Coil arrangement

Abstract

The present application provides a coil device capable of achieving miniaturization. The coil device (10) has: a former (20) having a winding core portion (21) in which a first wire (41c) and a second wire (42c) are wound around an outer peripheral surface, and a flange portion (22a) and (22b) formed at an end portion of the winding core portion (21) in an axial direction; and a terminal base (70) formed separately from the former (20) and mounted to the former (20). The terminal base (70) is disposed at a position separated from the outer peripheral surface of the winding core portion (21) in a direction orthogonal to the axial direction of the winding core portion (21).

Description

TECHNICAL FIELD

[0001] The present application relates to a coil device. BACKGROUND

[0002] As a coil device for a transformer or the like, for example, a coil device described in Patent Literatures 1 and 2 is known. The coil device described in Patent Literature 1 is a longitudinal coil device in which a winding axis of a coil is orthogonal to a surface of a mounting substrate, and the coil device described in Patent Literature 2 is a transverse coil device in which the winding axis of the coil is parallel to the surface of the mounting substrate.

[0003] In the longitudinal coil device described in Patent Literature 1, there is a problem that a height in the direction of the winding axis thereof is likely to be high and it is difficult to achieve thinness or the like. In contrast, in the transverse coil device described in Patent Literature 2, the above-described problem can be avoided and thinness is facilitated.

[0004] However, in the coil device described in Patent Literature 2, a first terminal land is formed below a first flange portion formed at one end in the axial direction of a former, and a second terminal land is formed below a second flange portion formed at the other end in the axial direction of the former. Therefore, in the axial direction of the former and a direction orthogonal thereto, the size of the coil device becomes large, and it is difficult to achieve miniaturization.

[0005] PRIOR ART DOCUMENTS

[0006] PATENT LITERATURES

[0007] Patent Literature 1: Japanese Patent Application Publication No. 2014-36194

[0008] Patent Literature 2: Japanese Patent Application Publication No. 2018-67673 SUMMARY

[0009] The present application is made in view of such a situation, and an object thereof is to provide a coil device capable of achieving miniaturization.

[0010] To achieve the above object, a coil device of the present application has:

[0011] a former having a winding core portion in which a wire is wound around an outer peripheral surface, and a flange portion formed at an end portion in an axial direction of the winding core portion;

[0012] a terminal land formed separately from the former and mounted to the former,

[0013] the terminal land is disposed at a position separated from the outer peripheral surface of the winding core portion in a direction orthogonal to the axial direction of the winding core portion.

[0014] In the coil device of the present application, a terminal base is provided separately from the bobbin and attached to the bobbin. Therefore, when winding the wire around the outer peripheral surface of the winding core portion during the manufacture of the coil device, the terminal base can be detached from the bobbin, and particularly when the winding is performed using an automatic winding machine, the terminal base can be prevented from becoming an obstacle to the automatic winding performed by the automatic winding machine. Further, by forming the terminal base (only the terminal base) separately from the bobbin by a high heat-resistant resin, the coil device having heat resistance can be realized at low cost.

[0015] Further, in the coil device of the present application, the terminal base is disposed at a position separated from the outer peripheral surface of the winding core portion in a direction orthogonal to the axial direction of the winding core portion. Therefore, the terminal base can be disposed laterally of the winding core portion, and the size (length) of the coil device in the axial direction of the winding core portion can be reduced as compared with the prior art in which the terminal base is formed at the end portion in the axial direction of the winding core portion. Further, the size (height) of the coil device in the direction orthogonal to the axial direction of the winding core portion (height direction of the coil device) can be reduced as compared with the prior art in which the terminal base is formed below the flange portion. Therefore, in the coil device of the present application, miniaturization can be achieved.

[0016] Preferably, the terminal base is connected to one end portion in the axial direction of the winding core portion and the other end portion in the axial direction of the winding core portion and is disposed substantially in parallel with the axial direction of the winding core portion. By being configured in this way, the terminal base can be prevented from being disposed in a state of unnecessarily protruding in the direction orthogonal to the axial direction of the winding core portion (laterally of the winding core portion), and the size of the coil device in the direction orthogonal to the axial direction of the winding core portion can be reduced.

[0017] Preferably, the terminal base has an arm portion protruding toward the bobbin, a first hook portion having a hook shape is formed at the tip end of the arm portion, and a flange engaging portion extending in a direction substantially orthogonal to the arm portion is formed at the flange portion and engaged by the first hook portion. By engaging the arm portion of the terminal base with the flange engaging portion of the flange portion via the first hook portion, the terminal base can be attached to the bobbin with sufficient fixing strength without using an adhesive or the like, and low cost and rapid manufacture can be achieved. Further, the terminal base can be disposed at a position separated from the outer peripheral surface of the winding core portion in the direction orthogonal to the axial direction of the winding core portion by a distance corresponding to the length of the arm portion, and the disposition of the terminal base can be adjusted by appropriately changing the length of the arm portion.

[0018] Preferably, a second hook portion having a hook shape is formed at a front end portion of the flange engaging portion, and the lead-out portion of the wire is led out toward the terminal base along the periphery of the arm portion in a state in which the first hook portion and the flange engaging portion are engaged. By leading out the lead-out portion of the wire toward the terminal base along the periphery of the arm portion, the lead-out portion can be led out from the winding core portion to the terminal base in a short distance, and it is possible to prevent the lead-out portion from being unnecessarily wound around, to improve the quality of the coil device, and to contribute to a reduction in electrical resistance or suppression of resonance of the wire. In addition, by forming the second hook portion at the flange engaging portion, it is possible to prevent the lead-out portion led out along the periphery of the arm portion from being displaced toward the front end of the flange engaging portion.

[0019] Preferably, a terminal base fixing portion for fixing the terminal base is formed at an end portion in the axial direction of the skeleton, the terminal base fixing portion has a first stepped portion, the terminal base has a second stepped portion, and the first stepped portion and the second stepped portion are engaged in a state in which a first stepped lower surface of the first stepped portion and a second stepped lower surface of the second stepped portion are in abutment. By providing such a structure, the first stepped portion and the second stepped portion are fixed to each other, and it is possible to prevent the terminal base from being displaced with respect to the terminal base fixing portion in the normal direction of each of the first stepped lower surface and the second stepped lower surface and to mount the terminal base to the terminal base fixing portion with sufficient fixing strength.

[0020] Preferably, a terminal base fixing portion for fixing the terminal base is formed at an end portion in the axial direction of the skeleton, the terminal base fixing portion has a protrusion portion that protrudes toward the terminal base, and the terminal base has a recess portion that engages with the protrusion portion. By engaging the protrusion portion of the terminal base fixing portion and the recess portion of the terminal base, it is possible to prevent the terminal base from being displaced with respect to the terminal base fixing portion in the extending direction of the terminal base (the axial direction of the winding core portion).

[0021] Preferably, the flange portion is formed along the circumferential direction of the winding core portion, and a notch portion through which the lead-out portion of the wire is inserted is formed at the flange portion. By providing such a structure, it is possible to lead out the lead-out portion of the wire wound around the winding core portion from the inside to the outside of the flange portion in which the winding core portion is located via the notch portion, and it is possible to prevent the lead-out portion from being unnecessarily wound around.

[0022] Preferably, one lead-out portion of the wire is led out toward the terminal base from the outside of the flange portion via the notch portion, and the other lead-out portion of the wire is led out toward the terminal base from the inside of the flange portion without passing through the notch portion. By providing such a structure, one lead-out portion of the wire passes through the outside of the flange portion, and the other lead-out portion of the wire passes through the inside of the flange portion, and thus it is possible to well insulate the one lead-out portion and the other lead-out portion via the flange portion.

[0023] Preferably, there is also a cover portion arranged around the terminal block, the winding is composed of a plurality of windings, and a plurality of terminals respectively connected to the lead-out portions of the plurality of windings are installed on the terminal block along the axial direction of the winding core portion, and the cover portion has a holding portion for holding the terminal block, a bottom portion arranged below the plurality of terminals, and a side portion rising from the side end portion of the bottom. By holding the terminal block by the holding portion, the cover portion can be installed on the terminal block with sufficient fixing strength even without using adhesives, etc., which can achieve low cost and rapid manufacturing. In addition, by providing the cover portion with a bottom and sides, the terminals installed on the terminal block are protected from external forces, etc., and the terminals and the core can be well insulated via the bottom and sides.

[0024] Preferably, the axial direction of the winding core is substantially parallel to the mounting surface. By setting such a structure, the height of the coil device can be suppressed, and the thickness of the coil device can be reduced.

[0025] Preferably, the coil assembly further comprises a housing for housing the bobbin, the housing being capable of being filled with a filling resin, and at least one through-hole being formed on the outer circumferential surface of the winding core. This structure allows heat generated by the bobbin, etc., to be dissipated to the outside via the housing and the filling resin, enabling efficient cooling of the coil assembly. Furthermore, by forming a through-hole in the bobbin, the filling resin can flow through the through-hole to the inside and outside of the bobbin, allowing the filling resin to reach every corner of the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a perspective view of the coil device according to the first embodiment of the present invention.

[0027] Figure 2 It is from Figure 1 The coil device shown is a perspective view with the case and resin omitted.

[0028] Figure 3 yes Figure 1 An exploded perspective view of the coil arrangement shown.

[0029] Figure 4A Viewed from the outside along the Y axis Figure 3 A side view of the base portion of the core is shown.

[0030] Figure 4B Viewed from the inside along the Y axis Figure 3 Side view of the core with the middle and outer legs shown.

[0031] Figure 5 It is along Figure 1 A cross-sectional view of the coil device taken along line VV is shown.

[0032] Figure 6 yesFigure 3 a perspective view of the skeleton shown.

[0033] Figure 7 is a perspective view of the skeleton shown. Figure 6 a perspective view of the skeleton shown. Figure 3 a side view of the first coil portion and the second coil portion shown.

[0034] Figure 8 is a perspective view of the terminal, the terminal base, and the cover portion shown. Figure 3 a perspective view of the terminal, the terminal base, and the cover portion shown.

[0035] Figure 9 is a perspective view of the skeleton shown. Figure 6 a perspective view of the skeleton shown. Figure 8 a perspective view of the terminal base and the cover portion shown.

[0036] Figure 10 is a perspective view of the terminal base and the skeleton shown. Figure 9 a perspective view of the terminal base and the skeleton shown.

[0037] Figure 11 is a perspective view of the coil device of the second embodiment of the present application.

[0038] Figure 12 is a perspective view of the coil device shown. Figure 11 an exploded perspective view of the coil device shown.

