 of the protruding portion 24 from the back surface 23a of the second core 20, the easier it is to form the front end surface 24a of the protruding portion 24 flat, and the better the magnetic connection with the front end surface 12a of the outer leg portion 12 of the first core 10. Further, the front end surface 24a of the protruding portion 24 of the second core 20 only needs to be in contact with the front end surface 12a of the outer leg portion 12 of the first core 10, and does not necessarily need to be bonded by an adhesive, but can also be bonded.

[0165] A gap Wl of a predetermined width is formed between the front end surface 12a of the middle leg portion 12 of the first core 10 and the back surface 23a of the base portion 23 of the second core 20. By forming the gap Wl, the coil characteristics of the inductor including the first core 10 can be controlled.

[0166] Further, the coil device 1 of the present embodiment further has a third core 30, and the front end surface 32a of the outer leg portion 32 of the third core 30 is connected to the front end surface 22a of the outer leg portion 22 of the second core 20. A second coil element such as a transformer can be configured by the second core 20 and the third core 30. Further, the front end surface 22a of the outer leg portion 22 of the second core 20 only needs to be in contact with the front end surface 32a of the outer leg portion 32 of the third core 30, and does not necessarily need to be bonded by an adhesive, but can also be bonded.

[0167] Figure 4 The length H3 of the third core 30 along the X axis (winding axis) is different from the length of the first core 10 along the X axis, and the length of the first core 10 along the X axis is different from the length of the second core 20 along the X axis. With this configuration, a coil device 1 having a plurality of coil elements with various characteristics different from each other can be realized.

[0168] In the present embodiment, as shown inFigure 5A As shown, the winding portion of the first electric wire 90 is arranged around the middle leg portion 11 of the first core 10, and the winding portion of the second electric wire 92 is arranged around the middle leg portion 21 of the second core 20. The winding portion of the first electric wire 90 constitutes a part of an inductor as a first coil element, and the winding portion of the second electric wire 92 constitutes a part of a transformer as a second coil element.

[0169] In addition, as shown in FIG. 1, the coil device 1 of the present embodiment has a first bobbin 40 that covers the middle leg portion 11 of the first core 10 and is wound with the first electric wire 90. In addition, the coil device 1 has a second bobbin 50 that covers the middle leg portion 21 of the second core 20 and has a second bobbin main body 57a that winds the second electric wire 92. Figure 5A

[0170] The second bobbin 50 also has a second bobbin main body 57a and a second bobbin main body 57b that is insulated from the second bobbin main body 57a in the X-axis direction by an intermediate flange 69. The second bobbin main body 57b covers the middle leg portion 31 of the third core 30 and is wound with the third electric wire 94. The first bobbin 40 and the second bobbin 50 are fit-joined on the outer side surface 23c of the base portion 23 of the second core 20.

[0171] By sandwiching the bobbins 40, 50 between these electric wires 90, 92, 94 and the cores 10, 20, 30, it is possible to mount each core 10, 20, 30 on the bobbins 40, 50 after winding the electric wires 90, 92, 94 on the bobbins 40, 50. In addition, it is easy to arrange the winding portions of each electric wire 90, 92, 94 around each middle leg portion 11, 21, 31 of the cores 10, 20, 30.

[0172] In addition, the insulation of the electric wires 90, 92, 94 and the cores 10, 20, 30 also becomes easy. Furthermore, by fitting the first bobbin 40 and the second bobbin 50 on the outer side surface 23c of the base portion 23 of the second core 20, it is also easy to integrate these bobbins 40, 50 with each other, as shown in FIG. 1. Figure 1

[0173] The lead portions 91a, 91b of the first electric wire 90 are connected to the first terminals 60a, 60b mounted on the second bobbin 50, and the lead portions 93a, 93b of the second electric wire 92 are connected to the second terminals 70a, 70b mounted on the first bobbin 40. The lead portions 95a, 95b of the third electric wire 94 are connected to the second terminals 80a, 80b mounted on the first bobbin 40. By being configured in this way, it is easy to mount the lead portions 91a, 91b, 93a, 93b, 95a, 95b of these electric wires 90, 92, 94 on the terminals while ensuring insulation.​​

[0174] Further, the coil device 1 of the present embodiment has a plurality of elements having different functions, and can mount elements having a plurality of functions in a single coil device, and can reduce materials and achieve a reduction in manufacturing costs compared to manufacturing the elements separately.

