Coil arrangement

Abstract

Provided is a coil device that can be made compact. A coil device (10) has a former (20) having a winding core portion (21), a first coil portion (41) provided on one side in the axial direction of the winding core portion (21), and a second coil portion (42) provided on the other side in the axial direction of the winding core portion (21). The winding core portion (21) has protruding portions (33) and (34) that extend outward from the outer peripheral surface of the winding core portion (21) and extend along the circumferential direction of the winding core portion, and the first coil portion (41) and the second coil portion (42) sandwich the protruding portions (33) and (34) and partially contact along the circumferential direction of the winding core portion (21).

Description

Technical Field

[0001] This invention relates to a coil device. Background Technology

[0002] As a coil device for transformers, etc., a coil device such as that described in Patent Document 1 is known. The coil device described in Patent Document 1 has a first frame with a primary winding wound on it and a second frame disposed inside the first frame with a secondary winding wound on it. In the coil device described in Patent Document 1, by radially overlapping the first and second frames, the primary and secondary windings can be radially separated, adjusting the leakage flux characteristics between the primary and secondary windings.

[0003] However, the coil device described in Patent Document 1 requires two frames, a first frame and a second frame, which not only increases the number of components but also increases the size of the coil device in the radial direction of the frames, making it difficult to achieve miniaturization.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2005-158927 Summary of the Invention

[0007] The present invention was made in view of the following actual situation, and its object is to provide a coil device that can be miniaturized.

[0008] The inventors conducted in-depth research and exploration into the above-mentioned objectives, and as a result, they discovered that by adjusting the degree of contact between the first coil section and the second coil section, the leakage magnetic characteristics between the first coil section and the second coil section can be adjusted, thus completing the present invention.

[0009] That is, in order to achieve the above objectives, the coil device according to the present invention has:

[0010] The skeleton has a core section;

[0011] The first coil portion is disposed on one side of the axial direction of the core portion; and

[0012] The second coil portion is located on the opposite side of the axial direction of the core portion.

[0013] The core portion has a protrusion that extends outward from the outer peripheral surface of the core portion and extends circumferentially along the core portion.

[0014] The first coil portion and the second coil portion sandwich the protrusion therebetween and partially contact each other along the circumference of the core portion.

[0015] In the coil device of the present invention, the first coil portion and the second coil portion are partially in contact along the circumferential direction of the core portion. In this way, by making the first coil portion and the second coil portion partially in contact along the circumferential direction of the core portion, the leakage magnetic characteristics between the first coil portion and the second coil portion can be adjusted according to their degree of contact (contact length).

[0016] In particular, in the coil device of the present invention, the core portion has a protrusion that extends outward from the outer peripheral surface of the core portion and along the circumferential direction of the core portion. The first coil portion and the second coil portion sandwich the protrusion therebetween and partially contact each other along the circumferential direction of the core portion. Therefore, in the location where the protrusion is formed, contact between the first coil portion and the second coil portion can be avoided; on the other hand, in the location where the protrusion is not formed, contact between the first coil portion and the second coil portion can be made. That is, by sandwiching the protrusion therebetween, partial contact between the first coil portion and the second coil portion can be easily made. In addition, by appropriately adjusting the length of the protrusion along the circumferential direction of the core portion, the degree of contact between the first coil portion and the second coil portion can be easily adjusted, thereby easily adjusting the leakage magnetic characteristics between the first coil portion and the second coil portion.

[0017] Furthermore, the coil device of the present invention does not have multiple frames, and the leakage magnetic characteristics between the first coil section and the second coil section can be adjusted with a single frame, thus contributing to the reduction of the number of components.

[0018] Preferably, the length of the protrusion along the circumference of the core portion is shorter than the circumferential length of the core portion. With this structure, the protrusion is not formed along the entire circumference of the outer circumference of the core portion, but only a portion along the circumference. This structure allows the first coil portion and the second coil portion to partially contact each other by sandwiching the protrusion between them along the circumference of the core portion.

[0019] Preferably, the core portion has a generally elliptical shape, and the protrusion is formed on the long side of the outer peripheral surface of the core portion. By forming the protrusion on the long side of the core portion, it is possible to prevent the winding of the first coil portion and the second coil portion from loosening. In the position where the protrusion is not formed, it is possible to improve the contact between the first coil portion and the second coil portion and to adjust the leakage magnetic characteristics between the first coil portion and the second coil portion with high precision.

[0020] Preferably, the protrusion is composed of a first protrusion and a second protrusion, which are arranged on opposite sides of each other along the radial direction of the core portion. With this structure, the leakage magnetic characteristics between the first coil portion and the second coil portion can be adjusted with high precision using the first and second protrusions, and positional misalignment of the first and second coil portions along the axial direction of the core portion can be prevented. Furthermore, by properly positioning the first and second coil portions, deviations in the leakage magnetic characteristics between them can be suppressed.

[0021] Preferably, the device further comprises a core mounted on the frame, the core having a base portion, a pair of outer legs connected to a first surface of the base portion, and a middle leg connected to the first surface and disposed between the pair of outer legs. A recess is formed on a second surface of the base portion, orthogonal to the first surface, at the position of the middle leg. By configuring the structure in this way, for example, when the core is surrounded by potting resin, the potting resin penetrates into the interior of the recess, thus ensuring sufficient contact area between the potting resin and the core, and adequately dissipating heat generated by the core through the potting resin.

[0022] Preferably, the coil also includes a core mounted on the frame. The core has a base portion, a pair of pairs of legs arranged along a first axis, and a middle leg disposed between the pair of pairs of legs. The middle leg is offset from the center of the base portion towards a second axis orthogonal to the first axis, and a wall thickness is formed at the end of each pair of legs on the other side of the second axis. By forming a wall thickness on the legs, the cross-sectional area of ​​the legs can be sufficiently ensured, resulting in a coil device with good inductance characteristics. Furthermore, because the cross-sectional area of ​​the legs is increased by the amount of wall thickness, even when the length of the legs along the first or second axis is reduced (i.e., the volume of the core is reduced), the necessary cross-sectional area can be sufficiently ensured, enabling good miniaturization of the core and, consequently, good miniaturization of the coil device. Additionally, miniaturizing the core, for example by filling the core with a filling resin, promotes the winding of the filling resin around the core.

[0023] Furthermore, by positioning the middle leg at a position offset from the center of the base portion towards one side in the second axial direction, sufficient space can be ensured on the other side of the base portion in the second axial direction for arranging the outer leg portion, and the cross-sectional area of ​​the outer leg portion can be adequately ensured in the wall thickness portion.

[0024] Preferably, the cross-sectional area of ​​the middle leg is approximately equal to the sum of the cross-sectional areas of the pair of outer legs. After the outer legs have a wall thickness, by adopting the structure described above, magnetic saturation of the magnetic flux through the middle leg and the pair of outer legs can be effectively prevented, thereby improving the inductance characteristics of the coil device.

[0025] Preferably, the axial direction of the core portion is substantially parallel to the mounting surface. This structure allows for the creation of a horizontal coil assembly, suppressing the height of the coil assembly and achieving a thinner coil assembly.

[0026] Preferably, the coil also includes a housing for receiving the skeleton, the housing being capable of being filled with filling resin, and at least one through-hole formed on the outer peripheral surface of the core portion. With this structure, heat generated by the skeleton or the like can be dissipated to the outside via the housing and the filling resin, enabling efficient cooling of the coil assembly. Furthermore, by forming the through-hole in the core portion, the filling resin can flow through the through-hole to both the inside and outside of the skeleton, ensuring that the filling resin is distributed throughout all corners of the housing. Attached Figure Description

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

[0028] Figure 2 From Figure 1 The coil assembly shown is a perspective view omitting the housing and resin.

[0029] Figure 3 yes Figure 1 An exploded perspective view of the coil device shown.

[0030] Figure 4A Viewed from the outside along the Y-axis. Figure 3 The side view of the core substrate shown.

[0031] Figure 4B Viewed from the inside along the Y-axis. Figure 3 The side view of the middle and outer legs of the core shown.

[0032] Figure 5 It is along Figure 1 The cross-sectional view of the V-V line of the coil device shown.

[0033] Figure 6 yes Figure 3 The diagram shows a three-dimensional view of the skeleton.

[0034] Figure 7 Is Figure 6 The skeleton shown has Figure 3 Side view of the first coil section and the second coil section shown.

[0035] Figure 8 It means Figure 3 A perspective view of the terminals, terminal blocks, and covers shown.

[0036] Figure 9 Is Figure 6 The skeleton shown is equipped with Figure 8 A perspective view of the terminal block and cover shown.

[0037] Figure 10 It means Figure 9 A perspective view of the structure of the connection between the terminal block and the frame.