[0039] Explanation of Symbols

[0040] 10, 110... coil device, 20, 120... bobbin, 21... winding core portion, 211... through hole, 22a, 22b... flange portion, 220a, 220b... flange portion main body, 23a, 23b... terminal base fixing portion, 230a, 230b... fixing main body portion, 24a, 24b... flange engaging portion, 25a, 25b... bobbin hook portion, 26a, 26b... partition portion, 27a, 27b... extension flange portion, 28a, 28b, 29a, 29b... notch portion, 30a, 30b... bobbin protrusion portion, 31a, 31b... bobbin step portion, 310a, 310b... step lower surface, 32a, 32b... placement portion, 33, 34... protrusion portion, 35a, 35b, 36a, 36b... through hole portion, 37a, 37b... concave bottom portion, 41... first coil portion, 42... second coil portion, 41a, 41b... first lead portion, 41c... first wire, 42a, 42b... second lead portion, 42c... second wire, 43... contact area, 44, 45... non-contact area, 50a, 50b... core, 51a, 51b... base portion, 510a, 510b... outer surface, 511a, 511b... inner surface, 512a, 512b... upper surface, 513a, 513b... lower surface, 52a, 52b... outer leg portion, 520a, 520b... outer leg inner side surface, 53a, 53b... middle leg portion, 54a, 54b... upper side recessed portion, 540a, 540b... upper side bottom surface, 541a, 541b... upper side tapered surface, 55a, 55b... lower side recessed portion, 550a,550b…lower bottom surface, 550a, 551b…lower tapered surface, 56a, 56b…wall thickness portion, 61_1, 61_2, 62_1, 62_2…terminal 610_1, 610_2, 620_1, 620_2…external connection portion, 611_1, 611_2, 621_1, 621_2…linking portion, 612_1, 612_2, 622_1, 622_2…wiring bottom portion, 613_1, 613_2, 623_1, 623_2…wiring turnback portion, 70, 70_1, 70_2…terminal platform, 71…terminal platform base portion, 72a, 72b…arm portion, 73a, 73b…terminal platform hook portion, 74a, 74b…terminal platform step portion, 740a, 740b…step lower surface, 75a, 75b…terminal platform recess portion, 76a, 76b…lead insertion slot, 77a_1, 77a_2, 77b_1, 77b_2…terminal fixing portion, 770a_1, 770a_2, 770b_1, 770b_2…terminal insertion slot, 78…cover mounting portion, 79…bottom surface fixing portion, 80, 80_1, 80_2…cover portion, 81…cover bottom portion, 82…insulation portion, 820…insulation recess portion, 83a, 83b…cover side portion, 84…gripping portion, 841…upper arm, 842…lower arm, 90…housing, 91…housing bottom portion, 92…housing side portion, 93…joint portion, 100…resin. DETAILED DESCRIPTION

[0041] Hereinafter, the present application will be described based on the embodiment shown in the drawings.

[0042] First embodiment

[0043] Figure 1 The coil device 10 of the present embodiment shown functions as a transformer, for example, for a vehicle-mounted charger for an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a commuter car, a circuit of a household or industrial electrical device, or a power supply circuit of a computer device, and the like. Hereinafter, the detailed structure of the coil device 10 will be described. In the following description, the Z-axis positive direction side is set as the upper side, and the Z-axis negative direction side is set as the lower side. In addition, the side toward the center of the coil device 10 is set as the inner side or the inner direction, and the side away from the center of the coil device 10 is set as the outer side or the outer direction.

[0044] As shown in FIG. 1, the coil device 10 includes a housing 90, a terminal platform 70, a cover 80, and a resin 100. Figure 3As shown, the coil device 10 has a skeleton 20, a first coil portion 41 and a second coil portion 42, cores 50a and 50b, first terminals 61_1 and 61_2, second terminals 62_1 and 62_2, a terminal block 70, a cover 80, and a housing 90. The coil device 10 is a horizontal coil device in which the winding axes of the first coil portion 41 and the second coil portion 42 are parallel to the surface of the mounting substrate (not shown). In addition, the mounting substrate is arranged on Figure 1 The upper side (Z-axis positive direction side) of the coil device 10 shown in the figure serves as an installation surface (mounting surface) of the coil device with respect to the mounting substrate.

[0045] The housing 90 is made of a metal with excellent cooling properties, such as aluminum, and includes a housing bottom 91 and a housing side 92. The top of the housing 90 is open, and the frame 20 and the like can be accommodated through the opening formed in the top of the housing 90. The housing bottom 91 has a generally rectangular shape and constitutes the bottom surface of the housing 90. The housing side 92 has a generally rectangular cylindrical shape and is formed along the outer edge of the housing bottom 91.

[0046] More specifically, the housing side portions 91 extend upward from each of the four sides that constitute the outer edge of the housing bottom portion 91. The housing 90 is formed by bending a single metal plate, etc., and the mating surfaces of the bent portions are formed on the housing side portions 92 as joints 93. Alternatively, the joints 93 may be sealed liquid-tightly by applying an adhesive or the like thereto.

[0047] The housing space formed by the housing bottom 91 and the housing side 92 accommodates the frame 20 and the like, and can be Figure 1 The housing 90 is filled with a filling resin 100. The filling resin 100 is made of silicone resin, polyurethane resin, epoxy resin, or the like. The filling resin 100 is filled to the position of the opening of the housing 90, and a portion of the frame 20, a portion of the first terminal 61_1, etc., or a portion of the cover 80 is exposed from the upper surface of the cured filling resin 100.

[0048] In the present embodiment, heat generated by the bobbin 20 and the like can be dissipated to the outside via the case 90 and the filling resin 100 , and the coil device 10 can be efficiently cooled.

[0049] like Figure 3 As shown, the first coil portion 41 is formed by winding a first winding wire 41c around the outer circumference of the winding core portion 21 of the bobbin 20. In addition, the second coil portion 42 is formed by winding a second winding wire 42c around the outer circumference of the winding core portion 21 of the bobbin 20. The first winding wire 41c and the second winding wire 42c are wound around the outer circumference of the winding core portion 21 using, for example, an automatic winding machine.

[0050] The first coil portion 41 is formed in two layers in a direction orthogonal to the winding axis thereof (radial direction), and the second coil portion 42 is formed in two layers in a direction orthogonal to the winding axis thereof (radial direction). Further, the winding axes of the first coil portion 41 and the second coil portion 42 are substantially identical, and correspond to the Y-axis direction.

[0051] The first coil portion 41 is provided on one side of the winding core portion 21 in the Y-axis direction (positive direction of the Y-axis), and the second coil portion 42 is provided on the other side of the winding core portion 21 in the Y-axis direction (negative direction of the Y-axis). Either of the first coil portion 41 and the second coil portion 42 constitutes a primary coil, and the other of the first coil portion 41 and the second coil portion 42 constitutes a secondary coil. The arrangement of the primary coil and the secondary coil of the winding core portion 21 can also be either of the one side and the other side of the winding core portion 21 in the Y-axis direction.

[0052] The first winding 41c and the second winding 42c are each formed of an insulated covered wire, and are formed of a conductor wire such as a copper wire. The first winding 41c and the second winding 42c can each be formed of a single wire, or can be formed of a stranded wire. The wire diameter (diameter) of the first winding 41c and the second winding 42c is, for example, preferably 1.0 to 3.0 mm. The wire diameters of the first winding 41c and the second winding 42c can be equal to each other, or can be different. For example, in the first winding 41c and the second winding 42c, the wire diameter of the winding through which a large current flows can be made thicker than the wire diameter of the other winding.

[0053] The lead portion 41a is formed at one end of the first coil portion 41, and the lead portion 41b is formed at the other end of the first coil portion 41. For example, the lead portion 41a is drawn out from the second layer of the first coil portion 41, and the lead portion 41b is drawn out from the first layer of the first coil portion 41.

[0054] Further, the lead portion 42a is formed at one end of the second coil portion 42, and the lead portion 42b is formed at the other end of the second coil portion 42. For example, the lead portion 42a is drawn out from the second layer of the second coil portion 42, and the lead portion 42b is drawn out from the first layer of the second coil portion 42.

[0055] The cores 50a and 50b are so-called E-shaped cores, and are attached to the bobbin 20. The material of the cores 50a and 50b can be a magnetic material such as a metal or a ferrite, but is not particularly limited. The cores 50a and 50b each have the same shape. The core 50a has a base portion 51a, a pair of outer leg portions 52a, and a middle leg portion 53a. The core 50b has a base portion 51b, a pair of outer leg portions 52b, and a middle leg portion 53b. Hereinafter, the structure of the core 50a will be described, but the description of the core 50a is also applicable to the core 50b. Therefore, unless otherwise required, the description of the structure of the core 50b will be omitted.

[0056] The base portion 51a has a prescribed thickness in the Y-axis direction, as shown in Figure 4A and Figure 4B has prescribed lengths in the X-axis direction and the Z-axis direction, respectively. Hereinafter, in the base portion 51a, the face on the outer side in the Y-axis direction is referred to as the outer face 510a, the face on the inner side in the Y-axis direction is referred to as the inner face 511a, the face on the upper side is referred to as the upper face 512a, and the face on the lower side is referred to as the lower face 513a. Also, in the base portion 51b, the face on the outer side in the Y-axis direction is referred to as the outer face 510b, the face on the inner side in the Y-axis direction is referred to as the inner face 511b, the face on the upper side is referred to as the upper face 512b, and the face on the lower side is referred to as the lower face 513b.

[0057] The upper face 512a and the lower face 513a are faces orthogonal to the outer face 510a and the inner face 511a. The upper face 512b and the lower face 513b are faces orthogonal to the outer face 510b and the inner face 511b.

[0058] In the present embodiment, an upper-side recessed portion 54a recessed at the position of the midfoot portion 53a is formed on the upper face 512a of the base portion 51a. The upper-side recessed portion 54a is formed in the substantially central portion of the base portion 51a in the X-axis direction and has a prescribed width in the X-axis direction and the Y-axis direction. The X-axis-direction width of the upper-side recessed portion 54a is substantially equal to the X-axis-direction width of the midfoot portion 53a. The Y-axis-direction width of the upper-side recessed portion 54a is substantially equal to the Y-axis-direction thickness of the base portion 51a (see Figure 3 ).

[0059] The upper-side recessed portion 54a is recessed from the upper face 512a toward the lower side by a prescribed depth, and a bottom face of the upper-side recessed portion 54a, that is, an upper-side bottom face 540a is formed at substantially the same height position as the upper portion of the outer peripheral face of the midfoot portion 53a. The upper-side bottom face 540a is constituted by a face curved convexly toward the upper side, and the degree of curvature of the upper-side bottom face 540a is substantially in accordance with the degree of curvature of the upper portion of the outer peripheral face of the midfoot portion 53a. Therefore, the upper-side bottom face 540a is connected to the upper portion of the outer peripheral face of the midfoot portion 53a in the Y-axis direction in such a manner as to become a substantially identical face (see Figure 3 ).

[0060] An upper-side tapered face 541a is formed on the inner wall face of the upper-side recessed portion 54a (a face rising from both sides in the X-axis direction of the upper-side bottom face 540a). The upper-side tapered face 541a is inclined at a prescribed angle and connects between the upper face 512a and the upper-side bottom face 540a.

[0061] The lower surface 513a of the base 51a is formed with a lower recessed portion 55a that is recessed at the position of the middle leg 53a. The lower recessed portion 55a is formed approximately in the center of the base 51a in the X-axis direction and has a predetermined width in the X-axis and Y-axis directions. The width of the lower recessed portion 55a in the X-axis direction is smaller than the width of the middle leg 53a in the X-axis direction and is aligned with the concave bottom 37a or 37b ( Figure 6 The width of the lower concave portion 55a in the Y-axis direction is substantially equal to the thickness of the base portion 51a in the Y-axis direction.

[0062] like Figure 4B As shown, the lower recess 55a is recessed upward from the lower surface 513a to a predetermined depth. The depth of the lower recess 55a is greater than that of the upper recess 54a. The bottom surface of the lower recess 55a, i.e., the lower bottom surface 550a, is formed at a position spaced a predetermined distance downward from the lower portion of the outer circumference of the middle leg 53a. The lower bottom surface 550a is substantially flat, with a step formed between the lower bottom surface 550a and the lower portion of the outer circumference of the middle leg 53a.

[0063] The inner wall surface of the lower concave portion 55a (the surface rising from both sides of the lower bottom surface 550a in the X-axis direction) is formed with a lower tapered surface 551a. The lower tapered surface 551a is inclined at a predetermined angle and connects the lower surface 513a and the lower bottom surface 550a. The shape of the lower concave portion 55a is consistent with the concave bottom 37a or 37b ( Figure 6 ) are roughly the same shape.

