Coil arrangement

Abstract

The present application provides a coil device (10) having a bobbin (20) for winding a wire (41a), a terminal (61a) of electric conductivity connecting a lead portion (43a1) of the wire (41a), a terminal holder (70) of insulating property mounting the terminal (61a), and a case (90) housing the bobbin (20). The bobbin (20) is disposed inside the case (90) in a manner that an axis of winding of the wire (41a) is substantially parallel to a bottom surface (90b) of the case (90). The case (90) has a terminal holder support portion (91) protruding toward the outside from a rim (96) of an upper opening (90a) of the case (90). The terminal holder 70 is mounted on the terminal holder support portion (91) via an insulation securing member (80).

Description

TECHNICAL FIELD

[0001] The present application relates to a coil device suitable for use as a coil device of a transformer or the like. BACKGROUND

[0002] As a coil device for a large transformer or the like, for example, a coil device given in Patent Literature 1 below has been developed. In the developed coil device, a bobbin (spool) in which a wire is wound is housed inside a case, the inside of the case is filled with a resin such as potting resin that is excellent in thermal conductivity, and heat dissipation is improved.

[0003] However, in recent years, low height of a coil device of a transformer or the like has been required. In addition, reduction in the setting area of the case and improvement in heat dissipation characteristics have been required.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent Application Publication No. 2014-93405 SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] The present application has been made in view of such circumstances, and an object thereof is to provide a coil device that can achieve low height, has a small setting area of a case, and is excellent in heat dissipation.

[0009] TECHNICAL SOLUTION FOR SOLVING THE PROBLEMS

[0010] In order to achieve the above object, the present application provides a coil device having:

[0011] a bobbin for winding a wire;

[0012] a terminal of electric conductivity that connects a lead portion of the wire;

[0013] a terminal holder of insulation that mounts the terminal; and

[0014] a case that houses the bobbin,

[0015] the bobbin is disposed inside the case in such a manner that an axis of winding of the wire is substantially parallel to a bottom surface of the case,

[0016] the case has a terminal holder support portion that protrudes toward the outside from a rim of an upper portion of the case,

[0017] the terminal holder is mounted on the terminal holder support portion via an insulation ensuring member.

[0018] In the coil device of the present application, the bobbin is disposed inside the housing with the winding axis of the wire substantially parallel to the bottom surface of the housing. That is, the coil device of the present application is a horizontal coil device, and compared to a vertical coil device in which the winding axis of the wire is substantially perpendicular to the bottom surface of the housing, low height can be easily achieved.

[0019] In addition, in the coil device of the present application, the terminal block is supported on the terminal block support portion that protrudes outward from the rim of the upper opening of the housing. Therefore, the setting area of the housing does not need to be increased in correspondence with the area of the terminal block, and the setting area of the housing can be reduced while being horizontal.

[0020] Furthermore, since the terminal block is supported by the terminal block support portion formed by extending the outer wall of the housing, the strength and reliability of the terminal block can be improved. In particular, when connecting the terminals possessed by the terminal block of the coil device to a substrate disposed on the coil device, since the terminal block support portion strengthens the terminal block, connection to the substrate becomes easy, and reliability is improved.

[0021] In addition, by filling the interior of the housing with a heat-dissipating resin such as potting resin, heat from the wire or the bobbin (including the core) can be released to the bottom surface of the housing via the heat-dissipating resin, and heat dissipation is improved. In addition, since the terminal block is supported on the terminal block support portion that protrudes outward from the rim of the upper opening of the housing, at least the majority of the bobbin (including the wire and the core) that includes the winding axis of the wire can be brought into contact with the heat-dissipating resin inside the housing without the terminal block becoming an obstacle. Therefore, heat dissipation can be effectively improved with the minimum necessary heat-dissipating resin.

[0022] Furthermore, in the coil device of the present application, the terminal block is mounted on the terminal block support portion via an insulation ensuring member. Therefore, after the bobbin has wound a plurality of wires and a plurality of terminals have been mounted on the terminal block, the operation of connecting the lead portions of the plurality of wires to the plurality of terminals at once becomes easy. Connection of the lead portions of the wires to the terminals uses, for example, heat press bonding such as soldering.

[0023] When connecting the lead portions of the wires to the terminals, a heat press bonding jig or the like needs to be pressed from both sides of the lead portions, and the heat press bonding jig or the like is easily pressed from both sides of the lead portions before the insulation ensuring member is mounted to the terminal block. In addition, after the lead portions of the wires have been connected to the terminals, the insulation ensuring member is disposed on one side of the wiring portions of the terminals and the lead portions of the wires, and thus the insulation of the wiring portions from the core on which the bobbin is mounted can be effectively ensured. In addition, the insulation ensuring member can also ensure the insulation of the wiring portions of the lead portions and the terminals from the housing.

[0024] Preferably, the insulation ensuring member has an insulation sheet portion,

[0025] The insulating piece portion is arranged between the terminal's wiring portion connecting the lead portion of the wire and the core mounted to the bobbin. With this structure, the insulating securing member can improve the insulation between the lead portion and the terminal's wiring portion and the outer leg portion of the core mounted to the bobbin. In addition, the insulating securing member can also improve the insulation between the lead portion and the terminal's wiring portion and the housing.

[0026] Preferably, the insulating securing member further has an intermediate portion integrally formed with the insulating piece portion and sandwiched between the terminal holder support portion and the terminal holder, the intermediate portion having an intermediate engaging portion engaging with the terminal holder. By engaging the intermediate engaging portion such as an engaging claw with the terminal holder, the terminal holder and the insulating securing member are easily positioned and mounted at the same time. In addition, the fixation of the terminal holder and the insulating securing member can be performed without using an adhesive. However, an adhesive can also be used.

[0027] Preferably, the intermediate portion has an intermediate protrusion entering a support through-hole formed in the terminal holder support portion. By having the intermediate protrusion enter the support through-hole, the positioning of the insulating securing member and the terminal holder support portion becomes easy.

[0028] The intermediate protrusion can have a receiving recess opening toward the terminal holder. A threaded portion for connecting an external terminal such as a circuit board with a terminal of the terminal holder can enter the receiving recess. Metal scraps and the like when screwing the threaded portion such as a bolt with a nut of the terminal holder can be received in the receiving recess.

[0029] The terminal holder can have an engaging protrusion engaging with an engaging hole formed in the terminal holder support portion through an intermediate through-hole formed in the intermediate portion. By having the engaging protrusion engage with the engaging hole formed in the terminal holder support portion through the intermediate through-hole, the positioning of the terminal holder and the insulating securing member becomes easy, and the terminal holder and the terminal holder support portion are positioned and mounted at the same time. In addition, the fixation of the terminal holder, the insulating securing member and the terminal holder support portion can be performed without using an adhesive. However, an adhesive can also be used.