[0038] Explanation of symbols

[0039] 10…coil assembly, 20…frame, 21…core section, 211…through hole, 22a, 22b…flange section, 220a, 220b…flange section body, 23a, 23b…terminal block fixing section, 230a, 230b…fixing body section, 24a, 24b…flange engaging section, 25a, 25b…frame hook section, 26a, 26b…separator section, 27a, 27b…extended flange section, 28a, 28b, 29a, 29b…notch section, 30a, 30b…frame protrusion, 31a, 31b…frame step section, 310a, 310b…step lower surface, 32a, 32b…support section, 33, 34…protrusion, 35a, 35b, 36a, 36b…through hole Part, 37a, 37b… concave bottom, 41… first coil part, 42… second coil part, 41a, 41b… first lead part, 41c… first winding, 42a, 42b… second lead part, 42c… second winding, 43… contact area, 44, 45… non-contact area, 50a, 50b… core, 51a, 51b… base part, 510a, 510b… outer surface, 511a, 511b… inner surface, 512a, 512b… upper surface, 513a, 513b… lower surface, 52a, 52b… outer foot part, 520a, 520b… inner side of outer foot part, 53a, 53b… middle foot part, 54a, 54b… upper concave part, 540a, 540b… upper bottom surface, 5 41a, 541b…Upper conical surface, 55a, 55b…Lower recess, 550a, 550b…Lower bottom surface, 550a, 551b…Lower conical 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…Connection portion, 612_1, 612_2, 622_1, 622_2…Bottom of wiring, 613_1, 613_2, 623_1, 623_2…Wiring foldback portion, 70…Terminal block, 71…Terminal block base portion, 72a, 72b…Arm portion, 73a, 73b… Terminal block hook, 74a, 74b… terminal block step, 740a, 740b… lower surface of step, 75a, 75b… terminal block recess, 76a, 76b… lead wire insertion slot, 77a_1, 77a_2, 77b_1, 77b_2… terminal fixing part, 770a_1, 770a_2, 770b_1, 770b_2… terminal insertion slot, 78… cover mounting part, 79… bottom surface fixing part, 80… cover part, 81… cover bottom, 82… insulation part, 820… insulation recess, 83a, 83b… cover side part, 84… gripping part, 841… upper arm, 842… lower arm, 90… housing, 91… housing bottom, 92… housing side part, 93… joint part, 100… resin. Detailed Implementation

[0040] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0041] Figure 1 The coil device 10 shown in this embodiment functions as a transformer, for example, in on-board chargers for EVs (Electric Vehicles), PHVs (Plug-in Hybrid Vehicles), or commuter vehicles, power circuits for household or industrial electrical equipment, or power circuits for computer equipment. The detailed structure of the coil device 10 will be described below. Furthermore, in the following description, the positive Z-axis direction side is designated as the upper side, and the negative Z-axis direction side is designated as the lower side. Additionally, the side facing the center of the coil device 10 is designated as the inner side or inner direction, and the side away from the center of the coil device 10 is designated as the outer side or outer direction.

[0042] like Figure 3 As shown, the coil assembly 10 includes a frame 20, a first coil section 41 and a second coil section 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 section 80, and a housing 90. The coil assembly 10 is a horizontally oriented coil assembly in which the winding axes of the first coil section 41 and the second coil section 42 are parallel to the surface of the mounting substrate (not shown). Furthermore, the mounting substrate is disposed on... Figure 1 The area above the coil device 10 (on the positive Z-axis side) becomes the mounting surface (mounting surface) of the coil device relative to the mounting substrate.

[0043] The shell 90 is made of a metal with excellent cooling properties, such as aluminum, and has a shell bottom 91 and shell sides 92. The top of the shell 90 is open, allowing the skeleton 20 and the like to be housed through an opening formed in the top of the shell 90. The shell bottom 91 has a generally rectangular shape and forms the bottom surface of the shell 90. The shell sides 92 have a generally quadrangular cylindrical shape and are formed along the outer edge of the shell bottom 91.

[0044] More specifically, the housing side portion 92 extends upward from each of the four sides forming the outer edge of the housing bottom 91. The housing 90 is formed by bending a piece of metal sheet or the like, and the mating surfaces of the bent portions are formed as joint portions 93 on the housing side portion 92. Furthermore, the joint portion 93 can be liquid-tightly sealed by attaching an adhesive or the like to it.

[0045] The frame 20, etc., are stored in the storage space formed by the bottom 91 and the side 92 of the shell, and as such Figure 1As shown, it can be filled with filling resin 100. The filling resin 100 is composed of silicone resin, polyurethane resin, epoxy resin, etc. When the filling resin 100 is filled into the opening of the housing 90, a part of the skeleton 20, a part of the first terminal 61-1, or a part of the cover 80 is exposed from the upper surface of the cured filling resin 100.

[0046] In this embodiment, the heat generated by the frame 20 and the like can be dissipated to the outside through the housing 90 and the filling resin 100, and the coil device 10 can be cooled efficiently.

[0047] like Figure 3 As shown, the first coil portion 41 is formed by winding a first winding 41c onto the outer peripheral surface of the core portion 21 of the frame 20. Similarly, the second coil portion 42 is formed by winding a second winding 42c onto the outer peripheral surface of the core portion 21 of the frame 20. The first winding 41c and the second winding 42c are wound onto the outer peripheral surface of the core portion 21, for example, using an automatic winding machine.

[0048] The first coil portion 41 is formed of two layers in a direction orthogonal to its winding axis (radial direction), and the second coil portion 42 is formed of two layers in a direction orthogonal to its winding axis (radial direction). Furthermore, the winding axes of the first coil portion 41 and the second coil portion 42 are approximately aligned and correspond to the Y-axis direction.

[0049] The first coil portion 41 is disposed on one side of the core portion 21 in the Y-axis direction (positive Y-axis side), and the second coil portion 42 is disposed on the other side of the core portion 21 in the Y-axis direction (negative Y-axis side). Either the first coil portion 41 or the second coil portion 42 constitutes the primary coil, and the other one constitutes the secondary coil. The primary and secondary coils in the core portion 21 can also be arranged on either side of the core portion 21 in the Y-axis direction.

[0050] The first winding 41c and the second winding 42c are each composed of insulated windings, such as copper wire or other conductors. The first winding 41c and the second winding 42c can be composed of single wires or stranded wires. The wire diameter of the first winding 41c and the second winding 42c is preferably 1.0 to 3.0 mm. The wire diameters of the first winding 41c and the second winding 42c can be equal or different. For example, the wire diameter of the winding in the first winding 41c and the second winding 42c that supplies a large current can be thicker than that of the other winding.

[0051] A lead portion 41a is formed at one end of the first coil portion 41, and a lead portion 41b is formed at the other end of the first coil portion 41. For example, the lead portion 41a is led out from the second layer of the first coil portion 41, and the lead portion 41b is led out from the first layer of the first coil portion 41.

[0052] Furthermore, a lead portion 42a is formed at one end of the second coil portion 42, and a lead portion 42b is formed at the other end of the second coil portion 42. For example, the lead portion 42a extends from the second layer of the second coil portion 42, and the lead portion 42b extends from the first layer of the second coil portion 42.

[0053] Cores 50a and 50b are so-called E-shaped cores, mounted on the frame 20. The materials of cores 50a and 50b can include magnetic materials such as metals and ferrite, but there are no particular limitations. Cores 50a and 50b have the same shape. Core 50a has a base portion 51a, a pair of outer legs 52a, and a middle leg 53a. Core 50b has a base portion 51b, a pair of outer legs 52b, and a middle leg 53b. The structure of core 50a will be described below, but the description of core 50a also applies to core 50b. Therefore, unless otherwise required, the description of the structure of core 50b will be omitted.

[0054] The base portion 51a has a specified thickness in the Y-axis direction, such as Figure 4A and Figure 4B As shown, it has a predetermined length in both the X-axis and Z-axis directions. Hereinafter, in the base portion 51a, its outer surface in the Y-axis direction is referred to as the outer surface 510a, its inner surface in the Y-axis direction as the inner surface 511a, its upper surface as the upper surface 512a, and its lower surface as the lower surface 513a. Similarly, in the base portion 51b, its outer surface in the Y-axis direction is referred to as the outer surface 510b, its inner surface in the Y-axis direction as the inner surface 511b, its upper surface as the upper surface 512b, and its lower surface as the lower surface 513b.

[0055] The upper surface 512a and the lower surface 513a are surfaces orthogonal to the outer surface 510a and the inner surface 511a. The upper surface 512b and the lower surface 513b are surfaces orthogonal to the outer surface 510b and the inner surface 511b.

[0056] In this embodiment, an upper recess 54a, recessed at the position of the middle foot 53a, is formed on the upper surface 512a of the base portion 51a. The upper recess 54a is formed approximately at the center of the base portion 51a in the X-axis direction and has a predetermined width in both the X-axis and Y-axis directions. The width of the upper recess 54a in the X-axis direction is approximately equal to the width of the middle foot 53a in the X-axis direction. The width of the upper recess 54a in the Y-axis direction is approximately equal to the thickness of the base portion 51a in the Y-axis direction (see reference). Figure 3 ).

[0057] The upper recess 54a is recessed downwards from the upper surface 512a to a predetermined depth. The bottom surface of the upper recess 54a, namely the upper bottom surface 540a, is formed at approximately the same height as the upper portion of the outer peripheral surface of the middle foot 53a. The upper bottom surface 540a is composed of a surface that curves upwards into a convex shape, and the curvature of the upper bottom surface 540a is approximately the same as the curvature of the upper portion of the outer peripheral surface of the middle foot 53a. Therefore, the upper bottom surface 540a is connected along the Y-axis in a manner that makes it approximately the same surface as the upper portion of the outer peripheral surface of the middle foot 53a (see reference). Figure 3 ).

[0058] An upper conical surface 541a is formed on the inner wall surface of the upper recess 54a (the surfaces that rise from both sides of the upper bottom surface 540a in the X-axis direction). The upper conical surface 541a is inclined at a predetermined angle and connects the upper surface 512a and the upper bottom surface 540a.

[0059] A lower recess 55a is formed on the lower surface 513a of the base portion 51a, recessed at the position of the middle foot portion 53a. The lower recess 55a is formed approximately at the center of the base portion 51a in the X-axis direction, and has a predetermined width in both the X-axis and Y-axis directions. The width of the lower recess 55a in the X-axis direction is smaller than the width of the middle foot portion 53a in the X-axis direction, and is similar to the concave bottom 37a or 37b of the skeleton 20. Figure 6 The width of the recessed portion 55a in the X-axis direction is approximately equal to the thickness of the base portion 51a in the Y-axis direction.

[0060] like Figure 4B As shown, the lower recess 55a is recessed upward from the lower surface 513a to a predetermined depth, and the depth of the lower recess 55a is greater than the depth of the upper recess 54a. The bottom surface of the lower recess 55a, namely the lower bottom surface 550a, is formed at a position further downward than the lower portion of the outer peripheral surface of the middle foot 53a by a predetermined distance. The lower bottom surface 550a is composed of a generally flat surface, and a step is formed between the lower bottom surface 550a and the lower portion of the outer peripheral surface of the middle foot 53a.

[0061] A lower conical surface 551a is formed on the inner wall surface of the lower recess 55a (the surfaces rising from both sides in the X-axis direction of the lower bottom surface 550a). The lower conical 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 recess 55a is similar to the concave bottom 37a or 37b of the skeleton 20. Figure 6 The shapes are roughly the same.