[0064] In this embodiment, if Figure 3 As shown, the filling resin 100 is filled into the interior of the housing 90, and a resin layer composed of the filling resin 100 is formed around the cores 50a and 50b. In this case, since the filling resin 100 enters Figure 4B Since the interiors of the upper recess 54 a and the lower recess 55 a are shown, a sufficient contact area between the filling resin 100 and the cores 50 a and 50 b can be ensured, and heat generated by the cores 50 a and 50 b can be sufficiently dissipated through the filling resin 100 .

[0065] Furthermore, by providing the upper concave portion 54a with an upper tapered surface 541a and the lower concave portion 55a with a lower tapered surface 551a, the surface area of ​​the inner wall of each of the upper concave portion 54a and the lower concave portion 55a can be increased, thereby increasing the contact area between the upper concave portion 54a and the lower concave portion 55a and the filling resin 100.

[0066] In addition, when filling the filling resin 100, because the filling resin 100 flows inside the upper recess 54a and the lower recess 55a, for example, from the inner side (outer side) toward the outer side (inner side) in the Y-axis direction of the base portion 51a (that is, because the upper recess 54a and the lower recess 55a serve as flow paths for the filling resin 100), the filling resin 100 can be spread to every corner inside the shell 90.

[0067] The middle leg portion 53a is arranged between the pair of outer legs 52a and is connected to the inner surface 511a of the base portion 51a. The middle leg portion 53a extends from the inner surface 511a along the Y-axis direction by a predetermined length and is arranged inside the through-hole 211 formed in the winding core portion 21 of the skeleton 20. The middle leg portion 53a of the core 50a and the middle leg portion 53b of the core 50b are arranged inside the through-hole 211 with their respective front ends docked. In addition, a gap may be formed along the Y-axis direction between the front ends of the middle leg portion 53a and the front ends of the middle leg portion 53b.

[0068] like Figure 4B As shown, the middle leg portion 53a is not formed at the center of the inner surface 511a of the base portion 51a, but is formed at a position offset upward (to one side in the Z-axis direction) from the center C1 of the inner surface 511a. The distance L1 between the center C2 of the middle leg portion 53a and the center C1 of the inner surface 511a of the base portion 51a (i.e., the width of the positional offset in the Z-axis direction of the center C2 of the middle leg portion 53a relative to the center C1 of the inner surface 511a) can also be determined based on the length L2 of the base portion 51a (outer leg portion 52a) along the Z-axis. The ratio L1 / L2 of L1 to L2 is preferably 0 < L1 / L2 < 1 / 4, and more preferably 0 < L1 / L2 < 1 / 6. In this embodiment, as will be described later, the middle leg portion 53a is positioned offset upward from the center C1 of the inner surface 511a below the inner surface 511a in order to ensure sufficient space for forming the thick wall portion 56a on the outer leg portion 52a.

[0069] The upper portion of the outer peripheral surface of the middle leg portion 53a is arranged close to the upper surface 512a of the base portion 51a and is located below the upper surface 512a. The shape of the upper portion of the outer peripheral surface of the middle leg portion 53a is consistent with the upper bottom surface 540a ( Figure 4A ) are substantially identical in shape. The lower portion of the outer circumference of the middle leg portion 53a is positioned near the lower bottom surface 550a of the lower recess 55a, and is located above the lower bottom surface 550a. That is, the middle leg portion 53a is located between the upper surface 512a and the lower recess 55a (lower bottom surface 550a) in the Z-axis direction.

[0070] like Figure 3As shown, the pair of outer legs 52a are arranged at a predetermined interval along the X-axis direction and connected to the inner surface 511a of the base portion 51a. One of the pair of outer legs 52a is arranged at one end of the inner surface 511a in the X-axis direction, and the other of the pair of outer legs 52a is arranged at the other end of the inner surface 511a in the X-axis direction.

[0071] The pair of outer leg portions 52 a extend from the inner surface 511 a along the Y-axis direction by a predetermined length and are arranged outside the winding core portion 21 of the frame 20 .

[0072] like Figure 4B As shown, a thick portion 56a is formed at each end of the pair of outer legs 52a in the Z-axis direction. The thick portion 56a is formed at the lower end of the outer legs 52a (i.e., the end on the opposite side of the Z-axis direction from the positional offset direction (upward) of the above-mentioned middle leg 53a).

[0073] The thick portion 56a protrudes inward in the X-axis direction (toward the center C1 of the inner surface 511a of the base portion 51a) and is formed so as to be thick in the X-axis direction. Forming the thick portion 56a on the outer leg 52a ensures a sufficient cross-sectional area of ​​the outer leg 52a, thereby achieving a coil device 10 with excellent inductance characteristics.

[0074] Furthermore, because the cross-sectional area of ​​the outer leg portion 52a is increased by the amount by which the thick wall portion 56a is formed, even when the length of the outer leg portion 52a along the X-axis direction or the Z-axis direction is reduced (i.e., when the volume of the core 50a is reduced), the required cross-sectional area can be sufficiently ensured, thereby effectively miniaturizing the core 50a and, in turn, the coil device 10. Furthermore, by making the core 50a small, when, for example, the core 50a is filled with the filling resin 100, the filling resin 100 can be more easily wrapped around the core 50a.

[0075] The width W1 of the thick portion 56a along the X-axis increases downward. The ratio W1 / W2 of the width W1 of the thick portion 56a along the X-axis to the maximum width W2 of the base portion 51a along the X-axis is preferably 0 < W1 / W2 < 1 / 2. By setting the value of W1 / W2 within the above range, the volume of the thick portion 56a can be sufficiently maintained, and the volume of the area without the thick portion 56a can also be sufficiently maintained, which helps improve the inductance characteristics of the coil device 10.

[0076] The outer-heel inner side surface 520a of the outer-heel portion 52a is curved toward the inner side in the X-axis direction as it goes toward the lower end of the outer-heel portion 52a. That is, because the wall-thick portion 56a is formed in the outer-heel portion 52a, the outer-heel inner side surface 520a is curved at the position of the wall-thick portion 56a toward the side on which the center C1 of the inner surface 511a of the base portion 51a is located. The curved portion of the outer-heel inner side surface 520a is curved substantially along the outer peripheral surface of the mid-heel portion 53a. In addition, as shown in Figure 5 , the curved portion of the outer-heel inner side surface 520a is curved substantially along the peripheral portion of the flange portion 22a (flange portion main body 220a) of the skeleton 20. Further, the outer side surface of the outer-heel portion 52a on the opposite side in the X-axis direction of the outer-heel inner side surface 520a extends in the Z-axis direction, and the shape of the outer-heel inner side surface 520a becomes a shape different from that of the outer side surface.

[0077] As shown in Figure 4B , in the present embodiment, the cross-sectional area S1 of the mid-heel portion 53a is substantially equal to the sum of one cross-sectional area S2 and another cross-sectional area S3 of the pair of outer-heel portions 52a. In the present embodiment, as a result of the wall-thick portion 56a being formed in the outer-heel portion 52a, the cross-sectional area of the outer-heel portion 52a increases, so even in the case where the size of the outer-heel portion 52a is reduced as a whole, it is possible to make the sum (S2+S3) of the cross-sectional areas of the pair of outer-heel portions 52a each approach substantially equal to the cross-sectional area S1 of the mid-heel portion 53a.

[0078] By providing such a structure after the wall-thick portion 56a is formed in the outer-heel portion 52a, it is possible to effectively prevent magnetic saturation of the magnetic flux passing through the mid-heel portion 53a and the pair of outer-heel portions 52a, and it is possible to improve the inductance characteristics of the coil device 10.

[0079] The skeleton 20 is made of, for example, plastic such as PPS, PET, PBT, LCP, or other insulating members (preferably, a material having heat resistance). As shown in Figure 3 , the skeleton 20 has the winding core portion 21, the flange portions 22a and 22b, and the terminal land fixing portions 23a and 23b.

[0080] The first winding 41c and the second winding 42c are wound around the outer peripheral surface of the winding core portion 21, and the first coil portion 41 and the second coil portion 42 are formed. The first coil portion 41 is disposed between the flange portion 22a and the following protruding portions 33 and 34 Figure 7 ) on one side in the Y-axis direction of the winding core portion 21.

[0081] One end portion of the first coil portion 41 in the winding axis direction is arranged adjacent to the flange portion 22a, and the other end portion of the first coil portion 41 in the winding axis direction is arranged adjacent to the protrusions 33 and 34. In addition, one end portion of the second coil portion 42 in the winding axis direction is arranged adjacent to the flange portion 22b, and the other end portion of the second coil portion 42 in the winding axis direction is arranged adjacent to the protrusions 33 and 34.

[0082] The winding core portion 21 is composed of a cylindrical body having a roughly elliptical shape, and the axial direction of the winding core portion 21 is consistent with the Y-axis direction. A through hole 211 is formed on the inner side of the winding core portion 21, and the middle legs 53a and 53b of the cores 50a and 50b can be accommodated inside the through hole 211. As described above, because the coil device 10 of this embodiment is a horizontal coil device, the axial direction of the winding core portion 21 is roughly parallel to the mounting surface of the coil device 10 or the mounting surface of the mounting substrate (not shown). Therefore, the height of the coil device 10 can be suppressed, and the thinning of the coil device 10 can be achieved.

[0083] The cross-sectional shape of the winding core 21 (the cross-sectional shape of the surface parallel to the XZ plane) is composed of a substantially elliptical shape (see Figure 5 The surfaces on the long sides of the core 21 (the upper and lower portions of the outer circumference of the core 21) are substantially flat, and the surfaces on the short sides of the core 21 (the lateral portions of the outer circumference of the core 21) are curved. The surfaces on the long sides of the core 21 may also be curved, but the degree of curvature is preferably smaller than that of the surfaces on the short sides of the core 21.

[0084] like Figure 6 As shown, the through-hole portions 35a and 35b are formed in the upper portion of the outer peripheral surface of the winding core portion 21 at predetermined intervals along the Y-axis direction. The through-hole portions 35a and 35b are located in the center of the winding core portion 21 in the X-axis direction. The through-hole portion 35a is located on the Y-axis side of the protrusion 33 (the position where the first coil portion 41 is arranged), and is located between the flange portion 22a and the protrusion 33 in the Y-axis direction. The through-hole portion 35b is located on the other Y-axis side of the protrusion 33 (the position where the second coil portion 42 is arranged), and is located between the flange portion 22b and the protrusion 33 in the Y-axis direction. The through-hole portions 35a and 35b are respectively formed of the same shape, and have an opening portion formed of a substantially elliptical shape with a long side in the Y-axis direction.

[0085] The through holes 36a and 36b are formed at a predetermined interval along the Y-axis direction in the lower portion of the outer peripheral surface of the winding core 21. The through holes 36a and 36b are located in the center of the winding core 21 in the X-axis direction. The through hole 36a is located at a position larger than the protrusion 34 ( Figure 7) on the other side in the Y-axis direction (a position where the second coil portion 42 is arranged) than the protruding portion 34, between the flange portion 22b and the protruding portion 34 in the Y-axis direction. The through-hole portions 36a and 36b are each configured by the same shape, and have an opening portion configured by a substantially elliptical shape having a long side in the Y-axis direction. In the Z-axis direction, the position of the through-hole portion 36a corresponds to the position of the through-hole portion 35a, and the position of the through-hole portion 36b corresponds to the position of the through-hole portion 35b.