[0030] The housing can have a cover member covering at least a portion of the upper opening of the housing with a prescribed gap. By having the cover member cover a portion of the upper opening of the housing with a prescribed gap, the protruding portion of the substrate, the substrate itself and the like from the substrate can be effectively prevented from contacting and damaging the protruding portion of the core, the lead portion of the wire and the like when connecting the terminal of the coil device with the substrate and the like.

[0031] It is preferable that the cover member cover at least a portion of the wire of the winding core housed in the interior of the housing. It is more preferable that the cover member cover the entire winding portion of the wire except for the lead portion of the wire. By forming the cover member of metal or the like, the effect of shielding the magnetic flux leaking from the winding portion (coil portion) of the wire is improved.

[0032] The cover member can be integrally formed with the housing or can be formed separately from the housing and attached by fitting or the like. By integrally bending a metal plate or the like to form the cover member and the housing, the manufacturing of the cover member and the housing becomes easy. In addition, it is preferable that the terminal holder support portion be integrally formed with the housing. By integrally bending a metal plate or the like to form the terminal holder support portion and the housing, the manufacturing of the terminal holder support portion and the housing becomes easy.

[0033] It is preferable that the winding core have a winding core portion in which the wire is wound and a flange portion attached to an end portion of the winding core portion. It is preferable that the flange portion have a protection hook portion protruding upward from an upper opening of the housing to guide the lead of the wire to the terminal holder. By hooking the lead of the wire in the protection hook portion, the lead portion of the wire is easily guided to the terminal attached to the terminal holder.

[0034] It is preferable that the protection hook portion have a height that is flush with or higher than an upper surface of the terminal, and the lead portion of the wire and the wiring portion of the terminal are disposed at a position lower than the upper surface of the terminal. By being disposed like this, the protection hook portion protects the wiring portion, and contact of the protruding portion from the substrate and the substrate itself with the wiring portion can be effectively prevented.

[0035] In addition, it is preferable that the protection hook portion be preferably lower than the lower surface of the cover member. By being disposed like this, the cover member and the protection hook portion together protect the wiring portion, and contact of the protruding portion from the substrate and the substrate itself with the wiring portion can be effectively prevented. BRIEF DESCRIPTION OF DRAWINGS

[0036] Figure 1A is a perspective view of a coil device according to an embodiment of the present application.

[0037] Figure 1B is a perspective view of a coil device according to another embodiment of the present application.

[0038] Figure 2 is Figure 1A is an exploded perspective view of the coil device shown in

[0039] Figure 3 is Figure 1A is a side view of the coil device shown in

[0040] Figure 4 is a side view of the coil device shown in Figure 1AA simplified three-dimensional view of the coil device as viewed from a slightly lower angle.

[0041] Figure 5A yes Figure 1A A schematic perspective view of the winding frame portion of the coil assembly shown.

[0042] Figure 5B From Figure 5A A rough three-dimensional view of the winding frame section as seen from a slightly lower angle.

[0043] Figure 6A yes Figure 1A A schematic perspective view of the housing of the coil device shown.

[0044] Figure 6B yes Figure 1B A schematic perspective view of the housing of the coil device shown.

[0045] Figure 6C yes Figure 1B A schematic perspective view of the cover of the coil device shown.

[0046] Figure 7 yes Figure 1A The diagram shows a cross-sectional view of the core of the coil assembly.

[0047] Figure 8 yes Figure 1A A schematic perspective view of the terminal block of the coil device shown.

[0048] Figure 9A yes Figure 1A An exploded perspective view of the terminal block and insulation protection components of the coil assembly shown.

[0049] Figure 9B It means Figure 9A A schematic perspective view of the assembled terminal block and insulation components.

[0050] Figure 10 yes Figure 1A The diagram shows a cross-sectional view of the coil assembly along line XX. Detailed Implementation

[0051] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0052] First embodiment

[0053] Figure 1AThe coil device 10 shown as an example of the coil device of the present embodiment functions as, for example, a transformer, and is used for an in-vehicle charger for an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a commuter vehicle, or a power supply circuit of a household or industrial electrical device, or a power supply circuit of a computer device, and the like.

[0054] Hereinafter, the detailed structure of the coil device 10 will be described. In the following description, in the drawings, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other. In addition, the side toward the center of the coil device 10 is set as the inner side or the inner direction, and the side away from the center of the coil device 10 is set as the outer side or the outer direction.

[0055] As shown in Figure 2 , the coil device 10 has a bobbin 20, conductive wires 41a, 41b, cores 50a and 50b, terminals 61a, 61b, 62a, 62b, a terminal holder 70, an insulation ensuring member 80, and a housing 90. The coil device 10 is a horizontal coil device configured in such a manner that the winding axis lines C of the coil portions 42a, 42b of the conductive wires 41a, 41b are parallel to the bottom surface 90b of the housing 90.

[0056] In addition, in the present embodiment, the X-axis is parallel to the winding axis lines C of the conductive wires 41a, 41b, and the Y-axis is substantially identical to the direction in which the lead portions 43a1, 43a2, 43b1, 43b2 of the conductive wires 41a, 41b are led out. The Z-axis corresponds to the height (thickness) direction of the coil device 10. In the present embodiment, the upper side of the coil device 10 along the Z-axis becomes the placement surface of the circuit board to which the terminals 61a, 61b, 62a, 62b of the coil device 10 (transformer) are connected.

[0057] As shown in Figure 2 , the coil portion 42a is formed by winding the conductive wire 41a around the outer peripheral surface of the winding core portion 21 of the bobbin 20 shown in Figure 5A . The coil portion 42b is formed by winding the conductive wire 41b around the outer peripheral surface of the winding core portion 21 of the bobbin 20 shown in Figure 5A . The conductive wires 41a, 41b are wound around the outer peripheral surface of the winding core portion 21 using, for example, an automatic winding machine.

[0058] As shown in Figure 10 , the coil portion 42a (42b) formed by the conductive wire 41a (41b) is one layer or two or more layers in the direction (radial direction) orthogonal to the winding axis line thereof. In addition, as shown in Figure 2 , the winding axis lines C of the coil portions 42a, 42b are substantially identical, and are each parallel to the X-axis.

[0059] like Figure 2 As shown, coil portion 42a is wound on one side of the winding core along the X-axis, and coil portion 42b is wound on the other side of the winding core along the X-axis. Either coil portion 42a or 42b constitutes a primary coil, and the other coil portion 42a or 42b constitutes a secondary coil. The primary and secondary coils in the winding core can also be arranged on either side of the winding core along the X-axis.

[0060] Conductors 41a and 41b are respectively made of, for example, insulated wires, such as copper wires covered with an insulating layer. The conductors of conductors 41a and 41b can be made of single wires or stranded wires. The wire diameter of conductors 41a and 41b is not particularly limited, for example, it is 1.0 to 3.0 mm. The wire diameters of conductors 41a and 41b can be equal or different. For example, the wire in conductors 41a and 41b that carries a large current may have a larger wire diameter than the other conductor.

[0061] A lead portion 43a1 is formed at one end of the conductor 41a, and a lead portion 43a2 is formed at the other end of the conductor 41a. Similarly, a lead portion 43b1 is formed at one end of the conductor 41b, and a lead portion 43b2 is formed at the other end of the conductor 41b.