[0062] In this embodiment, such as Figure 3As shown, the interior of the housing 90 is filled with filling resin 100, and a resin layer composed of filling resin 100 is formed around the cores 50a and 50b. In this case, because the filling resin 100 enters... Figure 4B The interiors of the upper recess 54a and the lower recess 55a shown can ensure sufficient contact area between the filling resin 100 and the cores 50a and 50b, so that the heat generated by the cores 50a and 50b can be sufficiently dissipated through the filling resin 100.

[0063] Furthermore, by providing an upper conical surface 541a to the upper recess 54a and a lower conical surface 551a to the lower recess 55a, the surface area of ​​the inner wall of each of the upper recess 54a and the lower recess 55a can be increased, as well as the contact area between the upper recess 54a and the lower recess 55a and the filling resin 100 can be increased.

[0064] Furthermore, when filling with the filling resin 100, since the filling resin 100 flows from the inside (outside) to the outside (inside) in the Y-axis direction of the base portion 51a within the upper recess 54a and the lower recess 55a (that is, since the upper recess 54a and the lower recess 55a function as flow paths for the filling resin 100), the filling resin 100 can be distributed throughout all corners of the housing 90.

[0065] A middle leg portion 53a is disposed between a pair of outer legs 52a and connected to the inner surface 511a of the base portion 51a. The middle leg portion 53a extends a predetermined length from the inner surface 511a along the Y-axis and is disposed inside the through hole 211 formed in the core portion 21 of the skeleton 20. The middle legs 53a of the core 50a and the middle legs 53b of the core 50b are disposed inside the through hole 211 with their respective front ends abutting. Alternatively, a gap may be formed along the Y-axis between the front ends of the middle legs 53a and 53b.

[0066] like Figure 4BAs shown, the middle foot 53a is not formed at the center of the inner surface 511a of the base portion 51a, but is formed at a position offset upwards (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 foot 53a and the center C1 of the inner surface 511a of the base portion 51a (i.e., the Z-axis offset width of the center C2 of the middle foot 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 foot 52a) along the Z-axis direction. The ratio L1 / L2 of the above-mentioned L1 and L2 is preferably 0 < L1 / L2 < 1 / 4, and more preferably 0 < L1 / L2 < 1 / 6. In this embodiment, the middle foot 53a is positioned at a position offset upwards from the center C1 of the inner surface 511a in order to ensure sufficient space below the inner surface 511a for forming the wall thickness portion 56a in the outer foot 52a, as described below.

[0067] The upper portion of the outer peripheral surface of the middle foot 53a is positioned close to the upper surface 512a of the base 51a, and is located below the upper surface 512a. The shape of the upper portion of the outer peripheral surface of the middle foot 53a is similar to the upper bottom surface 540a of the base 51a. Figure 4A The shapes are roughly the same. The lower part of the outer peripheral surface of the middle foot 53a is positioned close to the lower bottom surface 550a of the lower recess 55a, and is located above the lower bottom surface 550a. That is, the middle foot 53a is located between the upper surface 512a and the lower recess 55a (lower bottom surface 550a) in the Z-axis direction.

[0068] like Figure 3 As shown, a pair of feet 52a are arranged at predetermined intervals along the X-axis direction and are connected to the inner surface 511a of the base portion 51a. One of the pairs of feet 52a is disposed at one end of the inner surface 511a in the X-axis direction, and the other of the pairs of feet 52a is disposed at the other end of the inner surface 511a in the X-axis direction.

[0069] A pair of outer legs 52a extend a predetermined length from the inner surface 511a along the Y-axis and are disposed on the outer side of the core portion 21 of the skeleton 20.

[0070] like Figure 4B As shown, a wall thickness portion 56a is formed at the Z-axis end of each of the outer legs 52a. The wall thickness portion 56a is formed at the lower end of the outer leg 52a (that is, the end opposite to the Z-axis direction of the position offset direction (upward) of the middle leg 53a mentioned above).

[0071] The wall thickness portion 56a protrudes towards the inner side in the X-axis direction (the center C1 of the inner surface 511a of the base portion 51a), and is formed to become thicker in the X-axis direction. By forming the wall thickness portion 56a in the outer foot portion 52a, the cross-sectional area of ​​the outer foot portion 52a can be sufficiently ensured, and a coil device 10 with good inductance characteristics can be obtained.

[0072] Furthermore, because the cross-sectional area of ​​the outer leg portion 52a is increased by the amount that forms the wall thickness portion 56a, even when the length of the outer leg portion 52a along the X-axis or Z-axis direction is reduced (i.e., the volume of the core 50a is reduced), the necessary cross-sectional area can be sufficiently ensured, and the miniaturization of the core 50a can be well achieved, thereby enabling the miniaturization of the coil device 10. In addition, by miniaturizing the core 50a, for example by filling the core 50a with filling resin 100, the winding of the filling resin 100 around the core 50a can be promoted.

[0073] The width W1 of the wall thickness portion 56a along the X-axis direction increases as it faces downwards. The ratio W1 / W2 of the width W1 of the wall thickness portion 56a along the X-axis direction and the maximum width W2 of the base portion 51a along the X-axis direction is preferably 0 < W1 / W2 < 1 / 2. By setting the value of W1 / W2 to the above range, the volume of the wall thickness portion 56a can be sufficiently ensured, and the volume of the area where the wall thickness portion 56a is not formed can also be sufficiently ensured, which contributes to improving the inductance characteristics of the coil device 10.

[0074] The inner surface 520a of the outer leg portion 52a bends inward toward the X-axis direction as it approaches the lower end of the outer leg portion 52a. That is, because a wall thickness portion 56a is formed in the outer leg portion 52a, the inner surface 520a bends toward the side where the center C1 of the inner surface 511a of the base portion 51a is located at the position of the wall thickness portion 56a. The bent portion of the inner surface 520a bends approximately along the outer peripheral surface of the middle leg portion 53a. Furthermore, as... Figure 5 As shown, the curved portion of the inner side surface 520a of the outer foot curves approximately along the periphery of the flange portion 22a (flange body 220a) of the frame 20. Furthermore, the outer side surface of the outer foot portion 52a located on the opposite side of the inner side surface 520a in the X-axis direction extends along the Z-axis direction, and the shape of the inner side surface 520a of the outer foot is different from that of the outer side surface.

[0075] like Figure 4BAs shown, in this embodiment, the cross-sectional area S1 of the middle leg 53a is approximately equal to the sum of the cross-sectional areas S2 of one pair of outer legs 52a and the cross-sectional area S3 of the other pair. In this embodiment, as a result of forming the wall thickness portion 56a in the outer leg 52a, the cross-sectional area of ​​the outer leg 52a increases. Therefore, even if the overall size of the outer leg 52a is reduced, the sum of the cross-sectional areas (S2+S3) of each pair of outer legs 52a can be made approximately equal to the cross-sectional area S1 of the middle leg 53a.

[0076] After the wall thickness portion 56a is formed in the outer leg portion 52a, by setting it in this way, magnetic saturation of the magnetic flux passing through the middle leg portion 53a and a pair of outer legs portion 52a can be effectively prevented, thereby improving the inductance characteristics of the coil device 10.

[0077] The skeleton 20 is made of plastics such as PPS, PET, PBT, LCP, or other insulating components (preferably heat-resistant materials). Figure 3 As shown, the frame 20 has a core portion 21, flange portions 22a and 22b, and terminal block fixing portions 23a and 23b.

[0078] A first winding 41c and a second winding 42c are wound around the outer peripheral surface of the core portion 21 to form a first coil portion 41 and a second coil portion 42. The first coil portion 41 is disposed on one side of the core portion 21 in the Y-axis direction on the flange portion 22a and the protrusions 33 and 34 described below. Figure 7 )between.

[0079] One end of the first coil portion 41 in the winding axis direction is positioned adjacent to the flange portion 22a, and the other end of the first coil portion 41 in the winding axis direction is positioned adjacent to the protrusions 33 and 34. Similarly, one end of the second coil portion 42 in the winding axis direction is positioned adjacent to the flange portion 22b, and the other end of the second coil portion 42 in the winding axis direction is positioned adjacent to the protrusions 33 and 34.

[0080] The core portion 21 is composed of a cylindrical body with a generally elliptical shape, and the axial direction of the core portion 21 is aligned with the Y-axis direction. A through hole 211 is formed on the inner side of the core portion 21, which can accommodate the middle legs 53a and 53b of the cores 50a and 50b. As described above, since the coil device 10 of this embodiment is a horizontal coil device, the axial direction of the core portion 21 is approximately 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 coil device 10 can be made thinner.

[0081] The cross-sectional shape of the core portion 21 (the cross-sectional shape of the surface parallel to the XZ plane) is approximately elliptical (see reference). Figure 5The long-side surface of the core portion 21 (the upper and lower portions of the outer peripheral surface of the core portion 21) is composed of a generally flat surface, while the short-side surface of the core portion 21 (the side portions of the outer peripheral surface of the core portion 21) is composed of a curved surface. Furthermore, the long-side surface of the core portion 21 may also be curved, but its degree of curvature is preferably less than that of the short-side surface of the core portion 21.

[0082] like Figure 6 As shown, through holes 35a and 35b are formed at predetermined intervals in the Y-axis direction on the upper portion of the outer peripheral surface of the core portion 21. Through holes 35a and 35b are located at the center of the core portion 21 in the X-axis direction. Through hole 35a is located on the side of the protrusion 33 closer to the Y-axis (where the first coil portion 41 is disposed), and is located between the flange portion 22a and the protrusion 33 in the Y-axis direction. Through hole 35b is located on the other side of the protrusion 33 closer to the Y-axis (where the second coil portion 42 is disposed), and is located between the flange portion 22b and the protrusion 33 in the Y-axis direction. Through holes 35a and 35b are each formed of the same shape, having an opening formed of a generally elliptical shape with a long side in the Y-axis direction.