[0086] By forming the through-hole portions 35a, 35b, 36a, and 36b in the winding core portion 21, the filling resin 100 (see FIG. 2) can flow in and out of the framework 20 (winding core portion 21) via these through-hole portions, and the filling resin 100 can reach each corner in the case 90. Figure 1

[0087] The flange portion 22a is formed at one end portion in the axial direction of the winding core portion 21, and the flange portion 22b is formed at the other end portion in the axial direction of the winding core portion 21. The flange portion 22a and the flange portion 22b each have the same shape. The flange portion 22a has a flange portion main body 220a extending along the outer circumferential surface of the winding core portion 21 in the circumferential direction at one end in the Y-axis direction of the winding core portion 21. The flange portion 22b has a flange portion main body 220b extending along the outer circumferential surface of the winding core portion 21 in the circumferential direction at the other end in the Y-axis direction of the winding core portion 21. The flange portion main body 220a is configured by a plate body having a prescribed thickness in the Y-axis direction, and projects outward in the radial direction of the winding core portion 21. The flange portion main body 220b is configured by a plate body having a prescribed thickness in the Y-axis direction, and projects outward in the radial direction of the winding core portion 21.

[0088] A pair of placement portions 32a (see FIG. 2) is formed below the flange portion main body 220a. Figure 5 ) on the other side in the X-axis direction of the flange portion main body 220a, and the other placement portion 32a is formed on the other side in the X-axis direction of the flange portion main body 220a. The one placement portion 32a and the other placement portion 32a are arranged at a prescribed interval in the X-axis direction. The pair of placement portions 32a extends substantially in parallel with the flange portion main body 220a along the XZ plane, and the bottom surface of the pair of placement portions 32a is a substantially flat surface. The pair of placement portions 32a is placed on the case bottom portion 91 of the case 90 as shown in FIG. 2. Figure 3

[0089] ​​A pair of placement portions 32b is formed below the flange portion main body 220b. Since the structure and function of the pair of placement portions 32b are the same as those of the pair of placement portions 32a, detailed description thereof is omitted. The winding core portion 21 and the like of the skeleton 20 can be supported via the pair of placement portions 32a and the pair of placement portions 32b.

[0090] A concave bottom portion 37a is formed between each of the pair of placement portions 32a, and a concave bottom portion 37b is formed between each of the pair of placement portions 32b. The concave bottom portions 37a and 37b have a shape in which the position of the bottom surface of the placement portions 32a and 32b is recessed upward. The bottom of the concave bottom portions 37a and 37b constitutes the outer peripheral surface of the flange portion main bodies 220a and 220b, and a portion of the inner wall surface of the concave bottom portions 37a and 37b is inclined in a tapered shape. By forming the concave bottom portions 37a and 37b in the flange portion main bodies 220a and 220b, when the filling resin 100 is filled (i.e., since the concave bottom portions 37a and 37b function as a flow path of the filling resin 100), the filling resin 100 can be caused to flow inside the concave bottom portions 37a and 37b from the inside (the outside) of the concave bottom portions 37a and 37b in the Y-axis direction toward the outside (the inside) (i.e., since the concave bottom portions 37a and 37b function as a flow path of the filling resin 100), and thus the filling resin 100 can be caused to particularly spread to the lower side of the skeleton 20. Figure 1 ) can be caused to particularly spread to the lower side of the skeleton 20.

[0091] A flange engagement portion 24a is formed above the flange portion main body 220a. The flange engagement portion 24a is integrally connected to the upper side of the flange portion main body 220a and extends in the XZ plane substantially in parallel to the flange portion main body 220a. That is, the flange engagement portion 24a has a shape in which the flange portion main body 220a is extended upward and constitutes a portion of the flange portion main body 220a. The flange engagement portion 24a is formed on the X-axis negative direction side in the upper end portion of the flange portion main body 220a and protrudes upward more than the fixed main body portion 230a of the terminal stage fixed portion 23a.

[0092] The flange engagement portion 24a has a prescribed thickness in the Y-axis direction and has a surface substantially parallel to the XZ plane. In addition, the flange engagement portion 24a extends in a direction substantially orthogonal to the long side direction (X-axis direction) of the arm portion 72a (described below) of the terminal stage 70. Figure 8 ) formed on the front end portion of the arm portion 72a can be engaged with the flange engagement portion 24a. Figure 8

[0093] ​A skeleton hook portion 25a having a hook shape is formed at the front end portion (upper end portion) of the flange engaging portion 24a. The skeleton hook portion 25a is configured to protrude from the upper end portion of the flange engaging portion 24a to the inner side in the X-axis direction and to the outer side in the Z-axis direction. More specifically, the skeleton hook portion 25a protrudes further to the outer side in the Y-axis direction than the surface of the flange engaging portion 24a. In addition, the skeleton hook portion 25a protrudes further to the inner side in the X-axis direction than the surface of the flange engaging portion 24a. The cross-sectional area of the skeleton hook portion 25a along the XY plane is larger than the cross-sectional area of the flange engaging portion 24a along the XY plane. The skeleton hook portion 25a has a function (locking function) of preventing the lead portion 41a or 41b of the first coil portion 41 drawn along the periphery of the flange engaging portion 24a from being displaced in position toward the upper side of the flange engaging portion 24a.

[0094] Since the function and structure of the flange engaging portion 24b formed above the flange portion main body 220b and the skeleton hook portion 25b formed at the front end portion of the flange engaging portion 24b are the same as those of the above-described flange engaging portion 24a and skeleton hook portion 25a, respectively, detailed description thereof is omitted. In addition, the skeleton hook portion 25b has a function (locking function) of preventing the lead portion 42a or 42b of the second coil portion 42 drawn along the periphery of the flange engaging portion 24b from being displaced in position toward the upper side of the flange engaging portion 24b.

[0095] A terminal table fixing portion 23a fixing the Y-axis direction one end portion of the terminal table 70 is formed at the Y-axis direction one end portion of the skeleton 20, and a terminal table fixing portion 23b fixing the Y-axis direction other end portion of the terminal table 70 is formed at the Y-axis direction other end portion of the skeleton 20. Figure 8 ) of the terminal table 70. The terminal table fixing portions 23a and 23b have a function of fixing the terminal table 70, and in the case where the first winding 41c and the second winding 42c are wound around the winding core portion 21 by an automatic winding machine, function to fix a part of the automatic winding machine.

[0096] The terminal table fixing portion 23a has a fixing main body portion 230a, a skeleton protrusion portion 30a, and a skeleton step portion 31a. The terminal table fixing portion 23b has a fixing main body portion 230b, a skeleton protrusion portion 30b, and a skeleton step portion 31b.

[0097] The fixed body portions 230a and 230b are formed in a substantially flat plate shape having a surface substantially parallel to the XY plane, and have a prescribed thickness in the Z-axis direction. The width of the fixed body portions 230a and 230b in the X-axis direction is greater than the width of the winding core portion 21 in the X-axis direction, and is substantially equal to the width of the flange portion bodies 220a and 220b in the X-axis direction. The fixed body portion 230a is integrally connected to the surface on the outer side in the Y-axis direction of the flange portion body 220a of the flange portion 22a, and protrudes from this surface to the outer side in the Y-axis direction. The fixed body portion 230b is integrally connected to the surface on the outer side in the Y-axis direction of the flange portion body 220b of the flange portion 22b, and protrudes from this surface to the outer side in the Y-axis direction.

[0098] The skeleton protrusions 30a and 30b are formed in a protruding piece having a protruding shape, and protrude from the side portions (sides) of the fixed body portions 230a and 230b in the X-axis direction to the outer side in the X-axis direction by a prescribed length. The protruding directions of the skeleton protrusions 30a and 30b respectively correspond to the directions in which the terminal stages 70 are arranged.

[0099] The skeleton protrusions 30a and 30b have a substantially cuboid shape formed in a flat shape, and the thickness of the skeleton protrusions 30a and 30b in the Z-axis direction is smaller than the thickness of the fixed body portions 230a and 230b in the Z-axis direction. The skeleton protrusion 30a engages with the terminal stage recess 75a (75b) of the terminal stage 70, and the skeleton protrusion 30b engages with the terminal stage recess 75b (75a) of the terminal stage 70. Figure 8 ) of the terminal stage 70. Figure 8

[0100] The skeleton step portion 31a is formed on the back surface of the fixed body portion 230a, and is formed at a corner portion at which the end portion (side portion) on the X-axis negative direction side and the end portion on the Y-axis positive direction side of the fixed body portion 230a intersect. The skeleton step portion 31b is formed on the back surface of the fixed body portion 230b, and is formed at a corner portion at which the end portion (side portion) on the X-axis negative direction side and the end portion on the Y-axis negative direction side of the fixed body portion 230b intersect.

[0101] The skeleton step portion 31a is formed adjacent to the skeleton protrusion 30a, and the skeleton step portion 31b is formed adjacent to the skeleton protrusion 30b. In addition, the skeleton protrusion 30a is formed between the flange engaging portion 24a and the skeleton step portion 31a in the Y-axis direction, and the skeleton protrusion 30b is formed between the flange engaging portion 24b and the skeleton step portion 31b in the Y-axis direction.

[0102] ​The flange engaging portion 24a, the skeleton protruding portion 30a, and the skeleton stepped portion 31a are formed so as to concentrate to the end portion in the X-axis direction of the fixed body portion 230a, and function to form an engaging state with the terminal stage 70. Also, the flange engaging portion 24b, the skeleton protruding portion 30b, and the skeleton stepped portion 31b are formed so as to concentrate to the end portion in the X-axis direction of the fixed body portion 230b, and function to form an engaging state with the terminal stage 70.

[0103] The skeleton stepped portions 31a and 31b are formed with a step with respect to the back surface of the fixed body portions 230a and 230b. The skeleton stepped portions 31a and 31b have a stepped shape (concave shape) recessed from the back surface of the fixed body portions 230a and 230b by a prescribed depth in the Z-axis direction, and the shape of the skeleton stepped portions 31a and 31b as viewed in the Z-axis direction is a substantially rectangular shape (see FIG. 6). Figure 10 ).

[0104] The skeleton stepped portion 31a has a stepped lower surface 310a constituted by a surface (a substantially rectangular surface having a prescribed length in the X-axis direction and the Y-axis direction) substantially parallel to the back surface of the fixed body portion 230a. The skeleton stepped portion 31b has a stepped lower surface 310b constituted by a surface (a substantially rectangular surface having a prescribed length in the X-axis direction and the Y-axis direction) substantially parallel to the back surface of the fixed body portion 230b. The stepped lower surfaces 310a and 310b constitute the lower surfaces of the steps forming the skeleton stepped portions 31a and 31b. Also, the upper surfaces of the steps forming the skeleton stepped portions 31a and 31b become the back surfaces of the fixed body portions 230a and 230b. The skeleton stepped portion 31a engages with the terminal stage stepped portion 74a ( Figure 8 ) of the terminal stage 70, and the skeleton stepped portion 31b engages with the terminal stage stepped portion 74b ( Figure 8 ) of the terminal stage 70.

[0105] The extended flange portion 27a is formed above the flange portion body 220a. The extended flange portion 27a is integrally connected to the upper portion of the flange portion body 220a, and extends substantially parallel to the flange portion body 220a along the XZ plane. That is, the extended flange portion 27a has a shape extending the flange portion body 220a upward, and constitutes a portion of the flange portion body 220a. The extended flange portion 27a has a prescribed thickness in the Y-axis direction, and has a surface substantially parallel to the XZ plane.

[0106] The flange engaging portion 24a is formed at the end portion of the upper end portion of the flange portion main body 220a on the negative direction side of the X axis, and in contrast, the extended flange portion 27a is formed at the end portion of the upper end portion of the flange portion main body 220a on the positive direction side of the X axis. The extended flange portion 27a is arranged at a prescribed interval with respect to the flange engaging portion 24a along the X axis direction, and protrudes upward more than the fixed main body portion 230a of the terminal stand fixing portion 23a.