[0062] like Figure 2 As shown, cores 50a and 50b are so-called E-shaped cores, mounted on the winding frame 20. Cores 50a and 50b can be made of magnetic materials such as metals or ferrites, but there are no particular limitations.

[0063] Cores 50a and 50b have the same shape (e.g., type E and type E), but can also have different shapes (e.g., type E and type I). In this embodiment, core 50a has a base 51a, a pair of outer legs 52a, and a middle leg 53a. Core 50b has a base 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 specifically required, the description of the structure of core 50b will be omitted.

[0064] The base 51a has a specified thickness along the X-axis, such as Figure 7 As shown, it has specified lengths along the Y-axis and Z-axis respectively. The following, as... Figure 2As shown, in the base 51a, the face on the outer side along the X axis is referred to as an outer face 510a, the face on the inner side along the X axis is referred to as an inner face 511a, the face on the upper side is referred to as an upper face 512a, and the face on the lower side is referred to as a lower face 513a. Also, in the base 51b, the face on the outer side along the X axis is referred to as an outer face 510b, the face on the inner side along the X axis is referred to as an inner face 511b, the face on the upper side is referred to as an upper face 512b, and the face on the lower side is referred to as a lower face 513b.

[0065] The upper face 512a and the lower face 513a are faces orthogonal to the outer face 510a and the inner face 511a. The upper face 512b and the lower face 513b are faces orthogonal to the outer face 510b and the inner face 511b. As shown, Figure 7 As shown, the upper face 512a of the base 51a is at the same height as the outer leg upper face 522a of the outer leg 52a.

[0066] In the lower face 513a of the base 51a, a recess 55a recessed upward is formed in the position of the middle leg 53a along the Z axis. The recess 55a is formed in the substantially central portion of the base 51a in the Y axis direction, and has a prescribed width along the X axis and the Y axis. The width of the recess 55a along the Y axis is smaller than the width of the middle leg 53a along the Y axis, and the recess 55a is Figure 5B The widths along the Y axis of the recessed portions 37a or 37b of the reel 20 shown are substantially equal. Figure 7 The recess 55a shown is formed in a manner that penetrates the outer face from the inner face of the base 51a.

[0067] As shown, Figure 7 The recess 55a is recessed upward from the lower face 513a by a prescribed depth. The upper end of the inner peripheral face 550a of the recess 55a is located lower than the lower end of the outer peripheral face of the middle leg 53a, but can also be flush (on the same plane). In the present embodiment, the inner peripheral face 550a has a substantially flat top face, but can also be curved, triangular, or polygonal.

[0068] The inner peripheral face 550a of the recess 55a can also have tapered faces 551a on both sides along the Y axis. The tapered faces 551a are formed in a manner that narrows the width of the recess 55a along the Y axis as it goes upward from the lower face 513a. The shape of the recess 55a is substantially the same as Figure 5B The shape of the recessed portion 37a or 37b of the reel 20 shown is substantially the same as that of the recess 55a, but can also be different.

[0069] As shown, Figure 2As shown, a middle leg 53a is disposed between a pair of pairs of legs 52a and connected to the inner surface 511a of the base 51a. The middle leg 53a extends from the inner surface 511a along the X-axis for a predetermined length and is disposed inside the through hole 211 of the winding frame 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 end faces 531a and 531b abutting. Alternatively, a gap may be formed along the X-axis between the end faces 531a and 531b of the middle legs 53a and 53b.

[0070] like Figure 7 As shown, in this embodiment, the cross-section (the section perpendicular to the X-axis) of the middle foot 53a (53b) is a lower bulge shape. That is, the middle foot 53a (53b) is divided into an upper half ML1 and a lower half ML2 by a middle horizontal plane P0. This middle horizontal plane P0 passes through the midpoint of the vertical line connecting the upper horizontal plane P1 containing the upper end (along the Z-axis) E1 of the middle foot 53a (53b) and the lower horizontal plane P2 containing the lower end (along the Z-axis) E2 of the middle foot 53a (53b) in the shortest manner. The middle horizontal plane P0 is set as the plane of the central axis (along the center of the Z-axis) O of the middle foot 53a (53b).

[0071] In this case, in the coil device 10 of this embodiment, the cross-sectional area (CA2) of the lower half ML2 of the middle leg 53a (53b) of the core 50a (50b) is larger than the cross-sectional area (CA1) of the upper half ML1. Alternatively, the volume (V2) of the lower half ML2 of the middle leg 53a (53b) of the core 50a (50b) is larger than the volume (V1) of the upper half ML1. Alternatively, the area (OA2) of the outer peripheral surface of the lower half ML2 of the middle leg 53a (53b) of the core 50a (50b) is larger than the area (OA1) of the outer peripheral surface of the upper half ML1.

[0072] Furthermore, in this embodiment, such as Figure 7 As shown, the cross-section of the middle foot 53a (53b) is a lower expansion shape, but it can also be other cross-sectional shapes, such as circular, elliptical, or polygonal cross-sections. Furthermore, in this embodiment, the liquid level S of the potting resin (described later) is a predetermined height T1 lower than the upper end (along the Z-axis) E1 of the middle foot 53a (53b). Therefore, it is possible to include... Figure 1A The coil assembly 10, including the housing 90 shown, achieves a low height.

[0073] Further, in the present embodiment, the Z-axis position of the upper end E1 of the outer circumferential surface of the middle leg portion 53a is substantially the same as the Z-axis position of the upper surface 512a of the base portion 51a, and preferably the vertex of the middle leg portion 53a on the upper side along the Z-axis is connected to the upper surface 512a of the base portion 51a without a step. However, the Z-axis position of the upper end E1 of the outer circumferential surface of the middle leg portion 53a can be different from the Z-axis position of the upper surface 512a of the base portion 51a. Further, the lower portion of the middle leg portion 53a including the lower end E2 of the outer circumferential surface is disposed at a position close to the inner circumferential surface 550a of the recess 55a, and is preferably located above the inner circumferential surface 550a, but is not limited thereto.

[0074] As shown in FIG. 6, the pair of outer leg portions 52a are disposed at a predetermined interval along the Y-axis, and are connected to the inner surface 511a of the base portion 51a. One of the pair of outer leg portions 52a is disposed at one end portion of the inner surface 511a along the Y-axis, and the other of the pair of outer leg portions 52a is disposed at the other end portion of the inner surface 511a along the Y-axis. Figure 2 As shown in FIG. 6, the outer leg inner side surface 520a of the outer leg portion 52a is curved toward the inner side along the Y-axis as it goes upward and downward along the Z-axis from the middle horizontal plane P0 of the outer leg portion 52a. Further, the curved portion of the outer leg inner side surface 520a is curved at a predetermined interval substantially along the outer circumferential surface of the middle leg portion 53a. Further, the curved portion of the outer leg inner side surface 520a is curved substantially along the outer circumferential edge portion of the flange portion 22a (flange portion main body 220a) of the bobbin 20 shown in FIG. 2.