[0083] Through holes 36a and 36b are formed at predetermined intervals in the Y-axis direction on the lower portion of the outer peripheral surface of the core portion 21. Through holes 36a and 36b are located in the center of the core portion 21 in the X-axis direction. Through hole 36a is located at a distance from the protrusion 34 (…). Figure 7 The first coil portion 41 is located on the Y-axis side, between the flange portion 22a and the protrusion 34. The second coil portion 36b is located on the Y-axis side of the protrusion 34 (where the second coil portion 42 is located), between the flange portion 22a and the protrusion 34. The second coil portion 36b is located on the Y-axis side of the protrusion 34, between the flange portion 22b and the protrusion 34. The second coil portion 36a and the third coil portion 36b are each made of the same shape, having an opening formed by a generally elliptical shape with a long side in the Y-axis direction. In the Z-axis direction, the position of the second coil portion 36a corresponds to the position of the third coil portion 35a, and the position of the third coil portion 36b corresponds to the position of the third coil portion 35b.

[0084] By forming through holes 35a, 35b, 36a, and 36b in the core portion 21, the filling resin 100 ( Figure 1 Through these through holes, the resin 100 can circulate inside and outside the skeleton 20 (core part 21), allowing the filling resin 100 to be distributed throughout every corner of the housing 90.

[0085] A flange portion 22a is formed at one axial end of the core portion 21, and a flange portion 22b is formed at the other axial end of the core portion 21. Both flange portions 22a and 22b have the same shape. At one end of the core portion 21 in the Y-axis direction, the flange portion 22a has a flange body 220a extending circumferentially along the outer peripheral surface of the core portion 21. At the other end of the core portion 21 in the Y-axis direction, the flange portion 22b has a flange body 220b extending circumferentially along the outer peripheral surface of the core portion 21. The flange body 220a is constructed of a plate having a predetermined thickness in the Y-axis direction and protrudes radially outward along the core portion 21. The flange body 220b is constructed of a plate having a predetermined thickness in the Y-axis direction and protrudes radially outward along the core portion 21.

[0086] A pair of mounting portions 32a are formed below the flange body 220a (see reference). Figure 5 One mounting portion 32a is formed on one side of the flange body 220a in the X-axis direction, and another mounting portion 32a is formed on the other side of the flange body 220a in the X-axis direction. The mounting portions 32a and the other mounting portion 32a are arranged at a predetermined interval in the X-axis direction. The pair of mounting portions 32a extend substantially parallel to the flange body 220a along the XZ plane, and the bottom surfaces of the pair of mounting portions 32a are substantially flat. The pair of mounting portions 32a are placed on... Figure 3 The bottom 91 of the housing 90 shown.

[0087] A pair of mounting portions 32b are formed below the flange body 220b. Since the structure and function of the pair of mounting portions 32b are the same as those of the pair of mounting portions 32a, detailed descriptions are omitted. The core portion 21 of the frame 20 can be supported by the pair of mounting portions 32a and the pair of mounting portions 32b.

[0088] A concave bottom 37a is formed between each of a pair of mounting portions 32a, and a concave bottom 37b is formed between each of a pair of mounting portions 32b. The concave bottoms 37a and 37b have a shape that is recessed upwards from the bottom surface of the mounting portions 32a and 32b. The bottoms of the concave bottoms 37a and 37b form the outer peripheral surfaces of the flange bodies 220a and 220b, and a portion of the inner wall surface of the concave bottoms 37a and 37b is inclined into a conical shape. By forming concave bottoms 37a and 37b in the flange bodies 220a and 220b, and filling with filling resin 100 (… Figure 1 When the filling resin 100 flows from the inside (outside) to the outside (inside) of the concave bottoms 37a and 37b in the Y-axis direction (i.e., because the concave bottoms 37a and 37b function as a flow path for the filling resin 100), the filling resin 100 can be distributed to the area below the skeleton 20.

[0089] A flange engaging portion 24a is formed above the flange body 220a. The flange engaging portion 24a is integrally connected to the upper part of the flange body 220a and extends substantially parallel to the flange body 220a along the XZ plane. That is, the flange engaging portion 24a has a shape that extends upwardly from the flange body 220a and constitutes a part of the flange body 220a. The flange engaging portion 24a is formed on the negative X-axis side of the upper end of the flange body 220a and protrudes upward more than the fixing body portion 230a of the terminal block fixing portion 23a.

[0090] The flange engaging portion 24a has a predetermined thickness in the Y-axis direction and has a surface substantially parallel to the XZ plane. Furthermore, the flange engaging portion 24a extends along the arm portion 72a of the terminal block 70 described below. Figure 8 It extends in a direction approximately orthogonal to the long side direction (X-axis direction) of the arm 72a. This allows the terminal hook portion 73a (formed at the front end of the arm 72a) to extend in a direction approximately orthogonal to the long side direction (X-axis direction). Figure 8 It engages with the flange engagement part 24a.

[0091] A hook-shaped skeleton hook portion 25a is formed at the front end (upper end) of the flange engaging portion 24a. The skeleton hook portion 25a is configured to protrude from the upper end of the flange engaging portion 24a inward in the X-axis direction and outward in the Z-axis direction. More specifically, the skeleton hook portion 25a protrudes further outward in the Y-axis direction than the outer surface of the flange engaging portion 24a in the Y-axis direction. In addition, the skeleton hook portion 25a protrudes further inward in the X-axis direction than the inner surface of the flange engaging portion 24a in the X-axis direction. 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 the function of preventing the lead portion 41a or 41b of the first coil portion 41 extending around the flange engaging portion 24a from shifting towards the upper position of the flange engaging portion 24a (locking function).

[0092] Since the structure and function of the flange engaging portion 24b formed above the flange body 220b and the skeleton hook portion 25b formed at the front end of the flange engaging portion 24b are the same as those of the flange engaging portion 24a and the skeleton hook portion 25a described above, detailed descriptions are omitted. Furthermore, the skeleton hook portion 25b has the function of preventing the lead portion 42a or 42b of the second coil portion 42 extending around the flange engaging portion 24b from shifting towards the upper position of the flange engaging portion 24b (locking function).

[0093] A terminal block 70 is fixed at one end of the frame 20 in the Y-axis direction. Figure 8The terminal block fixing portion 23a is formed at one end of the frame 20 in the Y-axis direction, and a terminal block fixing portion 23b is formed at the other end of the frame 20 in the Y-axis direction, which fixes the terminal block 70. The terminal block fixing portions 23a and 23b have the function of fixing the terminal block 70, and when the first winding 41c and the second winding 42c are wound on the core portion 21 by the automatic winding machine, they also serve to fix a part of the automatic winding machine.

[0094] Terminal block fixing part 23a has a fixing body part 230a, a frame protrusion 30a, and a frame step part 31a. Terminal block fixing part 23b has a fixing body part 230b, a frame protrusion 30b, and a frame step part 31b.

[0095] The fixing body portions 230a and 230b are generally flat plate shapes having surfaces substantially parallel to the XY plane, and have a predetermined thickness in the Z-axis direction. The width of the fixing body portions 230a and 230b along the X-axis direction is greater than the width of the core portion 21 along the X-axis direction, and is approximately equal to the width of the flange portions 220a and 220b along the X-axis direction. The fixing body portion 230a is integrally connected to the outer surface of the flange portion body 220a of the flange portion 22a in the Y-axis direction, and protrudes outward from that surface. The fixing body portion 230b is integrally connected to the outer surface of the flange portion body 220b of the flange portion 22b in the Y-axis direction, and protrudes outward from that surface.

[0096] The skeleton protrusions 30a and 30b are composed of protruding pieces with a protruding shape, protruding a predetermined length from the side portion (side) of the fixed body portion 230a and 230b in the X-axis direction toward the outer side in the X-axis direction, respectively. The protruding directions of the skeleton protrusions 30a and 30b correspond to the direction in which the terminal block 70 is disposed.

[0097] The skeleton protrusions 30a and 30b have a generally cuboid shape composed of flat shapes, and the thickness of the skeleton protrusions 30a and 30b in the Z-axis direction is smaller than the thickness of the fixing body portions 230a and 230b in the Z-axis direction. The skeleton protrusion 30a and the terminal recess 75a of the terminal block 70 ( Figure 8 ) engage, the frame protrusion 30b and the terminal recess 75b of the terminal block 70 ( Figure 8 ) card.

[0098] A frame step portion 31a is formed on the back side of the fixing body portion 230a, and is formed at the corner where the end portion (side portion) on the negative X-axis direction side and the end portion on the positive Y-axis direction side of the fixing body portion 230a intersect. A frame step portion 31b is formed on the back side of the fixing body portion 230b, and is formed at the corner where the end portion (side portion) on the negative X-axis direction side and the end portion on the negative Y-axis direction side of the fixing body portion 230b intersect.

[0099] 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 in the Y-axis direction between the flange engaging portion 24a and the skeleton step portion 31a, and the skeleton protrusion 30b is formed in the Y-axis direction between the flange engaging portion 24b and the skeleton step portion 31b.

[0100] The flange engaging portion 24a, the skeleton protrusion 30a, and the skeleton step portion 31a all function to form an engaging state with the terminal block 70, and are concentrated at the end of the fixed body portion 230a in the X-axis direction. Similarly, the flange engaging portion 24b, the skeleton protrusion 30b, and the skeleton step portion 31b all function to form an engaging state with the terminal block 70, and are concentrated at the end of the fixed body portion 230b in the X-axis direction.

[0101] The skeleton step portions 31a and 31b form steps relative to the back surfaces of the fixed body portions 230a and 230b. The skeleton step portions 31a and 31b have a step shape (concave shape) that is recessed to a predetermined depth in the Z-axis direction from the back surfaces of the fixed body portions 230a and 230b. When viewed from the Z-axis direction, the skeleton step portions 31a and 31b are approximately rectangular in shape (see reference). Figure 10 ).