[0107] A partition portion 26a is formed between the flange engaging portion 24a and the extended flange portion 27a. The flange engaging portion 24a, the extended flange portion 27a, and the partition portion 26a are arranged along the X axis direction. The partition portion 26a is integrally connected to the upper portion of the flange portion main body 220a, and extends along the XZ plane substantially in parallel with the flange portion main body 220a. That is, the partition portion 26a has a shape that extends the flange portion main body 220a upward, and constitutes a portion of the flange portion main body 220a. The partition portion 26a has a prescribed thickness in the Y axis direction, and has a face substantially parallel with the XZ plane.

[0108] The extended flange portion 27b and the partition portion 26b are formed above the flange portion main body 220b. Since the structure of the extended flange portion 27b and the partition portion 26b is the same as that of the extended flange portion 27a and the partition portion 26a, detailed description thereof is omitted.

[0109] A notch portion 28a is formed between the flange engaging portion 24a and the partition portion 26a, and a notch portion 29a is formed between the extended flange portion 27a and the partition portion 26a. Either of the lead portions 41a and 41b of the first wire 41c Figure 3 ) can be inserted through the notch portion 28a. The same applies to the notch portion 29a.

[0110] A notch portion 28b is formed between the flange engaging portion 24b and the partition portion 26b, and a notch portion 29b is formed between the extended flange portion 27b and the partition portion 26b. Either of the lead portions 42a and 42b of the second wire 42c Figure 3 ) can be inserted through the notch portion 28b. The same applies to the notch portion 29b.

[0111] In the present embodiment, as shown in Figure 2 , the lead portion 41a of the lead portions 41a and 41b is inserted through the notch portion 29a, and the lead portion 41a is drawn out from the inside of the flange portion 22a in the Y axis direction toward the outside via the notch portion 29a, and is drawn out from the outside of the flange portion 22a in the Y axis direction toward the terminal stand 70. Thus, when the lead portion 41a is drawn out toward the terminal stand 70, it is possible to prevent unnecessary threading of the lead portion 41a.

[0112] On the other hand, the lead wire portion 41b is not led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22a through any of the notch portions 28a and 29a. As a result, the lead wire portion 41a is led out through the outer side in the Y-axis direction of the flange engaging portion 24a, and the lead wire portion 41b is led out through the inner side in the Y-axis direction of the flange engaging portion 24a, and thus the lead wire portions 41a and 41b can be well insulated via the flange engaging portion 24a.

[0113] In addition, since the partition portion 26a is formed between the notch portion 28a and the notch portion 29a, the position of the lead wire portion 41a that is inserted through the notch portion 29a can be adjusted by the partition portion 26a, and the position of the lead wire portion 41a can be prevented from shifting.

[0114] The lead wire portion 42a of the lead wire portions 42a and 42b is inserted through the notch portion 28b, and the lead wire portion 42a is led out from the inner side in the Y-axis direction of the flange portion 22b toward the outer side via the notch portion 28b, and is led out from the outer side in the Y-axis direction of the flange portion 22b toward the terminal land 70. Thus, when the lead wire portion 42a is led out toward the terminal land 70, the lead wire portion 42a can be prevented from being unnecessarily entangled.

[0115] On the other hand, the lead wire portion 42b is not led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22b through any of the notch portions 28b and 29b. As a result, the lead wire portion 42a is led out through the outer side in the Y-axis direction of the flange engaging portion 24b, and the lead wire portion 42b is led out through the inner side in the Y-axis direction of the flange engaging portion 24b, and thus the lead wire portions 42a and 42b can be well insulated via the flange engaging portion 24b.

[0116] Since the partition portion 26b is formed between the notch portion 28b and the notch portion 29b, the position of the lead wire portion 42a that is inserted through the notch portion 28b can be adjusted by the partition portion 26b, and the position of the lead wire portion 42a can be prevented from shifting by the partition portion 26b.

[0117] As shown in Figs. 1 and 2, in the present embodiment, the lead wire portions 41a and 41b are led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22a via the notch portion 28a. Figure 6 As shown in Figs. 1 and 2, in the present embodiment, the lead wire portions 41a and 41b are led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22a via the notch portion 28a. Figure 7 As shown in Figs. 1 and 2, in the present embodiment, the lead wire portions 41a and 41b are led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22a via the notch portion 28a. Figure 3 As shown in Figs. 1 and 2, in the present embodiment, the lead wire portions 41a and 41b are led out toward the terminal land 70 from the inner side in the Y-axis direction of the flange portion 22a via the notch portion 28a.

[0118] The protrusions 33 and 34 are formed integrally with the outer peripheral surface of the core portion 21, extending outward from the outer peripheral surface of the core portion 21 and extending along the circumferential direction of the core portion 21. The protrusions 33 and 34 are formed on the long side surfaces of the outer peripheral surface of the core portion 21. That is, the protrusion 33 is formed on the upper portion of the outer peripheral surface of the core portion 21, and the protrusion 34 is formed on the lower portion of the outer peripheral surface of the core portion 21. In addition, the upper and lower portions of the outer peripheral surface of the core portion 21 become substantially flat surfaces, and the protrusions 33 and 34 are preferably formed on the substantially flat surface of the core portion 21 as described above, which is closer to the curved portion (lateral portion) of the core portion 21.

[0119] The protrusions 33 and 34 are formed substantially in the axial direction (Y-axis direction) center of the winding core 21. The protrusions 33 and 34 are arranged on opposite sides of the winding core 21 in the radial direction and are formed at corresponding positions in the Z-axis direction.

[0120] The protrusions 33 and 34 have the same shape, consisting of a generally rectangular parallelepiped (flat shape) with a longitudinal direction perpendicular to the axial direction of the winding core 21 (the X-axis direction). The length of the protrusions 33 and 34 along the X-axis direction is greater than the length (height) of the protrusions 33 and 34 along the Z-axis direction, and the length of the protrusions 33 and 34 along the Z-axis direction is greater than the thickness of the protrusions 33 and 34 along the Y-axis direction. The Z-axis end (upper end) of the protrusion 33 has a curved surface (with corners ground off), but the shape of the protrusion 33 is not limited to this. Although detailed illustration is omitted, the shape of the protrusion 34 is similar.

[0121] The length of the protrusion 33 along the circumferential direction of the winding core 21 (or the length of the protrusion 33 along the X-axis direction) is smaller than the length of the winding core 21 along the circumferential direction. Figure 9 As shown, the ratio L3 / L4 of the length of the protrusion 33 along the circumference of the winding core 21 (or the length of the protrusion 33 along the X-axis direction) to the length (total length) L4 (not shown) of the winding core 21 along the circumference is preferably 0<L3 / L4<1 / 2, further preferably 0<L3 / L4<1 / 4, and particularly preferably 1 / 10<L3 / L4<1 / 5. By appropriately adjusting the value of L3 / L4 within the above range, the first coil portion 41 ( Figure 3 ) and the leakage characteristics between the second coil portion 42 are appropriately adjusted to a desired value. In addition, the ratio of the length of the protrusion 34 along the circumference of the winding core 21 (or the length of the protrusion 34 along the X-axis direction) to the length of the winding core 21 along the circumference is also the same.

[0122] The length of the protrusion 33 along the circumference of the winding core 21 (or the length of the protrusion 33 along the X-axis direction) is smaller than the length of the winding core 21 along the X-axis direction. The ratio L3 / L5 of the length of the protrusion 33 along the circumference of the winding core 21 (or the length of the protrusion 33 along the X-axis direction) L3 and the length L5 of the winding core 21 along the X-axis direction is preferably 0<L3 / L5<1, further preferably 0<L3 / L5<3 / 4, and particularly preferably 1 / 6<L3 / L5<2 / 3. By appropriately adjusting the value of L3 / L5 within the above range, the first coil portion 41 ( Figure 3 ) and the leakage characteristics between the second coil portion 42 are adjusted to a desired value. In addition, the ratio of the length of the protrusion 34 along the circumference of the winding core 21 (or the length of the protrusion 34 along the X-axis direction) to the length of the winding core 21 along the X-axis direction is also the same.

[0123] The length L6 of the protrusion 33 along the Z-axis direction is, for example, determined by the first winding 41c ( Figure 3 ) or the second winding 42c. In this embodiment, the first winding 41c and the second winding 42c are formed in two layers in the radial direction of the winding core 21. Therefore, the length L6 is preferably the first winding 41c ( Figure 3 ) or at least twice the wire diameter of the second winding 42c so that the first coil portion 41 and the second coil portion 42 can be fixed by the protrusion 33. In other words, it is preferable that the length L6 is greater than the height of the first coil portion 41 or the second coil portion 42 from the outer peripheral surface of the winding core portion 21. The same applies to the length of the protrusion 34 along the Z-axis direction.

[0124] By determining the length L6 of the protrusion 33 along the Z-axis direction as described above, the protrusion 33 can effectively prevent the first winding 41c and the second winding 42c from shifting in the Y-axis direction. Furthermore, by securing the first winding 41c and the second winding 42c to the protrusion 33, the winding of the first coil portion 41 and the second coil portion 42 can be prevented from becoming loose. Furthermore, when the first winding 41c and the second winding 42c are wound around the outer circumference of the winding core 21 in a reciprocating manner between the axial ends of the winding core 21 and the protrusions 33 and 34, the first winding 41c and the second winding 42c can be secured to the protrusions 33 and 34 and folded back, thereby preventing the first coil portion 41 and the second coil portion 42 from shifting in position or number of turns.

[0125] like Figure 7 As shown, the length L7 of the protrusion 33 along the axial direction of the winding core 21 is preferably smaller than the wire diameter of the first winding 41c or the second winding 42c. In this embodiment, the length L7 of the protrusion 33 is substantially equal to the thickness of the flange 22a or 22b along the Y-axis direction.

[0126] As shown in FIG. 1, the first coil portion 41 is disposed on the side of the protrusions 33 and 34 in the Y-axis direction, and the second coil portion 42 is disposed on the other side of the protrusions 33 and 34 in the Y-axis direction. That is, the protrusions 33 and 34 are disposed between the first coil portion 41 and the second coil portion 42 in the Y-axis direction. Figure 2 Figure 7 The first coil portion 41 and the second coil portion 42 sandwich the protrusions 33 and 34 therebetween and partially contact along the circumferential direction of the winding core portion 21. That is, when viewed along the circumferential direction of the winding core portion 21, at the position where the protrusion 33 is formed, the first coil portion 41 and the second coil portion 42 are not in contact because the protrusion 33 is interposed therebetween. That is, the protrusion 33 separates the first coil portion 41 and the second coil portion 42 in the Y-axis direction, and a non-contact region 44 is formed between the first coil portion 41 and the second coil portion 42.

[0127] In addition, at the position where the protrusion 34 is formed, the first coil portion 41 and the second coil portion 42 are not in contact because the protrusion 34 is interposed therebetween. That is, the protrusion 34 separates the first coil portion 41 and the second coil portion 42 in the Y-axis direction, and a non-contact region 45 is formed between the first coil portion 41 and the second coil portion 42.

[0128] On the other hand, at the position where the protrusions 33 and 34 are not formed, the first coil portion 41 and the second coil portion 42 are in contact because the protrusions 33 and 34 are not interposed therebetween. Thus, a contact region 43 is formed between the first coil portion 41 and the second coil portion 42.

[0129] The contact region 43 is formed in a manner of being sandwiched between the non-contact region 44 and the non-contact region 45, and is formed in a partial region along the circumferential direction of the winding core portion 21. The contact region 43 is formed so as to span the upper and lower portions of the outer circumferential surface of the winding core portion 21 from the side portion of the outer circumferential surface of the winding core portion 21, and extends along the outer circumferential surface of the winding core portion 21 in a manner of being curved in a substantially C shape for a prescribed length. The contact region 43 is discontinuously formed on one side and the other side in the X-axis direction of the winding core portion 21. The non-contact regions 44 and 45 are formed in the upper and lower portions of the outer circumferential surface of the winding core portion 21, and extend along the X-axis direction for a prescribed length. The contact region 43 and the non-contact regions 44 or 45 are alternately formed along the circumferential direction of the winding core portion 21.