[0075] Figure 7 As shown in FIG. 6, the outer leg inner side surface 520a of the outer leg portion 52a is curved toward the inner side along the Y-axis as it goes upward and downward along the Z-axis from the middle horizontal plane P0 of the outer leg portion 52a. Further, the curved portion of the outer leg inner side surface 520a is curved at a predetermined interval substantially along the outer circumferential surface of the middle leg portion 53a. Further, the curved portion of the outer leg inner side surface 520a is curved substantially along the outer circumferential edge portion of the flange portion 22a (flange portion main body 220a) of the bobbin 20 shown in FIG. 2. Figure 5A Further, the outer side surface of the outer leg portion 52a on the opposite side of the outer leg inner side surface 520a along the Y-axis has a plane perpendicular to the Y-axis, and is a shape different from the curved shape of the outer leg inner side surface 520a. Further, a wall thickness portion 56a having a thickness in the Y-axis direction thicker than the end portion on the upper side of the outer leg portion 52a is formed at the end portion on the lower side along the Z-axis of each of the pair of outer leg portions 52a (52b). The inner side surface 520a (520b) of the wall thickness portion 56a protrudes toward the inner side along the Y-axis, and becomes a plane perpendicular to the Y-axis.

[0076] Figure 7 In the present embodiment, by forming the wall thickness portion 56a in the outer leg portion 52a, the area of the outer leg portion 52 covered by the potting resin can be sufficiently ensured, and a coil device 10 having good inductance characteristics can be obtained.

[0077] In the present embodiment, by forming the wall thickness portion 56a in the outer leg portion 52a, the area of the outer leg portion 52 covered by the potting resin can be sufficiently ensured, and a coil device 10 having good inductance characteristics can be obtained.

[0078] ​​Further, in the present embodiment, in the case where each of the outer leg portions 52a (52b) is divided into an outer leg upper half portion OLl and an outer leg lower half portion OL2 by the intermediate horizontal plane PO, the outer leg portion 52a (52b) has a shape in which the volume (OV2) of the outer leg lower half portion OL2 is larger than the volume (OVl) of the outer leg upper half portion OLl. The outer leg portion 52a (52b) also has the volume of the outer leg lower half portion OL2 larger than the volume of the outer leg upper half portion OLl as with the mid leg portion 53a (53b), whereby low height and small size can be achieved, and improvement of heat dissipation can be achieved. Further, the balance of magnetic flux becomes better, and the characteristics are improved. Further, the volume can be replaced by the cross-sectional area or the area of the outer peripheral surface as with the mid leg portion 53a (53b).

[0079] As shown in FIG. 6, the pair of outer leg portions 52a extend from the inner surface 511a along the X axis by a prescribed length as with the mid leg portion 53a, and are disposed outside the winding core portion 21 of the bobbin 20. Further, the mid leg portion 53a is inserted inside the through hole 211 of the bobbin 20. Figure 2

[0080] As shown in FIG. 6, the pair of outer leg portions 52a extend from the inner surface 511a along the X axis by a prescribed length as with the mid leg portion 53a, and are disposed outside the winding core portion 21 of the bobbin 20. Further, the mid leg portion 53a is inserted inside the through hole 211 of the bobbin 20. Figure 5A Figure 5B As shown in FIG. 6, the pair of outer leg portions 52a extend from the inner surface 511a along the X axis by a prescribed length as with the mid leg portion 53a, and are disposed outside the winding core portion 21 of the bobbin 20. Further, the mid leg portion 53a is inserted inside the through hole 211 of the bobbin 20.

[0081] The winding core portion 21 of the bobbin 20 is wound with the conductive wires 41a, 41b shown in FIG. 6 to form the coil portions 42a, 42b. The coil portion 42a is disposed between the flange portion 22a and the protruding portion 33 (34) on one side of the winding core portion 21 along the X axis as shown in FIG. 6. Further, the coil portion 42b is disposed between the flange portion 22b and the protruding portion 33 (34) on the other side of the winding core portion 21 along the X axis as shown in FIG. 6. Figure 2 Figure 5A The winding core portion 21 of the bobbin 20 is wound with the conductive wires 41a, 41b shown in FIG. 6 to form the coil portions 42a, 42b. The coil portion 42a is disposed between the flange portion 22a and the protruding portion 33 (34) on one side of the winding core portion 21 along the X axis as shown in FIG. 6. Further, the coil portion 42b is disposed between the flange portion 22b and the protruding portion 33 (34) on the other side of the winding core portion 21 along the X axis as shown in FIG. 6. Figure 2 Figure 5A The winding core portion 21 of the bobbin 20 is wound with the conductive wires 41a, 41b shown in FIG. 6 to form the coil portions 42a, 42b. The coil portion 42a is disposed between the flange portion 22a and the protruding portion 33 (34) on one side of the winding core portion 21 along the X axis as shown in FIG. 6. Further, the coil portion 42b is disposed between the flange portion 22b and the protruding portion 33 (34) on the other side of the winding core portion 21 along the X axis as shown in FIG. 6.

[0082] As shown in FIG. 6, the pair of outer leg portions 52a extend from the inner surface 511a along the X axis by a prescribed length as with the mid leg portion 53a, and are disposed outside the winding core portion 21 of the bobbin 20. Further, the mid leg portion 53a is inserted inside the through hole 211 of the bobbin 20. Figure 2 As shown in FIG. 6, the pair of outer leg portions 52a extend from the inner surface 511a along the X axis by a prescribed length as with the mid leg portion 53a, and are disposed outside the winding core portion 21 of the bobbin 20. Further, the mid leg portion 53a is inserted inside the through hole 211 of the bobbin 20.

[0083] Figure 5B ​​​​​As shown, the wound core 21 is a cylindrical body, and its cross-section, with regard to the through hole 211 of the wound core 21, has the same cross-section as... Figure 7 The lower expansion shape corresponds to the cross-section of the middle leg portion 53a shown. The shaft of the winding core portion 21 is parallel to the X-axis. Inside the through hole 211, the middle legs 53a and 53b of the cores 50a and 50b can be housed with a predetermined gap (or locally zero) between them on their outer peripheral surfaces.

[0084] like Figure 5A As shown, a through hole 35 is formed on the upper portion of the outer peripheral surface of the winding core 21, penetrating both the inside and outside of the winding core 21. The through hole 35 is located approximately at the center of the winding core 21 about the X-axis and Y-axis, and is located between the protrusions 33 and 33. The through hole 35 has an opening of approximately elliptical shape with a longer diameter along the X-axis. The cross-sectional shape of the through hole 35 has a shape corresponding to the cross-sectional shape of the middle legs 53a and 53b, which can be inserted into the interior of the through hole 35 with a predetermined gap.