[0102] The skeleton step portion 31a has a lower step surface 310a formed by a surface (a generally rectangular surface with a predetermined length in the X-axis and Y-axis directions) that is substantially parallel to the back surface of the fixing body portion 230a. The skeleton step portion 31b has a lower step surface 310b formed by a surface (a generally rectangular surface with a predetermined length in the X-axis and Y-axis directions) that is substantially parallel to the back surface of the fixing body portion 230b. The lower step surfaces 310a and 310b constitute the lower surfaces of the steps forming the skeleton step portions 31a and 31b. Furthermore, the upper surfaces of the steps forming the skeleton step portions 31a and 31b become the back surface of the fixing body portion 230a. The skeleton step portion 31a and the terminal block step portion 74a of the terminal block 70 ( Figure 8 ) engage, the frame step portion 31b and the terminal block step portion 74b of the terminal block 70 ( Figure 8 ) card.

[0103] An extended flange portion 27a is formed above the flange body 220a. The extended flange portion 27a is integrally connected to the upper part of the flange body 220a and extends substantially parallel to the XZ plane relative to the flange body 220a. That is, the extended flange portion 27a has a shape that extends upwardly from the flange body 220a and constitutes a part of the flange body 220a. The extended flange portion 27a has a predetermined thickness in the Y-axis direction and has a surface that is substantially parallel to the XZ plane.

[0104] The aforementioned flange engaging portion 24a is formed at the end of the upper portion of the flange main body 220a on the negative X-axis side, and in contrast, the extended flange portion 27a is formed at the end of the upper portion of the flange main body 220a on the positive X-axis side. The extended flange portion 27a is arranged at a predetermined interval relative to the flange engaging portion 24a along the X-axis direction, and protrudes upward further than the fixing body portion 230a of the terminal block fixing portion 23a.

[0105] A partition 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 26a are arranged along the X-axis direction. The partition 26a is integrally connected to the upper part of the flange portion body 220a and extends substantially parallel to the XZ plane relative to the flange portion body 220a. That is, the partition 26a has a shape that extends upwardly from the flange portion body 220a and constitutes a part of the flange portion body 220a. The partition 26a has a predetermined thickness in the Y-axis direction and has a surface that is substantially parallel to the XZ plane.

[0106] An extended flange portion 27b and a partition portion 26b are formed above the flange portion 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, a detailed description thereof is omitted.

[0107] A notch 28a is formed between the flange engaging portion 24a and the partition portion 26a, and a notch 29a is formed between the extended flange portion 27a and the partition portion 26a. The first winding 41c can be inserted through the notch 28a. Figure 3 Either of the lead portions 41a and 41b. The notch portion 29a is the same.

[0108] A notch 28b is formed between the flange engaging portion 24b and the partition portion 26b, and a notch 29b is formed between the extended flange portion 27b and the partition portion 26b. A second winding 42c can be inserted through the notch 28b. Figure 3 Either of the lead portions 42a and 42b. The notch portion 29b is the same.

[0109] In this embodiment, such as Figure 2 As shown, in leads 41a and 41b, lead 41a is inserted into notch 29a. Lead 41a is led out from the inside of flange 22a in the Y-axis direction via notch 29a towards the outside, and from the outside of flange 22a in the Y-axis direction towards terminal block 70. Therefore, when leading 41a towards terminal block 70, unnecessary winding of lead 41a can be prevented.

[0110] On the other hand, the lead portion 41b is led out from the inside of the flange portion 22a in the Y-axis direction toward the terminal block 70 without passing through either of the notches 28a and 29a. As a result, the lead portion 41a passes through the outside of the flange engagement portion 24a in the Y-axis direction, and the lead portion 41b passes through the inside of the flange engagement portion 24a in the Y-axis direction. Therefore, the lead portion 41a and the lead portion 41b can be well insulated via the flange engagement portion 24a.

[0111] Furthermore, since a partition 26a is formed between the notch 28a and the notch 29a, the position of the lead portion 41a inserted into the notch 29a can be adjusted by the partition 26a, and the position of the lead portion 41a is prevented from shifting.

[0112] In leads 42a and 42b, lead 42a is inserted into notch 28b, and leads 42a outward from the inside of flange 22b in the Y-axis direction via notch 28b, and outward from the outside of flange 22b in the Y-axis direction toward terminal block 70. Therefore, when leading 42a toward terminal block 70, unnecessary winding of lead 42a can be prevented.

[0113] On the other hand, the lead portion 42b is led out from the inside of the flange portion 22b in the Y-axis direction toward the terminal block 70 without passing through either the notches 28b or 29b. As a result, the lead portion 42a passes through the outside of the flange engagement portion 24b in the Y-axis direction, and the lead portion 42b passes through the inside of the flange engagement portion 24b in the Y-axis direction. Therefore, the lead portion 42a and the lead portion 42b can be well insulated via the flange engagement portion 24b.

[0114] Because a partition 26b is formed between the notch 28b and the notch 29b, the position of the lead portion 42a inserted into the notch 28b can be adjusted by the partition 26b, and the position of the lead portion 42a is prevented from shifting by the partition 26b.

[0115] In this embodiment, the core portion 21 has protrusions 33 and 34. Figure 7 The protrusions 33 and 34 have a first coil portion 41 that can be adjusted according to its length along its circumferential direction (or along the X-axis direction) or its length (thickness) along the Y-axis direction. Figure 3 The function of leakage magnetic characteristics between the second coil section 42.

[0116] like Figure 6 and Figure 7As shown, protrusions 33 and 34 are integrally formed with the outer peripheral surface of the core portion 21, extending outward from the outer peripheral surface of the core portion 21 and along the circumferential direction of the core portion 21. Protrusions 33 and 34 are formed on the long side of the outer peripheral surface of the core portion 21. That is, protrusion 33 is formed on the upper portion of the outer peripheral surface of the core portion 21, and protrusion 34 is formed on the lower portion of the outer peripheral surface of the core portion 21. Furthermore, the upper and lower portions of the outer peripheral surface of the core portion 21 are generally flat surfaces, and protrusions 33 and 34 are preferably formed on the generally flat surface of the core portion 21 as described above, closer to the curved portion (lateral portion) of the core portion 21.

[0117] Protrusions 33 and 34 are formed approximately at the center of the core portion 21 in the axial direction (Y-axis direction). Protrusions 33 and 34 are arranged on opposite sides of each other along the radial direction of the core portion 21 and are formed at corresponding positions in the Z-axis direction.

[0118] Protrusions 33 and 34 have the same shape, consisting of a generally rectangular parallelepiped shape (flat shape) with its long side facing in the direction orthogonal to the axial direction of the core portion 21 (X-axis direction). The length of protrusions 33 and 34 along the X-axis direction is greater than their length (height) along the Z-axis direction, and the length of protrusions 33 and 34 along the Z-axis direction is greater than their thickness along the Y-axis direction. A curved surface (ground corner) is formed at the Z-axis end (upper end) of protrusion 33, but the shape of protrusion 33 is not limited to this. (Detailed illustration omitted) The shape of protrusion 34 is also the same.

[0119] The length of the protrusion 33 along the circumference of the core portion 21 (or the length of the protrusion 33 along the X-axis) is smaller than the circumferential length of the core portion 21. For example... Figure 9 As shown, the ratio L3 / L4 of the length of the protrusion 33 along the circumference of the core portion 21 (or the length of the protrusion 33 along the X-axis) L3 and the length of the core portion 21 along the circumference (total length) L4 (not shown) is preferably 0 < L3 / L4 < 1 / 2, more 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 The leakage magnetic characteristics between the core portion 21 and the second coil portion 42 are appropriately adjusted to the desired value. In addition, the ratio of the length of the protrusion 34 along the circumference of the core portion 21 (or the length of the protrusion 34 along the X-axis) to the length of the core portion 21 along the circumference is also the same.

[0120] The length of the protrusion 33 along the circumference of the core portion 21 (or the length of the protrusion 33 along the X-axis) is smaller than the length of the core portion 21 along the X-axis. The ratio L3 / L5 of the length of the protrusion 33 along the circumference of the core portion 21 (or the length of the protrusion 33 along the X-axis) L3 and the length of the core portion 21 along the X-axis L5 is preferably 0 < L3 / L5 < 1, more 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 The leakage magnetic characteristics between the core portion 21 and the second coil portion 42 are appropriately adjusted to the desired value. In addition, the ratio of the length of the protrusion 34 along the circumference of the core portion 21 (or the length of the protrusion 34 along the X-axis) to the length of the core portion 21 along the X-axis is also the same.

[0121] The length L6 of the protrusion 33 along the Z-axis direction is, for example, based on the first winding 41c ( Figure 3 The diameter of the first winding 41c or the second winding 42c is determined. In this embodiment, the first winding 41c and the second winding 42c are each formed in two layers in the radial direction of the core portion 21. Therefore, it is preferable that the length L6 is the diameter of the first winding 41c ( Figure 3 The diameter of the first coil portion 41 or the second coil portion 42 is more than twice the 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. That is, the length L6 is preferably greater than the height of the first coil portion 41 or the second coil portion 42 from the outer peripheral surface of the core portion 21. In addition, the length of the protrusion 34 along the Z-axis is also the same.

[0122] By determining the length L6 of the protrusion 33 along the Z-axis direction as described above, the position of the first winding 41c and the second winding 42c along the Y-axis direction can be effectively prevented by the protrusion 33. Furthermore, by fixing the first winding 41c and the second winding 42c at the protrusion 33, slack winding of the first coil portion 41 and the second coil portion 42 can be prevented. Additionally, when the first winding 41c and the second winding 42c are wound reciprocally between the axial end of the core portion 21 and the protrusions 33 and 34 on the outer peripheral surface of the core portion 21, the first winding 41c and the second winding 42c can be fixed at the protrusions 33 and 34 and then folded back, thereby preventing deviations in the position or number of turns of the first coil portion 41 and the second coil portion 42.

[0123] like Figure 7As shown, the length L7 of the protrusion 33 along the axial direction of the core portion 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 approximately equal to the thickness of the flange portion 22a or 22b along the Y-axis direction.

[0124] like Figure 2 and Figure 7 As shown, a first coil portion 41 is disposed on one side of the protrusions 33 and 34 in the Y-axis direction, and a 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.