[0130] The contact region 43 is formed in a manner of being sandwiched between the non-contact region 44 and the non-contact region 45, and is formed in a partial region along the circumferential direction of the winding core portion 21. The contact region 43 is formed so as to span the upper and lower portions of the outer circumferential surface of the winding core portion 21 from the side portion of the outer circumferential surface of the winding core portion 21, and extends along the outer circumferential surface of the winding core portion 21 in a manner of being curved in a substantially C shape for a prescribed length. The contact region 43 is discontinuously formed on one side and the other side in the X-axis direction of the winding core portion 21. The non-contact regions 44 and 45 are formed in the upper and lower portions of the outer circumferential surface of the winding core portion 21, and extend along the X-axis direction for a prescribed length. The contact region 43 and the non-contact regions 44 or 45 are alternately formed along the circumferential direction of the winding core portion 21.

[0131] ​The length of the contact region 43 along the circumference of the winding core 21 is longer than the length of the non-contact regions 44 or 45 along the circumference of the winding core 21, so that the first coil portion 41 and the second coil portion 42 are mostly in contact along the circumference of the winding core 21. By forming only a portion of the non-contact regions 44 and 45 between the first coil portion 41 and the second coil portion 42 along the circumference of the winding core 21, the leakage characteristics between the first coil portion 41 and the second coil portion 42 can be appropriately adjusted to a desired value.

[0132] like Figure 3 As shown, the terminal block 70 is formed separately from the skeleton 20 and can be loaded and unloaded relative to the skeleton 20. The terminal block 70 can also be composed of the same insulating component as the skeleton 20, but it is more preferably composed of an insulating component with excellent formability or heat resistance. The terminal block 70 is arranged on the side of the negative side of the X-axis of the core portion 21, that is, at a position separated from the outer peripheral surface of the core portion 21 along the direction (X-axis direction) perpendicular to the axial direction of the core portion 21. Therefore, there is a gap G ( Figure 9 ) is formed along the axial direction of the winding core portion 21.

[0133] like Figure 8 As shown, the terminal block 70 has a terminal block base portion 71, arm portions 72a and 72b, terminal block hook portions 73a and 73b, terminal block step portions 74a and 74b, terminal block recesses 75a and 75b, lead wire insertion grooves 76a and 76b, terminal fixing portions 77a_1 and 77a_2, terminal fixing portions 77b_1 and 77b_2, a cover mounting portion 78, and a bottom surface fixing portion 79.

[0134] The terminal block base 71 is composed of a roughly rectangular column having a long side in the Y-axis direction, and is arranged on the side of the winding core 21 in the X-axis direction and roughly parallel to the axial direction of the winding core 21. The length of the terminal block base 71 along the Y-axis direction is roughly equal to the length of the skeleton 20 along the Y-axis direction. Figure 5 As shown, the terminal block base portion 71 (the bottom surface of the terminal block base portion 71) is arranged above the center portion of the core portion 21 in the Z-axis direction at a position separated from the side portion of the outer peripheral surface of the core portion 21 along the X-axis direction, and is also arranged above the upper portion of the outer peripheral surface of the core portion 21. However, the height position of the terminal block base portion 71 is not limited to this. The terminal block base portion 71 (the bottom surface of the terminal block base portion 71) can be arranged at a height position substantially equal to the upper portion of the outer peripheral surface of the core portion 21, or can be arranged at a position lower than the upper portion.

[0135] like Figure 5 and Figure 9As shown, since the terminal block base portion 71 is arranged at a position separated from the outer peripheral surface of the core portion 21 by a gap G on the side in the X-axis direction, the end of the terminal block base portion 71 on the positive side of the X-axis (the side where the skeleton 20 is located) and the outer peripheral surface of the core portion 21 are not repeatedly arranged in the Z-axis direction.

[0136] However, the position of the terminal block base portion 71 may be displaced toward the positive X-axis direction, so that the end portion of the terminal block base portion 71 on the positive X-axis side and the outer peripheral surface of the core portion 21 overlap in the Z-axis direction (when viewed from the Z-axis direction). That is, if the terminal block base portion 71 is positioned at a position separated from the outer peripheral surface of the core portion 21 by a predetermined distance along the radial direction of the core portion 21, the position of the terminal block base portion 71 is not particularly limited. For example, the terminal block base portion 71 may be positioned at a position separated from any position on the outer peripheral surface of the core portion 21 by a predetermined distance toward the side of the core portion 21 (the negative X-axis side), and may also be positioned at a position separated from the position on the outer peripheral surface of the core portion 21 by a predetermined distance toward the top of the core portion 21 (the positive Z-axis side).

[0137] The position of the end (side portion) of the terminal block base portion 71 on the positive side in the X-axis direction is substantially equal to the position of the ends of the flange engaging portions 24a and 24b of the frame 20 on the negative side in the X-axis direction, and they are arranged close to each other.

[0138] like Figure 8 As shown, the arm portion 72a is formed on one side of the terminal base portion 71 in the Y-axis direction, and the arm portion 72b is formed on the other side of the terminal base portion 71 in the Y-axis direction. The arm portions 72a and 72b protrude from the end portion (side portion) of the terminal base portion 71 in the X-axis direction toward the frame 20 by a predetermined length. Figure 9 As shown, the length of the arms 72a and 72b along the X-axis direction is longer than the length of the gap G along the X-axis direction, and is substantially equal to the length of the flange engaging portions 24a and 24b of the frame 20 along the X-axis direction.

[0139] like Figure 8 As shown, a hook-shaped terminal block hook portion 73a is formed at the front end of arm portion 72a, and a hook-shaped terminal block hook portion 73b is formed at the front end of arm portion 72b. Terminal block hook portions 73a and 73b protrude from the front ends of arms 72a and 72b by a predetermined length along the Y-axis in a direction toward each other (inward of terminal block 70). The protruding direction of terminal block hook portions 73a and 73b is approximately perpendicular to the longitudinal direction of arms 72a and 72b.

[0140] like Figure 10As shown, in a state where the terminal block 70 is fixed to the terminal block fixing portions 23a and 23b of the frame 20, the arm portion 72a is arranged along the face on the outer side of the Y-axis direction of the flange engaging portion 24a of the frame 20, and the terminal block hook portion 73a is engaged with the side portion on the positive X-axis direction side of the flange engaging portion 24a. In addition, the arm portion 72b is arranged along the face on the outer side of the Y-axis direction of the flange engaging portion 24b of the frame 20, and the terminal block hook portion 73b is engaged with the side portion on the positive X-axis direction side of the flange engaging portion 24b. Thus, the terminal block 70 can be mounted to the terminal block fixing portions 23a and 23b via the arm portions 72a and 72b.

[0141] Further, in a state where the terminal block hook portion 73a is engaged with the flange engaging portion 24a, Figure 2 The lead portion 41a of the first wire 41c shown is drawn out toward the terminal block 70 along the periphery of the arm portion 72a. In addition, in a state where the terminal block hook portion 73b is engaged with the flange engaging portion 24b, Figure 2 The lead portion 42a of the second wire 42c shown is drawn out toward the terminal block 70 along the periphery of the arm portion 72b. Since the lead portions 41a and 41b are drawn out along the outer faces (the faces on the outer side of the Y-axis direction) of the arm portions 72a and 72b, respectively, the arm portions 72a and 72b function to guide the lead portions 41a and 41b toward the terminal block 70.

[0142] As shown, Figure 8 The terminal block step portion 74a is formed at one end portion of the terminal block base portion 71 in the Y-axis direction, and the terminal block step portion 74b is formed at the other end portion of the terminal block base portion 71 in the Y-axis direction. The terminal block step portions 74a and 74b are arranged on the outer side of the Y-axis direction than the arm portions 72a and 72b.

[0143] The terminal block step portion 74a has a step lower surface 740a composed of a face (a substantially rectangular face having a prescribed length in the X-axis direction and the Y-axis direction) substantially parallel to the upper surface or the lower surface of the terminal block base portion 71. The terminal block step portion 74b has a step lower surface 740b composed of a face (a substantially rectangular face having a prescribed length in the X-axis direction and the Y-axis direction) substantially parallel to the upper surface or the lower surface of the terminal block base portion 71. The step lower surfaces 740a and 740b constitute the lower surfaces of the steps that form the terminal block step portions 74a and 74b.

[0144] As shown, Figure 9 and Figure 10As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment.

[0145] As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment. Figure 8 As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment. Figure 6 As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment.

[0146] As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment.

[0147] As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment. Figure 9 Figure 10 As shown, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b of the frame 20. In more detail, the terminal stage portions 74a and 74b are engaged with the frame stage portions 31a and 31b in a state in which the step lower surfaces 740a and 740b of the terminal stage portions 74a and 74b and the step lower surfaces 310a and 310b of the frame stage portions 31a and 31b are in abutment.

[0148] Thus, in the present embodiment, by engaging the terminal hook portions 73a and 73b and the flange engaging portions 24a and 24b as the first engaging portions, it is possible to prevent the terminal 70 from shifting in position along the X-axis direction with respect to the terminal fixing portions 23a and 23b.

[0149] In addition, by engaging the terminal stage portions 74a and 74b and the frame stage portions 31a and 31b as the second engaging portions, it is possible to prevent the terminal 70 from shifting in position along the Z-axis direction with respect to the terminal fixing portions 23a and 23b.

[0150] ​Further, by engaging the terminal land recesses 75a and 75b and the frame protrusions 30a and 30b as the third engagement portions, displacement of the terminal land 70 in the Y-axis direction with respect to the terminal land fixing portions 23a and 23b can be prevented. Thus, the terminal land 70 can be mounted to the terminal land fixing portions 23a and 23b with sufficient fixing strength.

[0151] Further, by the engagement of the above-described respective engagement portions, the terminal land 70 can be connected to the one end portion and the other end portion of the core portion 21 in the axial direction and arranged substantially in parallel with the axial direction of the core portion 21. Fixing of the terminal land 70 with respect to the terminal land fixing portions 23a and 23b is performed by three-point support of the above-described respective engagement portions, and does not require fixing using an adhesive or the like. Furthermore, any one of the above-described respective engagement portions can be omitted. Further, fixing (strengthening) based on an adhesive or the like can be performed as needed.

[0152] As shown in FIG. 6, the cover mounting portion 78 is formed at a substantially central portion of the terminal land base portion 71 in the Y-axis direction. The cover mounting portion 78 has an upper surface and a lower surface constituted by substantially flat surfaces, and the holding portion 84 of the cover portion 80 is fixed to the cover mounting portion 78. Figure 8

[0153] The terminal fixing portions 77a_l and 77a_2 are formed on the Y-axis direction side of the cover mounting portion 78. The terminal fixing portion 77a_l is arranged on the Y-axis direction outer side of the terminal fixing portion 77a_2. The terminal fixing portions 77a_l and 77a_2 are formed to have a wall thickness greater than that of the surrounding portions, and the terminals 61_l and 61_2 can be fixed to the terminal fixing portions 77a_l and 77a_2, respectively.

[0154] The terminal insertion grooves 770a_l and 770a_2 are formed in the terminal fixing portions 77a_l and 77a_2, respectively. The terminal insertion grooves 770a_l and 770a_2 are constituted by grooves curved in a substantially L shape corresponding to the shapes of the terminals 61_l and 61_2. Furthermore, the terminals 61_l and 61_2 are fixed to the terminal fixing portions 77a_l and 77a_2 by integral molding (insert molding).