[0085] like Figure 5B As shown, a through hole 36 is also formed on the lower portion of the outer peripheral surface of the winding core 21, penetrating both the inside and outside of the winding core 21. The through hole 36 is located approximately at the center of the winding core 21 about the X-axis and Y-axis, and is located between the protrusions 34, 34. The through hole 36 has an opening of approximately elliptical shape with a longer diameter along the X-axis. Along the Z-axis, the through hole 36 is formed at the opposite position to the through hole 35.

[0086] By forming through holes 35 and 36 in the winding core 21, the potting resin 210 (see reference) can be used to encapsulate the resin. Figure 10 Through these through holes 35 and 36, the potting resin 210 can circulate inside and outside the winding frame 20 (winding core 21), allowing the potting resin 210 to be distributed throughout every corner of the housing 90.

[0087] like Figure 5A As shown, flange portion 22a is formed at one end of the winding core 21 along the axial core, and flange portion 22b is formed at the other end of the winding core 21 along the axial core. Flange portions 22a and 22b have the same shape, but may also differ. Flange portion 22a has a flange body 220a extending circumferentially along the outer peripheral surface of the winding core 21 at one end of the winding core 21 along the X-axis. Flange portion 22b has a flange body 220b extending circumferentially along the outer peripheral surface of the winding core 21 at the other end of the winding core 21 along the Y-axis.

[0088] The flange body 220a is composed of a plate having a predetermined thickness along the X-axis and protrudes outward along the radial direction of the winding core 21. The flange body 220b is composed of a plate having a predetermined thickness along the X-axis and protrudes outward along the radial direction of the winding core 21.

[0089] like Figure 5B As shown, a pair of mounting portions 32a are formed below the flange body 220a, protruding downwards from the main body 220a along the Z-axis. One mounting portion 32a is formed on one side of the flange body 220a along the Y-axis, and the other mounting portion 32a is formed on the other side of the flange body 220a along the Y-axis. The one mounting portion 32a and the other mounting portion 32a are arranged at a predetermined interval along the Y-axis. The pair of mounting portions 32a extend substantially parallel to the flange body 220a along the YZ plane, and the bottom surfaces of the pair of mounting portions 32a are substantially flat surfaces flush with the plane. The pair of mounting portions 32a are mounted on... Figure 2 The bottom surface 90b of the shell 90 shown.

[0090] like Figure 5B As shown, a pair of mounting portions 32b are formed below the flange body 220b, similar to the pair of mounting portions 32a. The structure and function of the pair of mounting portions 32b are the same as those of the pair of mounting portions 32a, therefore, detailed descriptions are omitted. The pair of mounting portions 32a and the pair of mounting portions 32b can support the winding core 21 of the winding frame 20.

[0091] 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 upward from the bottom surface of the mounting portions 32a and 32b. Conical inclined portions are formed on both sides of the inner peripheral surface of the concave bottoms 37a and 37b.

[0092] The inner peripheral surface shape of the concave bottoms 37a and 37b is preferably formed in Figure 7 The inner circumferential surface shape of the recess 55a (55b) of the core 50a (50b) shown corresponds to that of the core 50a (50b), and is approximately the same shape, but may be larger or smaller. Furthermore, as... Figure 5B As shown, the upper ends of the concave bottoms 37a and 37b can be at the same height as the lower end of the outer peripheral surface of the winding core 21, or they can be lower.

[0093] By forming concave bottoms 37a and 37b in the flange bodies 220a and 220b, and filling them with potting resin 210 ( Figure 10), the concave bottoms 37a and 37b function as flow paths of the potting resin 210. The potting resin 210 flows, for example, from the inner side (outer side) of the concave bottom 37a (37b) along the X axis toward the outer side (inner side) inside the concave bottom 37a (37b), and in particular, is able to spread the potting resin 310 over the lower side of the bobbin 20.

[0094] From the viewpoint of improving the heat dissipation by making the flowability of the potting resin in the X axis direction good, the larger the size of the concave bottoms 37a and 37b is, the better, but it is determined in accordance with the balance of the strength of the placement portions 32a and 32b and the like. This is also the same for the concave portions 55a and 55b of the cores 50a and 50b shown in FIG. 6. Figure 7

[0095] As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively. Figure 5A As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively.

[0096] As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively.

[0097] As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively. Figure 2 As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively. Figure 2 As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively.

[0098] In the present embodiment, as shown in FIG. 7, the lead portion 43a1 of the lead portions 43a1 and 43a2 is inserted through the notch portion 28a shown in FIG. 6 between the core separation wall 25a and the hook portion 23a, and is drawn out toward the terminal 61a. Figure 2 As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively. Figure 5A As shown in FIG. 7, the lead portions 43a1 and 43a2 of the lead wire 41a are inserted through the notch portions 28a shown in FIG. 6 between the core separation walls 25a and 24a and the hook portions 23a and 24a, respectively, and are drawn out toward the terminals 61a and 61b, respectively. Figure 2 ​The lead portion 43a2 shown is inserted through the gap portion 28a, passes between the core separation wall 26a and the protection hook portion 24a, is led out to the terminal 62a while being wrapped around the outside of the protection hook portion 24a along the Y axis. With the core separation walls 25a, 26a, the insulation of the lead portions 43a1, 43a2 from the core 50a can be ensured well.

[0099] As shown in Figure 5A the flange portion body 220b, the protection hook portions 23b, 24b are formed side by side along the Y axis. The protection hook portions 23b, 24b are connected to the upper side of the flange portion body 220b via the protection hook holding portions 23b1, 24b1. The core separation walls 25b, 26b are formed in the protection hook holding portions 23b1, 24b1. The core separation walls 25b, 26b protrude toward the outside along the X axis, facing the protection hook portions 23b, 24b.

[0100] The elongated flange portion 27b is formed on the upper side of the flange portion body 220b. The elongated flange portion 27b is integrally connected to the upper side of the flange portion body 220b, extends along the YZ plane substantially parallel to the flange portion body 220b. That is, the elongated flange portion 27b has a shape that elongates the flange portion body 220b upward, and constitutes a part of the flange portion body 220b. The elongated flange portion 27b has a prescribed thickness along the X axis, and has a face substantially parallel to the YZ plane.

[0101] The gap portion 28b is formed between the protection hook portions 23b, 24b. The lead portions 43b1, 43b2 of the lead wire 41b Figure 2 ) can be inserted through the gap portion 28b. In addition, the lead portion 43b1 can be inserted between the core separation wall 25b and the protection hook portion 23b. In addition, the lead portion 43b2 can be inserted between the core separation wall 26b and the protection hook portion 24b.

[0102] In the present embodiment, as shown in Figure 2 the lead portion 43b1 of the lead portions 43b1, 43b2 is inserted through the gap portion 28b, passes between the core separation wall 25b and the protection hook portion 23b, is led out to the terminal 61b. In addition, the lead 43b2 is inserted through the gap portion 28b, passes between the core separation wall 26b and the protection hook portion 24b, is led out to the terminal 62b while being wrapped around the outside of the protection hook portion 24b along the Y axis. With the core separation walls 25b, 26b, the insulation of the lead portions 43b1, 43b2 from the core 50b can be ensured well.