[0125] The first coil portion 41 and the second coil portion 42 sandwich the protrusions 33 and 34 and partially contact each other along the circumference of the core portion 21. That is, when viewed along the circumference of the core portion 21, at the location where the protrusion 33 is formed, because the protrusion 33 is between the first coil portion 41 and the second coil portion 42, the first coil portion 41 and the second coil portion 42 do not contact each other. In other words, the protrusion 33 separates the first coil portion 41 and the second coil portion 42 along the Y-axis direction, forming a non-contact area 44 between the first coil portion 41 and the second coil portion 42.

[0126] Furthermore, at the location where the protrusion 34 is formed, since the protrusion 34 is located between the first coil portion 41 and the second coil portion 42, the first coil portion 41 and the second coil portion 42 do not contact each other. That is, the protrusion 34 separates the first coil portion 41 and the second coil portion 42 along the Y-axis direction, forming a non-contact area 45 between the first coil portion 41 and the second coil portion 42.

[0127] On the other hand, in the positions where protrusions 33 and 34 are not formed, since protrusions 33 and 34 are not located between the first coil portion 41 and the second coil portion 42, the first coil portion 41 and the second coil portion 42 are in contact. Therefore, a contact area 43 is formed between the first coil portion 41 and the second coil portion 42.

[0128] The contact area 43 is formed between the non-contact areas 44 and 45, and is formed in a region along a portion of the circumference of the core portion 21. The contact area 43 is formed from a side portion of the outer peripheral surface of the core portion 21, spanning the upper and lower portions of the outer peripheral surface of the core portion 21, and extends a predetermined length along the outer peripheral surface of the core portion 21 in a generally C-shaped manner. The contact area 43 is formed discontinuously on one side and the other side of the core portion 21 in the X-axis direction. The non-contact areas 44 and 45 are formed on the upper and lower portions of the outer peripheral surface of the core portion 21, respectively, and extend a predetermined length along the X-axis direction. The contact area 43 and the non-contact area 44 or 45 are formed alternately along the circumference of the core portion 21.

[0129] The length of the contact area 43 along the circumference of the core portion 21 is longer than the length of the non-contact area 44 or 45 along the circumference of the core portion 21, and most of the first coil portion 41 and the second coil portion 42 are in contact along the circumference of the core portion 21. By forming only a portion of the non-contact areas 44 and 45 between the first coil portion 41 and the second coil portion 42 along the circumference of the core portion 21, the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42 can be appropriately adjusted to the desired value.

[0130] like Figure 3 As shown, the terminal block 70 is formed separately from the frame 20 and is detachably mounted on the frame 20. The terminal block 70 may also be constructed from the same insulating component as the frame 20, but is more preferably constructed from an insulating component with excellent formability or heat resistance. The terminal block 70 is positioned on the side of the core portion 21 in the negative X-axis direction, that is, at a position separating it from the outer periphery of the core portion 21 in a direction orthogonal to the axial direction of the core portion 21 (X-axis direction). Therefore, a gap G of a predetermined length is formed in the X-axis direction. Figure 9 It is formed along the axial direction of the core portion 21 between the side portion of the outer peripheral surface of the core portion 21 and the terminal block 70.

[0131] 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 recess portions 75a and 75b, lead wire insertion slots 76a and 76b, terminal fixing portions 77a-1 and 77a-2, terminal fixing portions 77b-1 and 77b-2, cover mounting portion 78, and bottom surface fixing portion 79.

[0132] The terminal block base portion 71 is composed of a columnar body with a generally rectangular parallelepiped shape in the Y-axis direction, and is disposed approximately parallel to the axial direction of the core portion 21 on its side in the X-axis direction. The length of the terminal block base portion 71 along the Y-axis direction is approximately equal to the length of the frame 20 along the Y-axis direction. Figure 5As shown, the terminal block base portion 71 (the bottom surface of the terminal block base portion 71) is positioned above the center portion of the winding core portion 21 in the Z-axis direction, separated from the side portion of the outer peripheral surface of the winding core portion 21 in the X-axis direction, and is also positioned above the upper portion of the outer peripheral surface of the winding core portion 21. However, the height 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 positioned at approximately the same height as the upper portion of the outer peripheral surface of the winding core portion 21, or it can be positioned lower than that.

[0133] like Figure 5 and Figure 9 As shown, because the terminal block base 71 is positioned at a location where the gap G is separated from the outer periphery of the core 21 in the X-axis direction, the end of the terminal block base 71 in the positive X-axis direction (the side where the frame 20 is located) and the outer periphery of the core 21 are not repeatedly arranged in the Z-axis direction.

[0134] However, the position of the terminal block base portion 71 can also be shifted towards the positive X-axis direction, and the end of the terminal block base portion 71 on the positive X-axis direction and the outer peripheral surface of the core portion 21 can be repeatedly arranged along the Z-axis direction (when viewed from the Z-axis direction). That is, as long as the terminal block base portion 71 is arranged at a position that is 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 can be arranged at a position that is separated from the outer peripheral surface of the core portion 21 by a predetermined distance to the side (negative X-axis direction) of the core portion 21, and at a position that is separated from that position on the outer peripheral surface of the core portion 21 by a predetermined distance to the top of the core portion 21 (positive Z-axis direction).

[0135] The position of the end (side) of the terminal block base 71 on the positive X-axis direction is approximately equal to the position of the end of the flange engaging portions 24a and 24b of the frame 20 on the negative X-axis direction, and they are arranged close to each other.

[0136] like Figure 8 As shown, arm 72a is formed on one side of the terminal block base portion 71 in the Y-axis direction, and arm 72b is formed on the other side of the terminal block base portion 71 in the Y-axis direction. Arms 72a and 72b protrude a predetermined length from the end (side) of the terminal block base portion 71 in the X-axis direction toward the frame 20. Figure 9 As shown, the lengths of the arms 72a and 72b along the X-axis are longer than the length of the gap G along the X-axis. In addition, the lengths of the flange engaging portions 24a and 24b of the frame 20 along the X-axis are approximately equal.

[0137] like Figure 8As 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. The terminal block hook portions 73a and 73b protrude a predetermined length from the front ends of arms 72a and 72b along the Y-axis in a direction approaching each other (inside the terminal block 70). The protruding directions of the terminal block hook portions 73a and 73b are approximately orthogonal to the long side directions of arms 72a and 72b.

[0138] like Figure 10 As shown, with the terminal block 70 fixed to the terminal block fixing portions 23a and 23b of the frame 20, the arm portion 72a is arranged along the outer surface of the flange engaging portion 24a in the Y-axis direction of the frame 20, and the terminal block hook portion 73a engages with the side portion of the flange engaging portion 24a in the positive X-axis direction. Similarly, the arm portion 72b is arranged along the outer surface of the flange engaging portion 24b in the Y-axis direction of the frame 20, and the terminal block hook portion 73b engages with the side portion of the flange engaging portion 24b in the positive X-axis direction. Therefore, the terminal block 70 can be mounted to the terminal block fixing portions 23a and 23b via the arms 72a and 72b.

[0139] Furthermore, when the terminal block hook 73a is engaged with the flange engaging portion 24a, Figure 2 The lead portion 41a of the first winding 41c shown extends outward from the periphery of the arm portion 72a toward the terminal block 70. Furthermore, when the terminal block hook portion 73b is engaged with the flange engagement portion 24b, Figure 2 The lead portion 42a of the second winding 42c shown extends outward toward the terminal block 70 along the periphery of the arm portion 72b. Since the lead portions 41a and 41b extend outward along the outer surfaces (outer surfaces in the Y-axis direction) of the arms 72a and 72b respectively, the arms 72a and 72b serve to guide the lead portions 41a and 41b toward the terminal block 70.

[0140] like Figure 8 As shown, terminal block step portion 74a is formed at one end of terminal block base portion 71 in the Y-axis direction, and terminal block step portion 74b is formed at the other end of terminal block base portion 71 in the Y-axis direction. Terminal block step portions 74a and 74b are disposed on the outer side of arm portions 72a and 72b in the Y-axis direction.

[0141] The terminal block step portion 74a has a lower step surface 740a formed by a surface (a generally rectangular surface with a predetermined length in the X-axis and Y-axis directions) that is substantially parallel to the upper or lower surface of the terminal block base portion 71. The terminal block step portion 74b has a lower step surface 740b formed by a surface (a generally rectangular surface with a predetermined length in the X-axis and Y-axis directions) that is substantially parallel to the upper or lower surface of the terminal block base portion 71. The lower step surfaces 740a and 740b constitute the lower surface of the steps forming the terminal block step portions 74a and 74b.

[0142] like Figure 9 and Figure 10 As shown, the terminal block step portions 74a and 74b engage with the frame step portions 31a and 31b of the frame 20. More specifically, the terminal block step portions 74a and 74b and the frame step portions 31a and 31b engage when the lower surfaces 740a and 740b of the terminal block step portions 74a and 74b abut against the lower surfaces 310a and 310b of the frame step portions 31a and 31b.

[0143] like Figure 8 As shown, terminal block recess 75a is formed at one end of terminal block base portion 71 in the Y-axis direction, and terminal block recess 75b is formed at the other end of terminal block base portion 71 in the Y-axis direction. Terminal block recess 75a is disposed between arm portion 72a and terminal block step portion 74a in the Y-axis direction, and terminal block recess 75b is disposed between arm portion 72b and terminal block step portion 74b in the Y-axis direction. Terminal block recesses 75a and 75b are composed of recesses with a predetermined depth, and are open in the positive X-axis direction. The depth of terminal block recesses 75a and 75b is related to the skeleton protrusions 30a and 30b of skeleton 20. Figure 6 The thickness of the components along the Z-axis is approximately equal.

[0144] Terminal block recesses 75a and 75b are recessed from the end (side) of the terminal block base portion 71 in the positive X-axis direction toward the negative X-axis direction by a predetermined length. The bottom surfaces of the terminal block recesses 75a and 75b are generally rectangular in shape, corresponding to the shapes of the upper and lower surfaces of the skeleton protrusions 30a and 30b of the skeleton 20.