[0175] In addition, in the present embodiment, the first core 10 functions as a part of an inductor, and the second core 20 and the third core 30 function as a part of a transformer. Such a coil device 1 can be applied to, for example, a charger or the like mounted on a vehicle.

[0176] Second embodiment

[0177] As shown in FIG. 1, the coil device 1 of the present embodiment is the same as the first embodiment except for the structure of the second bobbin 50 and the arrangement of the second electric wire 92 and the third electric wire 94. In the following description, the description of the parts common to the first embodiment is omitted. Figure 5B

[0178] In the present embodiment, the second bobbin 50 has a single second bobbin main body 157 without an intermediate flange. On the second bobbin main body 157, the second electric wire 92 is wound on the lower layer side, and the third electric wire 94 is wound on the upper layer side above the second electric wire 92. Each of the electric wires 92, 94 is composed of an insulated covered electric wire, and is insulated. Alternatively, an insulating tape or the like can be wound between the electric wires 92, 94.

[0179] In the present embodiment, the coupling of the second coil element part formed by the second electric wire 92 and the third coil element part formed by the third electric wire 94 is higher than that of the first embodiment.

[0180] Third embodiment

[0181] As shown in FIG. 1, the coil device 1 of the present embodiment is the same as the first embodiment except for the structure of the second bobbin 50 and the arrangement of the second electric wire 92 and the third electric wire 94. In the following description, the description of the parts common to the first embodiment is omitted. Figure 5C

[0182] In the present embodiment, the second bobbin 50 has a plurality of intermediate flanges 259a to 259g to divide into a plurality of (for example, eight) second bobbin main bodies 257a to 257h. The second bobbin main bodies 257a to 257h are arranged in the outer periphery of the bobbin 50 in order along the X axis from the side close to the first core 10. Electric wires are alternately wound on each of the second bobbin main bodies 257a to 257h in the order of the second electric wire 92 and the third electric wire 94. ​​

[0183] In the present embodiment, the coupling of the second coil element portion formed by the second electric wire 92 and the third coil element portion formed by the third electric wire 94 is higher than that of the first embodiment.

[0184] Further, the present application is not limited to the above-described embodiments, and various changes can be made within the scope of the present application.

[0185] For example, in the above-described embodiments, the second core 20 is a so-called E-shaped core, but is not limited thereto, and can be a flat plate-shaped core having only the base portion 23. For example, on the inner surface 23b of the base portion 23, the same protrusions as the protrusions 24 formed on the back surface 23a are formed on the symmetric positions across the base portion 23 in place of the outer leg portions 22.

[0186] In this case, as in the above-described embodiments, on the back surface of the base portion 23 of the second core 20 to which the outer leg portion 32 of the third core 30 is connected, the protrusions 24 connected to the front end surfaces of the outer leg portions 12 of the first core 10 are formed corresponding to the outer leg portions 12 of the first core 10.

[0187] Fourth embodiment

[0188] As shown in FIG. 1, the coil device of the present embodiment is the same as the coil device of the first embodiment except for the structures of the first core 110, the second core 120, and the third core 130. In the following description, the description of the portions common to the first embodiment is omitted. Figure 3B In the first embodiment, the first core 10, the second core 20, and the third core 30 are formed using a mold divided along the X axis (longitudinal extrusion molding), and in contrast thereto, in the present embodiment, the first core 110, the second core 120, and the third core 130 are formed using a mold divided along the Z axis (lateral extrusion molding).

[0189] That is, in the present embodiment, the first outer leg portion 12 of the first core 110 has the inner side surface 12b parallel to the Z axis, and the both sides of the first middle leg portion 11 along the Y axis have the flat surfaces 11b parallel to the Z axis. Therefore, the first core 110 is formed in a simple structure having no curved surface on the X-Z plane.