[0103] As shown in Figure 6AAs shown, the housing 90 is constructed by bending a single plate-shaped component made of a metal with excellent cooling properties, such as aluminum. The housing 90 is composed of a plate-shaped component forming a bottom surface 90b along the Z-axis, plate-shaped components forming two sides 90c along the X-axis, and plate-shaped components forming two sides 90d along the Y-axis. An upper opening 90a is formed along the upper side of the Z-axis. Gaps exist between the plate-shaped components on the side surfaces 90c, and gaps also exist between the plate-shaped components between the side surfaces 90c and the bottom surface 90b.

[0104] The housing 90 has a terminal support portion 91. The terminal support portion 91 is disposed on the upper side of one side 90d along the Y-axis and along the Z-axis, protruding outward from the opening edge 96 of the upper opening 90a along the X-axis. The terminal support portion 91 has support through holes 92a, 92b, 93a, 93b, engagement holes 94a, 94b and a central hole 95.

[0105] The housing 90 is also integrally formed with the cover member 100. The side cover portion 102 of the cover member 100 is connected to the other side 90d of the housing 90 along the Y-axis. The opening cover portion 101 of the cover member 100 is connected to the side cover portion 102, covering the upper part of the upper opening 90a along the Z-axis.

[0106] like Figure 2 As shown, the terminal block 70 and the winding frame 20 are formed separately and are mounted on the upper side of the terminal block support 91 along the Z-axis via the insulation protection member 80. The terminal block 70 may also be made of the same insulating material as the winding frame 20, but is more preferably made of an insulating material with excellent formability (or heat resistance or insulation). Similarly, the insulation protection member 80 may also be made of the same insulating material as the winding frame 20, but is more preferably made of an insulating material with excellent insulation properties. Furthermore, the winding frame 20 is made of plastics such as PPS, PET, PBT, LCP, or other insulating materials (preferably heat-resistant materials).

[0107] like Figure 8 As shown, the terminal block 70 has a terminal block base 701 extending along the X-axis. Fastener mounting holes 71a, 71b, 72a, and 72b are formed along the X-axis in the terminal block base 701. Fasteners 78a, 78b, 79a, and 79b can be embedded in the fastener mounting holes 71a, 71b, 72a, and 72b, respectively.

[0108] Fasteners 78a, 78b, 79a, and 79b can also be integrally formed with the terminal base 701. Bolts and the like for securing external terminals from the circuit board, etc., can be detachably installed on each fastener 78a, 78b, 79a, and 79b. Fastener mounting holes 71a, 71b, 72a, and 72b extend downward along the Z-axis from the upper surface of the terminal base 701.

[0109] In this embodiment, fasteners 78a, 78b, 79a, and 79b are, for example, hexagonal nuts with a hexagonal shape corresponding to fastener mounting holes 71a, 71b, 72a, and 72b. Around each fastener mounting hole 71a, 71b, 72a, and 72b, mounting claw holes 73a1–73a4, 73b1–73b4, 74a1–74a4, and 74b1–74b4 are formed from the upper surface along the Z-axis of the terminal base 701 and downwards along the Z-axis. By inserting the mounting claws of the terminals (described later) into the mounting claw holes 73a1–73a4, 73b1–73b4, 74a1–74a4, and 74b1–74b4, the terminals and the terminal base 70 can be secured.

[0110] like Figure 9A As shown, in this embodiment, a terminal separation wall fitting groove 77 is formed along the Z-axis on the inner surface of the terminal base 701 along the Y-axis. The terminal separation wall fitting groove 77 is formed so that the terminal separation wall 87 can be inserted. In addition, a locking notch 76 is formed in the middle of the fastener mounting holes 72a and 72b and on the outer surface of the terminal base 701 along the Y-axis. By engaging the locking claw 861 of the middle locking portion 86 of the insulation protection member 80 on the locking notch 76, the terminal base 70 and the insulation protection member 80 can be fixed.

[0111] like Figure 9A As shown, engaging protrusions 75a and 75b are formed on the lower side of the terminal base 701 along the Z-axis of the terminal base 70. The engaging protrusions 75a and 75b extend downward along the Z-axis. The engaging protrusions 75a and 75b are formed on the surface of the terminal base 70 with... Figure 9B The insulation protection component 80 shown has intermediate through holes 85a, 85b and Figure 6A The positions corresponding to the support through holes 94a and 94b of the terminal block support 91 shown.

[0112] The engaging protrusions 75a and 75b are inserted into the... Figure 9B The insulation protection component 80 shown has intermediate through holes 85a, 85b and Figure 6A The terminal block support 91 shown has support through holes 94a and 94b, as shown. Figure 4As shown, the engaging protrusions 75a, 75b of the terminal seat 70 are engaged with the engaging recesses 86 of the intermediate portion 82 of the insulation ensuring member 80. As shown, the engaging protrusions 75a, 75b of the terminal seat 70 are engaged with the engaging recesses 86 of the intermediate portion 82 of the insulation ensuring member 80. Thus, the terminal seat 70, the insulation ensuring member 80 and the terminal seat supporting portion 91 can be fixed.

[0113] As shown, the insulation ensuring member 80 has an intermediate portion 82 arranged between the terminal seat 70 and the terminal seat supporting portion 91, and an insulation sheet portion 81 arranged between the outer leg portions 52a, 52b of the cores 50a, 50b and the terminals 61a, 61b, 62a, 62b. The intermediate portion 82 and the insulation sheet portion 81 are integrally formed with a thin sheet along a plane perpendicular to the Z-axis. The intermediate portion 82 is connected to the outer side of the insulation sheet portion 81 along the Y-axis. Figure 2 As shown, in the intermediate portion of the insulation ensuring member 80 along the X-axis, a terminal separation wall 87 extending upward along the Z-axis is formed. As shown, the terminal separation wall 87 is arranged between the terminals 62a, 62b, and can ensure the insulation between the terminal 62a and the terminal 62b which are in a tendency of having a voltage difference increased.

[0114] Figure 9A As shown, in the intermediate portion of the insulation ensuring member 80 along the X-axis, a terminal separation wall 87 extending upward along the Z-axis is formed. As shown, the terminal separation wall 87 is arranged between the terminals 62a, 62b, and can ensure the insulation between the terminal 62a and the terminal 62b which are in a tendency of having a voltage difference increased. Figure 1A As shown, in the intermediate portion 82 of the insulation ensuring member 80, intermediate through holes 85a, 85b through which the engaging protrusions 75a, 75b of the terminal seat 70 are inserted are formed. As shown, in the intermediate portion 82, intermediate engaging portions 86 corresponding to the engaging recesses 76 of the terminal seat 70 are formed.

[0115] Figure 9A As shown, in the lower surface of the intermediate portion 82, a central protrusion 88 protruding downward along the Z-axis is integrally formed at the central position along the X-axis. As shown, the central protrusion 88 of the insulation ensuring member 80 is inserted into the central hole 95 of the terminal seat supporting portion 91, and the insulation ensuring member 80 and the housing 90 are positioned.