[0145] like Figure 9 and Figure 10 As shown, the terminal block recesses 75a and 75b engage with the frame protrusions 30a and 30b of the frame 20. More specifically, by housing the frame protrusions 30a and 30b inside the terminal block recesses 75a and 75b respectively, the terminal block recesses 75a and 75b and the frame protrusions 30a and 30b engage.

[0146] Thus, in this embodiment, by engaging the terminal block hook portions 73a and 73b and the flange engaging portions 24a and 24b as first engaging portions, it is possible to prevent the terminal block 70 from shifting in position relative to the terminal block fixing portions 23a and 23b along the X-axis direction.

[0147] In addition, by engaging the terminal block step portions 74a and 74b and the frame step portions 31a and 31b as second engaging portions, it is possible to prevent the terminal block 70 from shifting in position relative to the terminal block fixing portions 23a and 23b along the Z-axis direction.

[0148] Furthermore, by engaging the terminal block recesses 75a and 75b and the frame protrusions 30a and 30b as third engaging portions, it is possible to prevent the terminal block 70 from shifting relative to the terminal block fixing portions 23a and 23b along the Y-axis direction. Thus, the terminal block 70 can be mounted to the terminal block fixing portions 23a and 23b with sufficient fixing strength.

[0149] Furthermore, through the engagement of the aforementioned engaging portions, the terminal block 70 can be connected to one and the other ends of the winding core 21 along its axial direction, and is configured to be substantially parallel to the axial direction of the winding core 21. The terminal block 70 is fixed to the terminal block fixing portions 23a and 23b via three-point support of the aforementioned engaging portions, eliminating the need for adhesives or the like. Alternatively, any one of the aforementioned engaging portions may be omitted. Furthermore, fixation (reinforcement) based on adhesives or the like may be performed as needed.

[0150] like Figure 8 As shown, the cover mounting portion 78 is formed approximately at the center of the terminal block base portion 71 in the Y-axis direction. The cover mounting portion 78 has an upper surface and a lower surface that are generally flat surfaces, and the gripping portion 84 of the cover portion 80 is fixed in the cover mounting portion 78.

[0151] Terminal fixing portions 77a_1 and 77a_2 are formed on the side of the cover mounting portion 78 in the Y-axis direction. Terminal fixing portion 77a_1 is disposed on the outer side of terminal fixing portion 77a_2 in the Y-axis direction. Terminal fixing portions 77a_1 and 77a_2 are formed with a wall thickness greater than that of their surroundings, so that terminals 61_1 and 61_2 can be fixed in terminal fixing portions 77a_1 and 77a_2 respectively.

[0152] Terminal insertion slots 770a_1 and 770a_2 are formed in terminal fixing portions 77a_1 and 77a_2, respectively. Terminal insertion slots 770a_1 and 770a_2 are formed by grooves bent into a generally L-shape corresponding to the shapes of terminals 61_1 and 61_2. Furthermore, terminals 61_1 and 61_2 are fixed to terminal fixing portions 77a_1 and 77a_2 by integral molding (insert molding).

[0153] Terminal fixing portions 77b_1 and 77b_2 are formed on the opposite side of the cover mounting portion 78 in the Y-axis direction. Terminal fixing portion 77b_1 is disposed on the outer side of terminal fixing portion 77b_2 in the Y-axis direction. Terminal fixing portions 77b_1 and 77b_2 are formed with a wall thickness greater than that of their surrounding parts, so that terminals 62_1 and 62_2 can be fixed in terminal fixing portions 77b_1 and 77b_2 respectively.

[0154] Terminal insertion slots 770b_1 and 770b_2 are formed in terminal fixing portions 77b_1 and 77b_2, respectively. Terminal insertion slots 770b_1 and 770b_2 are formed by grooves bent into a generally L-shape corresponding to the shapes of terminals 62_1 and 62_2. Furthermore, terminals 62_1 and 62_2 are fixed to terminal fixing portions 77b_1 and 77b_2 by integral molding (insert molding).

[0155] A lead-through groove 76a is formed between terminal fixing portions 77a-1 and 77a-2, and a lead-through groove 76b is formed between terminal fixing portions 77b-1 and 77b-2. Lead-through grooves 76a and 76b are formed by recesses extending from the end of the terminal block base portion 71 in the positive X-axis direction, extending from the upper end to the lower end of the terminal block base portion 71. The lead portion 41b of the first winding 41c is inserted into the lead-through groove 76a, and the lead portion 42b of the second winding 41c is inserted into the lead-through groove 76b (see reference). Figure 2 ).

[0156] The bottom fixing portion 79 is formed in a stepped shape on the bottom surface of the terminal block base portion 71 on the negative X-axis direction side (opposite to the side where the frame 20 is disposed). The bottom fixing portion 79 has a generally flat surface, a predetermined length along the X-axis direction, and a predetermined length along the Y-axis direction. The bottom fixing portion 79 is formed from one end of the terminal block base portion 71 in the Y-axis direction to the other end along the Y-axis direction. The bottom end of the cover portion 80 in the X-axis direction is fixed to the bottom fixing portion 79.

[0157] Terminals 61_1, 61_2, 62_1, and 62_2 are mounted on terminal block 70 at predetermined intervals along the Y-axis. Terminals 61_1 and 61_2 have the same shape and are fixed to terminal fixing portions 77a_1 and 77a_2, respectively. A lead portion 41a of the first winding 41c is connected to terminal 61_1, and a lead portion 41b of the first winding 41c is connected to terminal 61_2.

[0158] Furthermore, terminals 62_1 and 62_2 have the same shape and are fixed to terminal fixing portions 77b_1 and 77b_2, respectively. A lead portion 42a of the second winding 42c is connected to terminal 62_1, and a lead portion 42b of the second winding 42c is connected to terminal 62_2.

[0159] Terminal 61_1 has an external connecting portion 610_1, a connecting portion 611_1, a wiring bottom 612_1, and a wiring fold-back portion 613_1. The external connecting portion 610_1 is the part that connects to the mounting base plate, protruding from the upper part of the terminal fixing portion 77a_1 (terminal insertion slot 770a_1) and extending upwards. The external connecting portion 610_1 protrudes upwards further than the upper edge of the housing 90. Figure 1 ).

[0160] The connecting part 611_1 is the part that connects the external connecting part 610_1 and the bottom of the wiring 612_1, and it bends outward in the Y-axis direction and extends toward the negative X-axis direction.

[0161] The terminal block 612_1 and the terminal fold-back portion 613_1 are the parts for wiring the lead portion 41a, and the lead portion 41a can be clamped (crimped) by the terminal block 612_1 and the terminal fold-back portion 613_1. The terminal fold-back portion 613_1 is integrally connected to the outer end of the terminal block 612_1 in the Y-axis direction, and is arranged opposite to the terminal block 612_1 in the Z-axis direction. The terminal fold-back portion 613_1 has a curved surface, but it can also be formed with a generally flat shape.

[0162] Terminal 61_2 has an external connection part 610_2, a connecting part 611_2, a wiring bottom 612_2, and a wiring fold-back part 613_2. Since the shape and function of each part constituting terminal 61_2 are the same as the shape and function of each part constituting terminal 61_1, detailed descriptions are omitted.

[0163] Terminal 62_1 has an external connection part 620_1, a connecting part 621_1, a wiring bottom 622_1, and a wiring fold-back part 623_1. Terminal 62_1 differs from terminal 61_1 at points that are symmetrical about the X-axis, but shares the same points as terminal 61_1. Therefore, a detailed description of terminal 62_1 is omitted.

[0164] Terminal 62_2 has an external connection part 620_2, a connecting part 621_2, a wiring bottom 622_2, and a wiring fold-back part 623_2. Terminal 62_2 differs from terminal 61_2 at points that are symmetrical about the X-axis, but shares the same points as terminal 61_2. Therefore, a detailed description of terminal 62_2 is omitted.

[0165] The cover 80 has a cover bottom 81, an insulating portion 82, cover sides 83a and 83b, and a grip portion 84. The cover 80 is separately formed from the terminal block 70 and is detachably mounted on the terminal block 70 in a manner that it is disposed around the terminal block 70.

[0166] The bottom of the cover 81 has a plate surface that is substantially parallel to the XY plane and is disposed below terminals 61_1 and 61_2 and terminals 62_1 and 62_2 mounted on the terminal block 70. The front end of the bottom of the cover 81 in the X-axis direction is fixed in a state of engaging with the bottom surface fixing part 79 of the terminal block 70. By fixing the bottom of the cover 81 to the bottom surface fixing part 79, it is possible to prevent the cover 80 from shifting in position relative to the terminal block 70 in the Z-axis direction.

[0167] An insulating portion 82 is formed approximately at the center of the cover portion 80 in the Y-axis direction. An insulating recess 820 is formed in the insulating portion 82. The insulating recess 820 is composed of a recess that is recessed downward from the upper surface of the insulating portion 820 and recessed from the side of the insulating recess 820 in the negative X-axis direction towards the positive X-axis direction. A terminal 61_2 is disposed on one side of the insulating portion 82 in the Y-axis direction, and a terminal 62_2 is disposed on the other side of the insulating portion 82 in the Y-axis direction.

[0168] By forming an insulating portion 82 with an insulating recess 820 on 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.

[0169] The cover sides 83a and 83b extend upward and stand upright from the end of the cover bottom 81 on the negative X-axis direction side in a state that is approximately orthogonal to the cover bottom 81. The cover side 83a is formed on the side of the insulating portion 82 that is closer to the Y-axis direction, and the cover side 83b is formed on the other side of the insulating portion 82 that is closer to the Y-axis direction.

[0170] By forming a bottom cover 81 and side covers 83a and 83b on the cover portion 80, the terminals 61_1 and 61_2 and terminals 62_1 and 62_2 mounted on the terminal block 70 can be protected from external forces and other influences. Furthermore, the bottom cover 81 and side covers 83a can be used to connect the terminals 61_1 and 61_2 and the core 50a (…). Figure 3 ) well insulated, and the terminals 62_1 and 62_2 and the core 50b are connected via the bottom of the cover 81 and the side of the cover 83b. Figure 3 It provides good insulation.