[0155] The terminal fixing portions 77b_l and 77b_2 are formed on the other side of the cover mounting portion 78 in the Y-axis direction. The terminal fixing portion 77b_l is arranged on the Y-axis direction outer side of the terminal fixing portion 77b_2. The terminal fixing portions 77b_l and 77b_2 are formed to have a wall thickness greater than that of the surrounding portions, and the terminals 62_l and 62_2 can be fixed to the terminal fixing portions 77b_l and 77b_2, respectively.

[0156] ​Terminal insertion grooves 770b_1 and 770b_2 are formed in the terminal fixing portions 77b_1 and 77b_2, respectively. The terminal insertion grooves 770b_1 and 770b_2 are composed of grooves bent into substantially L shapes corresponding to the shapes of the terminals 62_1 and 62_2. Further, the terminals 62_1 and 62_2 are fixed to the terminal fixing portions 77b_1 and 77b_2 by integral molding (insert molding).

[0157] Lead insertion grooves 76a are formed between the terminal fixing portions 77a_1 and 77a_2, and lead insertion grooves 76b are formed between the terminal fixing portions 77b_1 and 77b_2. The lead insertion grooves 76a and 76b are composed of recesses recessed from the end portions of the terminal base body portion 71 on the positive X-axis direction side, and extend from the upper end to the lower end of the terminal base body portion 71. The lead portions 41b of the first winding 41c are inserted into the lead insertion grooves 76a, and the lead portions 42b of the second winding 42c are inserted into the lead insertion grooves 76b (refer to FIG. 6). Figure 2 ).

[0158] A bottom surface fixing portion 79 is formed in the bottom surface of the terminal base body portion 71 at the end portion thereof on the negative X-axis direction side (the side opposite to the side on which the skeleton 20 is disposed). The bottom surface fixing portion 79 has a substantially flat surface, has a prescribed length in the X-axis direction, and has a prescribed length in the Y-axis direction. The bottom surface fixing portion 79 is formed from one end to the other end of the terminal base body portion 71 in the Y-axis direction. The X-axis direction end portion of a cover bottom portion 81 of a cover portion 80 is fixed to the bottom surface fixing portion 79.

[0159] The terminals 61_1, 61_2, 62_1, and 62_2 are mounted to the terminal stand 70 at prescribed intervals in the Y-axis direction. The terminals 61_1 and 61_2 have the same shape, and are fixed to the terminal fixing portions 77a_1 and 77a_2, respectively. The lead portions 41a of the first winding 41c are connected to the terminals 61_1, and the lead portions 41b of the first winding 41c are connected to the terminals 61_2.

[0160] Further, the terminals 62_1 and 62_2 have the same shape, and are fixed to the terminal fixing portions 77b_1 and 77b_2, respectively. The lead portions 42a of the second winding 42c are connected to the terminals 62_1, and the lead portions 42b of the second winding 42c are connected to the terminals 62_2.

[0161] The terminal 61_1 has an external connection portion 610_1, a connecting portion 611_1, a wiring base portion 612_1, and a wiring turn-back portion 613_1. The external connection portion 610_1 is a portion to be connected to a mounting substrate, and protrudes from the upper portion of the terminal fixing portion 77a_1 (terminal insertion slot 770a_1) toward the upper side and extends upward. The external connection portion 610_1 protrudes toward the upper side than the upper edge of the housing 90. Figure 1

[0162] The connecting portion 611_1 is a portion to connect the external connection portion 610_1 and the wiring base portion 612_1, and is bent toward the outer side in the Y-axis direction and extends toward the negative side of the X-axis.

[0163] The wiring base portion 612_1 and the wiring turn-back portion 613_1 are portions to which the lead portion 41a is to be connected, and the lead portion 41a is sandwiched (crimped) by the wiring base portion 612_1 and the wiring turn-back portion 613_1. The wiring turn-back portion 613_1 is integrally connected to the end portion on the outer side in the Y-axis direction of the wiring base portion 612_1, and is disposed opposite to the wiring base portion 612_1 in the Z-axis direction. The wiring turn-back portion 613_1 has a curved surface, but can also be formed in a substantially flat shape.

[0164] The terminal 61_2 has an external connection portion 610_2, a connecting portion 611_2, a wiring base portion 612_2, and a wiring turn-back portion 613_2. Since the shapes and functions of the respective portions that constitute the terminal 61_2 are the same as those of the respective portions that constitute the terminal 61_1, detailed description thereof is omitted.

[0165] The terminal 62_1 has an external connection portion 620_1, a connecting portion 621_1, a wiring base portion 622_1, and a wiring turn-back portion 623_1. The terminal 62_1 differs from the terminal 61_1 in the point that it is formed to be symmetrical about the X-axis line, and the other points are common to the terminal 61_1, and thus detailed description of the terminal 62_1 is omitted.

[0166] The terminal 62_2 has an external connection portion 620_2, a connecting portion 621_2, a wiring base portion 622_2, and a wiring turn-back portion 623_2. The terminal 62_2 differs from the terminal 61_2 in the point that it is formed to be symmetrical about the X-axis line, and the other points are common to the terminal 61_2, and thus detailed description of the terminal 62_2 is omitted.

[0167] The cover portion 80 has a cover base portion 81, an insulating portion 82, cover side portions 83a and 83b, and a grip portion 84. The cover portion 80 is formed separately from the terminal stage 70, and is detachably attached to the terminal stage 70 in a manner to be disposed around the terminal stage 70.

[0168] ​Cover bottom 81 has a plate surface that is generally parallel to the XY plane and is positioned below terminals 61_1 and 61_2 and terminals 62_1 and 62_2 mounted on terminal block 70. The front end of cover bottom 81 in the X-axis direction is secured by engaging with bottom fixing portion 79 of terminal block 70. By securing cover bottom 81 to bottom fixing portion 79, positional displacement of cover 80 relative to terminal block 70 in the Z-axis direction is prevented.

[0169] The insulating portion 82 is formed approximately in the center of the cover 80 in the Y-axis direction. An insulating recess 820 is formed in the insulating portion 82. The insulating recess 820 is formed by a recess that is recessed downward from the upper surface of the insulating portion 820 and extends from the side surface of the insulating recess 820 on the negative X-axis side toward the positive X-axis side. Terminals 61_2 are located on one side of the insulating portion 82 in the Y-axis direction, and terminals 62_2 are located on the other side of the insulating portion 82 in the Y-axis direction.

[0170] By forming an insulating portion 82 having an insulating recess 820 in the cover portion 80, the insulation distance between the terminal 61_2 of the lead portion 41b connected to the first winding 41c and the terminal 62_2 of the lead portion 42b connected to the second winding 42c can be extended, and good insulation between these windings (primary coil and secondary coil) can be achieved.

[0171] Cover side portions 83a and 83b extend upward and rise from the end portion of cover bottom portion 81 on the negative side in the X-axis direction, substantially perpendicular to cover bottom portion 81. Cover side portion 83a is formed on one side of insulating portion 82 in the Y-axis direction, while cover side portion 83b is formed on the other side of insulating portion 82 in the Y-axis direction.

[0172] By forming the cover bottom 81 and the cover side portions 83a and 83b on the cover portion 80, the terminals 61_1 and 61_2 and the terminals 62_1 and 62_2 mounted on the terminal block 70 can be protected from external forces. In addition, the terminals 61_1 and 61_2 and the core 50a ( Figure 3 ) is well insulated, and the terminals 62_1 and 62_2 and the core 50b ( Figure 3 ) is well insulated.

[0173] The grip portion 84 is formed at a substantially central portion of the cover bottom portion 81 in the Y-axis direction and projects from the insulating portion 82 toward the terminal block 70 . The grip portion 84 is used to grip the cover mounting portion 78 of the terminal block 70 .

[0174] The gripping portion 84 includes an upper arm 841 and a lower arm 842. The upper arm 841 is formed at the upper end of the insulating portion 82 and extends toward the terminal block 70. The lower arm 842 is formed at the lower end of the insulating portion 82 (at the location of the cover bottom 81) and extends toward the terminal block 70 in a manner substantially parallel to the upper arm 841. The front ends of the upper arm 841 and the lower arm 842 have a hook shape and are bent toward each other. The upper arm 841 and the lower arm 842 respectively grip the upper and lower surfaces of the cover mounting portion 78, thereby enabling the gripping portion 84 to be mounted on the cover mounting portion 78.

[0175] By gripping the cover mounting portion 78 of the terminal block 70 with the upper arm 841 and the lower arm 842 , the cover 80 can be mounted on the cover mounting portion 78 with sufficient fixing strength without using adhesives, thereby achieving cost reduction and rapid manufacturing.

[0176] Next, refer to Figure 3 The method for manufacturing the coil device 10 is described below. Figure 3 The components shown are shown. Terminals 61_1 and 61_2, and terminals 62_1 and 62_2 are pre-attached to terminal block 70 by insert molding or the like. Furthermore, cover 80 is attached to terminal block 70. These are attached by gripping cover attachment portion 78 of terminal block 70 with gripping portion 84 of cover 80, eliminating the need for adhesives or the like.

[0177] Next, a first winding 41c and a second winding 42c are wound around the outer circumference of the winding core 21 of the bobbin 20, forming the first coil portion 41 on the Y-axis side relative to the protrusions 33 and 34, and the second coil portion 42 on the other side. The lead portions 41a and 41b of the first winding 41c extend from one axial end of the winding core 21. Furthermore, the lead portions 42a and 42b of the second winding 42c extend from the other axial end of the winding core 21.

[0178] Next, one end of the terminal block 70 in the Y-axis direction is fixed to the terminal block fixing portion 23a of the skeleton 20, and the other end of the terminal block 70 in the Y-axis direction is fixed to the terminal block fixing portion 23b of the skeleton 20, and the terminal block 70 is arranged at a position separated from the outer side (laterally) of the outer peripheral surface of the winding core portion 21 in the X-axis direction by a specified distance.

[0179] Next, the lead portion 41a is connected to the terminal 61_1 by crimping, the lead portion 41b is connected to the terminal 61_2 by crimping, the lead portion 42a is connected to the terminal 62_1 by crimping, and the lead portion 42b is connected to the terminal 62_2 by crimping (see Figure 2). Next, the middle leg portions 53a of the core 50a and the middle leg portions 53b of the core 50b are inserted into the through holes 211 of the skeleton 20, and the cores 50a and 50b are attached to the skeleton 20.

[0180] Next, by accommodating the skeleton 20 and the like in the inside of the case 90 and filling the filling resin 100 in the case 90, it is possible to obtain the coil device 10 as shown in FIG. 1. Figure 1

[0181] As described above, in the coil device 10 of the present embodiment, as shown in FIG. 1, the terminal table 70 is formed separately from the skeleton 20. Therefore, in manufacturing the coil device 10, in a state where the terminal table 70 is detached from the skeleton 20, it is possible to wind the first wire 41c and the second wire 42c around the outer peripheral surface of the winding core portion 21, and in particular, in a case where the first wire 41c and the second wire 42c are wound by using an automatic wire winder, it is possible to prevent the terminal table 70 from becoming an obstacle to automatic winding by the automatic wire winder. In addition, the terminal table 70 is formed only by a high heat-resistant resin separately from the skeleton 20, and thus it is possible to realize the coil device 10 having heat resistance at a low cost. Figure 3

[0182] In addition, the terminal table 70 is disposed at a position separated from the outer peripheral surface of the winding core portion 21 in the X-axis direction. Therefore, it is possible to dispose the terminal table 70 to the side in the X-axis direction of the winding core portion 21, it is possible to reduce the size of the coil device 10 in the X-axis direction and the Z-axis direction, and it is possible to realize the miniaturization of the coil device 10.