[0116] As shown, in the intermediate portion 82 of the insulation ensuring member 80, intermediate protrusions 83a, 83b, 84a, 84b are formed. The intermediate protrusions 83a, 83b, 84a, 84b respectively protrude downward along the Z-axis. The intermediate protrusions 83a, 83b, 84a, 84b are formed side by side along the X-axis corresponding to the positions of the supporting through holes 92a, 92b, 93a, 93b of the terminal seat supporting portion 91 as shown. Figure 9A Figure 9B As shown, in the intermediate portion 82 of the insulation ensuring member 80, intermediate protrusions 83a, 83b, 84a, 84b are formed. The intermediate protrusions 83a, 83b, 84a, 84b respectively protrude downward along the Z-axis. The intermediate protrusions 83a, 83b, 84a, 84b are formed side by side along the X-axis corresponding to the positions of the supporting through holes 92a, 92b, 93a, 93b of the terminal seat supporting portion 91 as shown. Figure 4 As shown, in the intermediate portion 82 of the insulation ensuring member 80, intermediate protrusions 83a, 83b, 84a, 84b are formed. The intermediate protrusions 83a, 83b, 84a, 84b respectively protrude downward along the Z-axis. The intermediate protrusions 83a, 83b, 84a, 84b are formed side by side along the X-axis corresponding to the positions of the supporting through holes 92a, 92b, 93a, 93b of the terminal seat supporting portion 91 as shown.

[0117] Figure 9B As shown, in the intermediate portion 82 of the insulation ensuring member 80, intermediate protrusions 83a, 83b, 84a, 84b are formed. The intermediate protrusions 83a, 83b, 84a, 84b respectively protrude downward along the Z-axis. The intermediate protrusions 83a, 83b, 84a, 84b are formed side by side along the X-axis corresponding to the positions of the supporting through holes 92a, 92b, 93a, 93b of the terminal seat supporting portion 91 as shown. Figure 4

[0118] Figure 9B ​​​​​The illustrated intermediate protrusions 83a, 83b, 84a, 84b of the insulation securing member 80 can also be inserted through the support through holes 92a, 92b, 93a, 93b to position the insulation securing member 80 and the terminal seat support portion 91. Figure 6A The illustrated support through holes 92a, 92b, 93a, 93b position the insulation securing member 80 and the terminal seat support portion 91.

[0119] As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis. Figure 9B As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis.

[0120] As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis. Figure 9A As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis.

[0121] The threaded portion of a bolt for connecting an external terminal of an unillustrated circuit board or the like to the terminal 61a, 61b, 62a, 62b of the terminal seat 70 is configured to be able to enter each of the receiving recesses 83a1, 83b1, 84a1, 84b1. In addition, metal scraps or the like when the unillustrated bolt is threadedly coupled to the fasteners 78a, 78b, 79a, 79b can be received in each of the receiving recesses 83a1, 83b1, 84a1, 84b1.

[0122] As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis. Figure 1A As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis. In addition, the terminal 61b has a terminal main portion 63b and a wiring portion 63b. In addition, the terminal 62a has a terminal main portion 64a and a wiring portion 64a. In addition, the terminal 62b has a terminal main portion 64b and a wiring portion 64b. Hereinafter, the structure of the terminal 61a will be described, but the description of the terminal 61a also applies to the terminals 61b, 62a, 62b. Therefore, unless specifically required, the description of the structure of the terminals 61b, 62a, 62b will be omitted.

[0123] Figure 1A As shown in FIG. 6, the intermediate protrusions 83a, 83b of the insulation securing member 80 are formed in the shape of a rectangular prism. The intermediate protrusions 83a, 83b are formed so that the outer circumferential surface of the intermediate protrusions 83a, 83b is parallel to the Z axis. Figure 9AThe positions corresponding to fasteners 78a, 78b, 79a, and 79b are shown. By... Figure 1A or Figure 2 The mounting claws 63a1 to 63a4 shown are respectively inserted into Figure 9A In the mounting claw holes 73a1 to 73a4 shown, terminal 61a is fixed to terminal block 70.

[0124] Figure 1A The terminal main portion 63a shown is connected to the wiring portion 67a along the Y-axis on the inner side. The wiring portion 67a has a folding tab 67a1, which can clamp and fix the lead portion. Figure 3 As shown, the wiring portion 67a is positioned h2 lower than the terminal main portion 63a along the Z-axis. Furthermore, the wiring portion 67a is positioned slightly higher than the insulating sheet portion 81 along the Z-axis.

[0125] like Figure 1A As shown, terminals 61a, 61b, 62a, and 62b are mounted on the terminal block 70 at specified intervals along the X-axis. Figure 9A The terminal fixing parts 71a1, 71b1, 72a1, and 72b1 are shown.

[0126] In this embodiment, such as Figure 1A As shown, terminal 61a is connected to lead portion 43a1. Additionally, terminal 61b is connected to lead portion 43b1. Furthermore, terminal 62a is connected to lead portion 43a2. Additionally, terminal 62b is connected to lead portion 43b2.

[0127] The coil device 10 of this embodiment can be assembled, for example, as follows.

[0128] First, such as Figure 2 As shown, wires 41a and 41b are wound onto the winding core 21 of the winding frame 20 using, for example, an automatic winding machine. The mounting claws 63a1–63a4 (63b1–63b4, 64a1–64a4, 64b1–64b4) of terminals 61a (61b, 62a, 62b) are inserted into mounting claw holes 73a1–73a4 (73b1–73b4, 74a1–74a4, 74b1–74b4) before, after, or simultaneously with these claws, thus mounting terminals 61a (61b, 62a, 62b) onto the terminal block 70.

[0129] Next, the lead portion 43a1(43a2, 43b1, 43b2) is sandwiched and temporarily fixed between the wiring portion 67a(67b, 68a, 68b) and the turn-back piece 67a1(67b1, 68a1, 68b1) of the terminal 61a(61b, 62a, 62b). Next, the wiring portion 67a(67b, 68a, 68b) is pressed from the upper side with an electrode along the Z axis, and the turn-back piece 67a1(67b1, 68a1, 68b1) is pressed from the lower side with another electrode along the Z axis, a voltage is applied between the electrodes, whereby the terminal 61a(61b, 62a, 62b) and the lead portion 43a1(43a2, 43b1, 43b2) are electrically and mechanically connected by fusion.

[0130] In the present embodiment, at the time of fusion, there are no components above and below the wiring portion 67a(67b, 68a, 68b) along the Z axis, so the wiring portion 67a(67b, 68a, 68b) and the turn-back piece 67a1(67b1, 68a1, 68b1) can be pressed from above and below with electrodes.

[0131] Next, the insulation ensuring member 80 is installed in the terminal seat 70. Before this, the fasteners 78a, 78b, 79a, 79b are installed in the terminal seat 70. At the time of installation of the insulation ensuring member 80 in the terminal seat 70, as shown in Figure 9A the engaging claw 861 of the intermediate engaging portion 86 is engaged with the engaging notch 76, and the terminal separation wall 87 is fitted in the terminal separation wall fitting groove 77.