[0190] Further, in the present embodiment, the second outer leg portion 22 of the second core 120 has the inner side surface 22b parallel to the Z axis, the protrusions 24 have the inner side surfaces 24b parallel to the Z axis, and the both sides of the second middle leg portion 21 along the Y axis have the flat surfaces 21b parallel to the Z axis. Therefore, the second core 120 is formed in a simple structure having no curved surface on the X-Z plane.

[0191]

[0192] ​In addition, in the present embodiment, the third outer leg portion 32 of the third core 130 has an inner side surface 32b parallel to the Z-axis, and the both sides of the third middle leg portion 31 along the Y-axis have flat surfaces 31b parallel to the Z-axis. Thus, the first core 130 has a simple structure without a curved surface in the X-Z plane.

[0193] As described above, in the present embodiment, the first core 110, the second core 120, and the third core 130 can be formed by using a mold divided along the Z-axis (lateral extrusion formation), respectively.

[0194] In addition, the coil device of the present application can be used for purposes other than the coil device that integrates a transformer and an inductor for a vehicle-mounted charger, such as a resonant transformer used in a resonant circuit used in, for example, a power supply for home electric appliances, AV, communication, and the like.

Claims

1. A coil device, wherein the coil device has a first core, a second core, and a first bobbin, a pair of protrusions connected to the front end surfaces of the pair of outer leg portions of the first core are formed at both ends in the axial direction of the back surface of the base portion of the second core in which the middle leg portion and the outer leg portion are provided, a flat surface between the pair of protrusions of the back surface of the base portion has a gap formed therein that faces the middle leg portion of the first core, the first bobbin has a first end wall flange, the first end wall flange is positioned between the pair of protrusions formed in the back surface of the second core, the upper portion of the first end wall flange protrudes upward from between the pair of protrusions toward a position higher than the upper end of the second core, the first end wall flange enters between the pair of protrusions of the second core, and a first stopper plate formed in the upper portion of the first end wall flange is bent in the direction of the middle leg portion of the second core with respect to the first end wall flange.

2. The coil device according to claim 1, wherein an R portion or a chamfered portion that smoothly connects between the inner side surface of the protrusion and the back surface of the base portion of the second core is formed at the intersection angle portion at which the protrusion protrudes from the back surface of the base portion of the second core.

3. The coil device according to claim 1 or 2, wherein the front end surface of the outer leg portion of the first core and the front end surface of the middle leg portion of the first core are positioned on substantially the same plane.

4. The coil device according to claim 1 or 2, wherein the protrusion protrudes from the back surface of the second core to a height that is less than the thickness of the base portion of the second core.

5. The coil device according to claim 1 or 2, wherein a gap of a prescribed width is formed between the front end surface of the middle leg portion of the first core and the back surface of the base portion of the second core.

6. The coil device according to claim 1 or 2, wherein a third core is further provided, the front end surface of the outer leg portion of the third core is connected to the front end surface of the outer leg portion of the second core.

7. The coil device according to claim 6, wherein the length along the winding axis of the third core is different from the length along the winding axis of the first core, the length along the winding axis of the first core is different from the length along the winding axis of the second core.

8. The coil device according to claim 6, wherein a gap of a prescribed width is formed between the middle leg portion of the second core and the middle leg portion of the third core.

9. The coil device according to claim 1 or 2, wherein a winding portion of a first electric wire is provided around the middle leg portion of the first core, and a winding portion of a second electric wire is provided around the middle leg portion of the second core.

10. The coil arrangement of claim 9, wherein, with: a first bobbin that covers the middle leg portion of the first core and on which the first electric wire is wound; and a second bobbin that covers the middle leg portion of the second core and on which the second electric wire is wound, a second terminal platform formed at the upper end of an end wall flange of the second bobbin overlaps the first stopper plate of the first bobbin, and thus the first bobbin and the second bobbin are fitted on the side surface of the base portion of the second core. ​ 11. The coil device according to claim 10, wherein the lead portion of the first electric wire is connected to a first terminal mounted to the second terminal block of the second bobbin, the lead portion of the second electric wire is connected to a second terminal mounted to the first terminal block of the first bobbin.

12. The coil device according to claim 1 or 2, wherein elements having a plurality of different functions.

13. The coil device according to claim 12, wherein the first core functions as a part of an inductor, and the second core functions as a part of a transformer.

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