[0183] In addition, the terminal table 70 is disposed substantially in parallel with the axial direction of the winding core portion 21. Therefore, it is possible to prevent the terminal table 70 from being disposed in the side in the X-axis direction of the winding core portion 21 in a state of unnecessarily protruding, and it is possible to reduce the size of the coil device 10 in the X-axis direction.

[0184] In addition, in the present embodiment, as shown in FIG. 1, the arm portions 72a and 72b are engaged with the flange engagement portions 24a and 24b (refer to FIG. 2) via the terminal table hook portions 73a and 73b, and thus even without using an adhesive or the like, it is possible to attach the terminal table 70 to the skeleton 20 with sufficient fixing strength, and it is possible to realize the low cost and the rapidity of manufacturing. In addition, it is possible to dispose the terminal table 70 at a position separated from the outer peripheral surface of the winding core portion 21 in the X-axis direction by a distance corresponding to the lengths of the arm portions 72a and 72b, and it is possible to adjust the disposition of the terminal table 70 by appropriately changing the lengths of the arm portions 72a and 72b. Figure 8 Figure 6 In addition, in the present embodiment, as shown in FIG. 1, the arm portions 72a and 72b are engaged with the flange engagement portions 24a and 24b (refer to FIG. 2) via the terminal table hook portions 73a and 73b, and thus even without using an adhesive or the like, it is possible to attach the terminal table 70 to the skeleton 20 with sufficient fixing strength, and it is possible to realize the low cost and the rapidity of manufacturing. In addition, it is possible to dispose the terminal table 70 at a position separated from the outer peripheral surface of the winding core portion 21 in the X-axis direction by a distance corresponding to the lengths of the arm portions 72a and 72b, and it is possible to adjust the disposition of the terminal table 70 by appropriately changing the lengths of the arm portions 72a and 72b.

[0185] In addition, in the present embodiment, as shown in FIG. 1, the arm portions 72a and 72b are engaged with the flange engagement portions 24a and 24b (refer to FIG. 2) via the terminal table hook portions 73a and 73b, and thus even without using an adhesive or the like, it is possible to attach the terminal table 70 to the skeleton 20 with sufficient fixing strength, and it is possible to realize the low cost and the rapidity of manufacturing. In addition, it is possible to dispose the terminal table 70 at a position separated from the outer peripheral surface of the winding core portion 21 in the X-axis direction by a distance corresponding to the lengths of the arm portions 72a and 72b, and it is possible to adjust the disposition of the terminal table 70 by appropriately changing the lengths of the arm portions 72a and 72b.​​​Figure 2 、 Figure 9 、 Figure 10 ), so it is possible to lead the lead wire portions 41a and 42a out of the bobbin portion 21 to the terminal stages 70 at a short distance, to prevent unnecessary winding (increase in length of the lead wire portions 41a and 42a) of the lead wire portions 41a and 42a, to improve the quality of the coil device 10, and to contribute to reduction in resistance or suppression of resonance of the first winding 41c and the second winding 42c.

[0186] Further, as shown in Figure 6 , because the skeleton hook portions 25a and 25b are formed in the flange engaging portions 24a and 24b, it is possible to prevent the lead wire portions 41a and 42a led along the periphery of the arm portions 72a and 72b from being displaced toward the upper ends of the flange engaging portions 24a and 24b.

[0187] Further, in the present embodiment, as shown in Figure 1 , it is possible to dissipate heat generated by the skeleton 20 or the like to the outside via the housing 90 and the filled resin 100, and to efficiently cool the coil device 10. Further, as shown in Figure 6 , because the through-hole portions 35a and 35b, the through-hole portions 36a and 36b are formed in the skeleton 20, it is possible to circulate the filled resin 100 in and out of the skeleton 20 via them, and to cause the filled resin 100 to reach every corner inside the housing 90.

[0188] Second embodiment

[0189] The coil device 110 of the second embodiment of the present application differs only in the following points, and is the same as the first embodiment described above in other structures, and achieves the same effects. In the drawings, common symbols are attached to the components common to the first embodiment, and the description of the overlapping parts is omitted.

[0190] As shown in Figure 11 , the coil device 110 has the terminal stages 70_1 and 70_2, and the cover portions 80_1 and 80_2. That is, the coil device 110 of the present embodiment is common to the coil device 10 of the first embodiment in that it has the terminal stages 70_1 and the cover portions 80_1 at a position separated from the outer peripheral surface of the bobbin portion 21 to the negative direction side of the X axis, and is different from the coil device 10 of the first embodiment in that it also has the terminal stages 70_2 and the cover portions 80_2 at a position separated from the outer peripheral surface of the bobbin portion 21 to the positive direction side of the X axis.

[0191] As shown in Figure 12As shown, in order to be able to mount the terminal table 70_2 at the terminal table fixing portions 23a and 23b of the winding core portion 120, flange engaging portions 24a and 24b, frame protrusions 30a and 30b, and frame step portions 31a and 31b are formed at the end portion on the positive direction side of the X axis in addition to the end portion on the negative direction side of the X axis. Therefore, the shape of the winding core 120 on one side of the center in the X axis direction is equal to (symmetrical with) the shape of the winding core 120 on the other side of the center in the X axis direction.

[0192] In the present embodiment, the same effects as those of the first embodiment can also be obtained. Further, in the present embodiment, because the terminal tables 70_1 and 70_2 are formed at both sides in the X axis direction of the winding core portion 21, the lead portions 41a and / or 41b of the first winding 41c can be led out and fixed to the side on which the terminal table 70_2 is disposed instead of being led out and fixed to the side on which the terminal table 70_1 is disposed. In addition, the lead portions 42a and / or 42b of the second winding 42c can be led out and fixed to the side on which the terminal table 70_2 is disposed instead of being led out and fixed to the side on which the terminal table 70_1 is disposed. Further, for example, in a case in which four windings are wound around the outer peripheral surface of the winding core portion 21, the lead portions of the respective windings can be led out and fixed to the side on which the terminal table 70_2 is disposed instead of being led out and fixed to the side on which the terminal table 70_1 is disposed. Figure 11 The eight terminals shown are respectively connected.

[0193] 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.

[0194] In the above-described embodiments, examples of application of the present application to a transformer have been described, but the present application can be applied not only to a transformer but also to other coil devices.

[0195] In the above-described embodiments, the cores 50a and 50b are each composed of an E-shaped core, but either one of the cores 50a and 50b can be composed of an E-shaped core and the other can be composed of an I-shaped core. Alternatively, the cores 50a and 50b can each be composed of a U-shaped core. Alternatively, either one of the cores 50a and 50b can be composed of a U-shaped core and the other can be composed of an I-shaped core. Alternatively, the core 50a can be composed of a combination of two U-shaped cores, and the core 50b can be composed of a combination of two U-shaped cores.

[0196] In the above-described embodiments, a plurality of (four) through-hole portions (through-hole portions 35a, 35b, 36a, 36b) are formed in the outer peripheral surface of the winding core portion 21, but the number of through-hole portions can be one. For example, only one through-hole portion can be formed in either one of the upper portion and the lower portion of the outer peripheral surface of the winding core portion 21. In addition, the number of through-hole portions can be two to three or five or more.

[0197] In the first embodiment described above, the lead portion 41a can also be inserted through the notch portion 28a as shown in FIG. 8. In addition, the lead portion 41b of the lead portions 41a and 41b can also be inserted through the notch portion 28a or the notch portion 29a. Figure 2 In addition, the lead portion 42a of the lead portions 42a and 42b can also be inserted through the notch portion 29b. In addition, the lead portion 42b of the lead portions 42a and 42b can also be inserted through the notch portion 28b or the notch portion 29b.

[0198] In addition, the lead portion 42a of the lead portions 42a and 42b can also be inserted through the notch portion 29b. In addition, the lead portion 42b of the lead portions 42a and 42b can also be inserted through the notch portion 28b or the notch portion 29b.

[0199] In each of the embodiments described above, the protruding portions 33 and 34 are formed at the substantially central portion of the core portion 21 in the Y-axis direction, but can also be formed at a position shifted from this position to one side or the other side in the Y-axis direction.

[0200] In each of the embodiments described above, two protruding portions (the protruding portions 33 and 34) are formed at the core portion 21, but the number of protruding portions can be one, or can also be three or more.

[0201] In each of the embodiments described above, two coil portions (the first coil portion 41 and the second coil portion 42) are formed at the core portion 21, but three or more coil portions can also be formed.

Claims

1. A coil device, wherein: have: a bobbin having a winding core portion on an outer peripheral surface of which a winding wire is wound, and a flange portion formed at an axial end portion of the winding core portion; and a terminal block formed separately from the frame and mounted on the frame, The terminal block is arranged at a position separated from the outer peripheral surface of the winding core in a direction perpendicular to the axial direction of the winding core, and is connected to one axial end portion of the winding core and the other axial end portion of the winding core. A flat terminal block fixing body portion is formed on the flange portion of the frame and protrudes from the outer end surface of the flange portion in a substantially vertical direction. The terminal station fixing body has a frame protrusion. The terminal block includes a terminal block base portion, and a terminal block extension portion having a terminal block recess formed at an end portion in a longitudinal direction of the terminal block base portion. An arm portion is formed on the terminal block base portion on the inner side along the longitudinal direction of the terminal block recess and protruding toward the terminal block fixing body portion. The convex portion of the frame and the concave portion of the terminal block are engaged with each other. The arm portion is mounted on the frame above the terminal block fixing body portion. The lead-out portion of the winding wire is led out toward the terminal block along the arm portion.

2. The coil device according to claim 1, wherein The terminal block is arranged substantially parallel to the axial direction of the winding core.

3. The coil device according to claim 1 or 2, wherein: A first hook portion having a hook shape is formed at the front end of the arm portion. The flange portion includes a flange engaging portion formed thereon. The flange engaging portion extends in a direction substantially perpendicular to the terminal block fixing body portion and is engaged with the first hook portion.

4. The coil device according to claim 3, wherein A second hook portion having a hook shape is formed at the front end portion of the flange engaging portion. The lead-out portion of the winding wire is led out toward the terminal block along the arm portion in a state in which the first hook portion is engaged with the flange engaging portion.

5. The coil device according to claim 1 or 2, wherein: The terminal station fixing body has a first step portion, The terminal block base portion has a second step portion on the outer side along the longitudinal direction of the terminal block recess. The first step portion and the second step portion are engaged with each other in a state in which a first step lower surface of the first step portion and a second step lower surface of the second step portion are in contact with each other.

6. The coil device according to claim 1 or 2, wherein: The flange portion is formed along the circumference of the winding core portion, The flange portion is formed with a notch portion through which the lead-out portion of the winding wire is inserted.

7. The coil device according to claim 6, wherein A lead portion of the winding wire passes through the notch and is led out from the outside of the flange toward the terminal block. The other lead-out portion of the winding wire does not pass through the notch portion, and is led out from the inner side of the flange portion toward the terminal block.

8. The coil device according to claim 1 or 2, wherein: It also includes a cover portion arranged around the terminal block, The winding is composed of a plurality of windings, A plurality of terminals, each connected to a plurality of lead-out portions of the winding wires, are mounted on the terminal block along the axial direction of the winding core. The cover portion includes a grip portion for gripping the terminal block, a bottom portion disposed below the plurality of terminals, and side portions rising from side ends of the bottom portion.

9. The coil device according to claim 1 or 2, wherein: The axial direction of the winding core is substantially parallel to the mounting surface.

10. The coil device according to claim 1 or 2, wherein: It also has a shell for accommodating the skeleton, The housing can be filled with a filling resin, At least one through-hole is formed on the outer peripheral surface of the winding core.

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