[0171] A gripping portion 84 is formed approximately at the center of the bottom of the cover 81 in the Y-axis direction, protruding from the insulating portion 82 toward the terminal block 70. The gripping portion 84 is used to grip the cover mounting portion 78 of the terminal block 70.

[0172] The gripping portion 84 has 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 position 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 grip the upper surface and the lower surface of the cover mounting portion 78, respectively, thereby enabling the gripping portion 84 to be mounted on the cover mounting portion 78.

[0173] By holding 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 even without the use of adhesives, thereby achieving low cost and rapid manufacturing.

[0174] Next, refer to Figure 3 The manufacturing method of the coil device 10 will be explained below. First, prepare... Figure 3 The components shown are pre-installed on the terminal block 70 using insert molding or the like. Additionally, a cover 80 is installed on the terminal block 70. This installation is achieved by holding the cover mounting portion 78 of the terminal block 70 with the holding portion 84 of the cover 80, without the need for special adhesives.

[0175] Next, a first winding 41c and a second winding 42c are wound around the outer peripheral surface of the core portion 21 of the frame 20. A first coil portion 41 is formed on the side of the protrusions 33 and 34 in the Y-axis direction, and a second coil portion 42 is formed on the other side. The lead portions 41a and 41b of the first winding 41c are led out from one end of the core portion 21 in the axial direction. In addition, the lead portions 42a and 42b of the second winding 42c are led out from the other end of the core portion 21 in the axial direction.

[0176] Next, one end of the terminal block 70 in the Y-axis direction is fixed at the terminal block fixing part 23a of the frame 20, and the other end of the terminal block 70 in the Y-axis direction is fixed at the terminal block fixing part 23b of the frame 20, so that the terminal block 70 is positioned at a position separated by a predetermined distance from the outer periphery of the core part 21 in the X-axis direction.

[0177] Next, lead wire 41a is connected to terminal 61-1 via crimping or similar means, lead wire 41b is connected to terminal 61-2 via crimping or similar means, lead wire 42a is connected to terminal 62-1 via crimping or similar means, and lead wire 42b is connected to terminal 62-2 via crimping or similar means (see reference). Figure 2Next, insert the middle leg 53a of core 50a and the middle leg 53b of core 50b into the through hole 211 of the frame 20, and install core 50a and 50b on the frame 20.

[0178] Next, by storing the skeleton 20 and the like inside the shell 90, and filling the shell 90 with the filling resin 100, it is possible to obtain... Figure 1 The coil device 10 shown.

[0179] As described above, in the coil device 10 of this embodiment, such as Figure 7 As shown, the first coil portion 41 and the second coil portion 42 are in partial contact along the circumference of the core portion 21. In this way, by making the first coil portion 41 and the second coil portion 42 partially contact along the circumference of the core portion 21, the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42 can be adjusted according to their degree of contact (contact length).

[0180] Especially in the coil device 10 of this embodiment, such as Figure 3 and Figure 7 As shown, the core portion 21 has protrusions 33 and 34 that extend outward (radially outward) from the outer peripheral surface of the core portion 21 and extend circumferentially along the core portion 21. The first coil portion 41 and the second coil portion 42 sandwich the protrusions 33 and 34 between them and partially contact each other along the circumferential direction of the core portion 21. Therefore, in the position where the protrusions 33 and 34 are formed, contact between the first coil portion 41 and the second coil portion 42 can be avoided. On the other hand, in the position where the protrusions 33 and 34 are not formed, contact between the first coil portion 41 and the second coil portion 42 can be made. That is, by sandwiching the protrusions 33 and 34 between them, partial contact between the first coil portion 41 and the second coil portion 42 can be easily made. Furthermore, by appropriately adjusting the lengths of the protrusions 33 and 34 along the circumference of the core portion 21, the degree of contact between the first coil portion 41 and the second coil portion 42 can be easily adjusted, thereby making it easy to adjust the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42.

[0181] Furthermore, in the coil device 10 of this embodiment, since the leakage magnetic characteristics between the first coil section 41 and the second coil section 42 can be adjusted by a single frame 20 without having multiple frames 20, it helps to reduce the number of components.

[0182] Furthermore, in this embodiment, the lengths of the protrusions 33 and 34 along the circumference of the core portion 21 are shorter than the circumferential length of the core portion 21. Therefore, the protrusions 33 and 34 are not formed along the entire circumference of the outer peripheral surface of the core portion 21, but are only formed on a portion of it. With such a structure, the first coil portion 41 and the second coil portion 42 can be used to sandwich the protrusions 33 and 34 between them and make partial contact along the circumference of the core portion 21.

[0183] Furthermore, in this embodiment, the core portion 21 has a generally elliptical shape, and protrusions 33 and 34 are formed on the long side of the outer peripheral surface of the core portion 21. By forming protrusions 33 and 34 on the long side of the core portion 21, it is possible to prevent the winding of the first coil portion 41 and the second coil portion 42 from loosening. In the position where protrusions 33 and 34 are not formed, the contact between the first coil portion 41 and the second coil portion 42 can be improved, and the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42 can be adjusted with high precision.

[0184] Furthermore, in this embodiment, protrusions 33 and 34 are arranged on opposite sides of each other along the radial direction of the core portion 21. Therefore, the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42 can be adjusted with high precision by means of protrusions 33 and 34, and positional deviation of the first coil portion 41 and the second coil portion 42 along the axial direction of the core portion 21 can be prevented. In addition, by properly positioning the first coil portion 41 and the second coil portion 42, deviations in the leakage magnetic characteristics between the first coil portion 41 and the second coil portion 42 can be suppressed.

[0185] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the present invention.

[0186] In the above embodiments, an application example of the present invention to a transformer has been described, but the present invention can be applied not only to transformers, but also to other coil devices.

[0187] In the above embodiments, cores 50a and 50b are each composed of E-shaped cores. However, either core 50a or 50b can be composed of E-shaped cores, and the other can be composed of I-shaped cores. Alternatively, cores 50a and 50b can be composed of U-shaped cores. Alternatively, either core 50a or 50b can be composed of U-shaped cores, and the other can be composed of I-shaped cores. Alternatively, core 50a can be composed of a combination of two U-shaped cores, and core 50b can be composed of a combination of two U-shaped cores.

[0188] In the above embodiment, a plurality of (four) through holes (through holes 35a, 35b, 36a, 36b) are formed on the outer peripheral surface of the core portion 21, but the number of through holes may also be one. For example, only one through hole may be formed on either the upper or lower portion of the outer peripheral surface of the core portion 21. In addition, the number of through holes may be two to three or more.

[0189] In the above embodiment, the lead portion 41a can also be inserted into... Figure 2 The notch 28a is shown. Alternatively, the lead portion 41b of the lead portion 41a and 41b can be inserted through the notch 28a or the notch 29a.

[0190] Similarly, lead portion 42a can be inserted into notch portion 29b. Alternatively, lead portion 42b of lead portions 42a and 42b can be inserted into notch portion 28b or notch portion 29b.

[0191] In the above embodiment, the protrusions 33 and 34 are formed at approximately the center of the core portion 21 in the Y-axis direction, but they may also be formed at a position offset from that position to one side or the other side in the Y-axis direction.

[0192] In the above embodiment, two protrusions (protrusions 33 and 34) are formed in the core portion 21, but the number of protrusions may be one or more.

[0193] In the above embodiment, two coil portions (first coil portion 41 and second coil portion 42) are formed in the core portion 21, but three or more coil portions may also be formed.

[0194] In the above embodiments, the structure of the horizontal coil device 10 (or frame 20) has been described, but the present invention can also be applied to the vertical coil device 10 (or frame 20).

Claims

1. A coil device, wherein, have: The skeleton has a core section; A first coil portion, which is composed of a first winding, is disposed on one side of the axial direction of the core portion; and The second coil section, which is composed of a second winding, is located on the opposite side of the axial direction of the core section. The core portion has a protrusion that extends outward from the outer peripheral surface of the core portion and extends circumferentially along the core portion. The first coil portion and the second coil portion sandwich the protrusion therebetween and partially contact each other along the circumferential direction of the core portion. The protrusion is composed of a first protrusion and a second protrusion. The first protrusion and the second protrusion are arranged on opposite sides of each other along the radial direction of the core portion. A contact area is formed between the first coil portion and the second coil portion, where the first coil portion and the second coil portion come into contact, and a non-contact area is formed between the first coil portion and the second coil portion separated by the protruding portion. In the circumferential direction along the core portion, the length of the contact area is longer than the length of the non-contact area.

2. The coil device according to claim 1, wherein, The length of the protrusion along the circumference of the core portion is shorter than the circumferential length of the core portion.

3. The coil device according to claim 1 or 2, wherein, The core portion has a generally elliptical shape. The protrusion is formed on the long side of the outer peripheral surface of the core portion.

4. The coil device according to claim 1 or 2, wherein, It also has a core mounted on the skeleton. The core has a base portion, a pair of outer legs connected to a first surface of the base portion, and a middle leg portion connected to the first surface and disposed between the pair of outer legs. A recess is formed on the second surface of the base portion, which is orthogonal to the first surface, at the position of the middle foot portion.

5. The coil device according to claim 1 or 2, wherein, It also has a core mounted on the skeleton. The core has a base portion, a pair of outer legs arranged along a first axis, and a middle leg disposed between the pair of outer legs. The middle foot portion is offset from the center of the base portion to one side in a second axis direction orthogonal to the first axis direction. A wall thickness is formed at the end of each of the pair of outer legs on the other side of the second axial direction.

6. The coil device according to claim 5, wherein, The cross-sectional area of ​​the middle foot is approximately equal to the sum of the cross-sectional areas of the pair of outer feet.

7. The coil device according to claim 1 or 2, wherein, The axial direction of the core portion is approximately parallel to the mounting surface.

8. The coil device according to claim 1 or 2, wherein, It also has a shell for housing 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 core portion.

9. The coil device according to claim 1 or 2, wherein, Between the first protrusion and the second protrusion, the contact area extends along the circumference of the core portion in a generally C-shaped manner.

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