[0132] Next, as shown in Figure 2 the intermediate foot portions 53a, 53b of the cores 50a, 50b are inserted in the through holes 21 of the bobbin 20, and the bobbin 20 and the cores 50a, 50b are fixed with, for example, an adhesive or the like. The adhesive can suitably be a thermosetting adhesive.

[0133] Next, the bobbin 20 in which the cores 50a, 50b are combined is housed in a case 90 in which a potting resin (resin excellent in heat dissipation) 210 is injected (filled) in advance. At this time, as shown in Figure 4 the insulation ensuring member 80 in which the terminal seat 70 is installed is installed in the terminal seat support portion 91. Furthermore, it is also possible to inject the potting resin from the opening 90a after the bobbin 20 and the cores 50a, 50b are housed in the case 90.

[0134] When the insulation securing member 80 having the terminal holder 70 mounted thereon is mounted on the terminal holder support portion 91, the intermediate protrusions 83a (83b, 84a, 84b) are inserted into the support through holes 92a (92b, 93a, 93b). In addition, the central protrusion 88 is inserted into the central hole 95. Further, the engagement protrusions 75a, 75b are inserted into the intermediate through holes 85a, 85b, and the claws formed on the engagement protrusions 75a, 75b are engaged with the terminal holder support portion 91. In this way, the terminal holder 70 and the insulation securing member 80 are fixed to the terminal holder support portion 91.

[0135] After the bobbin 20 is housed in the case 90, as shown in Figure 2 , the cover member 100 of the case 90 is bent to form an open cover portion 101 as shown in Figure 1A . By forming the open cover portion 101 in this way, it is not necessary to separately form and mount the cover member 100 from the case 90, and assembly can be facilitated.

[0136] In the present embodiment, as shown in Figure 2 , in the coil device 10, the bobbin 20 is disposed inside the case 90 in such a manner that the winding axis C of the wires 41a, 41b is substantially parallel to the bottom surface 90b of the case 90. That is, the coil device 10 of the present embodiment is a horizontal coil device, and is substantially parallel to the mounting surface of the coil device 10 or the mounting surface of the mounting substrate (not shown). The coil device 10 can be easily made low in height as compared with a vertical coil device in which the winding axis of the wires 41a, 41b is substantially perpendicular to the bottom surface 90b of the case 90.

[0137] In addition, as shown in Figure 1A , in the coil device 10 of the present embodiment, the terminal holder 70 is supported on the terminal holder support portion 91 which protrudes outward along the Y axis from the opening edge 96 of the upper opening 90a of the case 90. Therefore, it is not necessary to increase the installation area of the case 90 in correspondence with the area of the terminal holder 70, and it is possible to reduce the installation area of the case 90 while making it horizontal. Also, as compared with the case where the terminal holder is disposed on both sides along the X axis, it is possible to reduce the installation area of the case along the X axis.

[0138] Further, the terminal holder support portion 91 which is formed by extending the outer wall of the case 90 supports the terminal holder 70, and therefore it is possible to improve the strength and reliability of the terminal holder 70. In particular, when the terminals 61a, 61b, 62a, 62b possessed by the terminal holder 70 of the coil device 10 are connected to a substrate (not shown) disposed on the coil device 10, the terminal holder support portion 91 strengthens the terminal holder 70, and therefore the connection to the substrate becomes easy and the reliability is improved.

[0139] In addition, as shown in Figure 10As shown, by filling the interior of the housing 90 with a heat-dissipating resin (potting resin 210) or similar treatment, heat from the conductors 42, 44 or the winding frame 20 (including cores 50a, 50b) can be dissipated to the bottom surface of the housing 90 via the potting resin 210, thus improving heat dissipation. Furthermore, a cooling mechanism is provided on the bottom surface of the housing 90.

[0140] In addition, such as Figure 1A As shown, a terminal block 70 is supported on a terminal block support 91 that protrudes outward from the opening edge 96 of the upper opening 90a of the housing 90. Therefore, at least a large portion of the winding frame 20 (containing the wires and core) with the winding axis of the wires 41a and 41b can be in contact with the potting resin 210 inside the housing 90 without the terminal block 70 becoming an obstruction. Thus, heat dissipation can be effectively improved using the minimum required amount of potting resin.

[0141] In this embodiment, such as Figure 6A As shown, position adjustment portions 97a and 97b can also be formed on the side 90d of the housing 90. Figure 10 As shown, the position adjustment part 97a (97b) protrudes inward along the Y-axis inside the housing 90.

[0142] When the winding frame 20 and cores 50a and 50b are housed in the housing 90, the elasticity of the lead portion of the wire may sometimes cause them to be pressed against the side 90d of the housing 90, which is located on the side opposite to the terminal block 70 along the Y-axis. By abutting the outer foot 52a (52b) of the core 50a (50b) with the position adjustment part 97a (97b), a gap can be formed between the side 90d and the core 50a for the potting resin 210 to enter.

[0143] Moreover, such as Figure 1A As shown, in the coil device 10 of this embodiment, a terminal base 70 is mounted on the terminal base support 91 via an insulation protection member 80. Therefore, after the winding frame 20 winds the wires 41a and 41b, and the terminal base 70 mounts the terminals 61a, 61b, 62a, and 62b, the operation of connecting the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, and 62b in one step becomes easy. The connection of the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, and 62b is appropriately performed using, for example, thermoforming by welding.

[0144] When connecting the lead portions 43a1, 43a2, 43b1, 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, 62b, it is necessary to press a heat-pressing fixture or the like from both sides of the lead portions 43a1, 43a2, 43b1, 43b2. In this embodiment, as described above, before installing the insulation protection component 80 on the terminal block 70, it is easy to press a heat-pressing fixture or the like from both sides of the lead portions 43a1, 43a2, 43b1, 43b2.

[0145] Furthermore, after the lead portions 43a1, 43a2, 43b1, and 43b2 of the conductors 41a and 41b are connected to the terminals 61a, 61b, 62a, and 62b, the insulation protection component 80 is disposed on one side of the connection portions 67a, 67b, 68a, and 68b of the conductors 41a and 41b. Therefore, the insulation between the connection portions 67a, 67b, 68a, and 68b and the cores 50a and 50b mounted on the winding frame 20 can be effectively ensured.

[0146] In addition, the insulation protection component 80 can also ensure the insulation of the lead portions 43a1, 43a2, 43b1, 43b2 and the wiring portions 67a, 67b, 68a, 68b of the terminals 61a, 61b, 62a, 62b with the housing 90.

[0147] like Figure 3 As shown, in this embodiment, the insulation assurance component 80 has an insulating sheet portion 81. The insulating sheet portion 81 is disposed between the lead portions 43a1, 43a2, 43b1, 43b2 of the conductors 41a, 41b and the wiring portions 67a, 67b, 68a, 68b of the terminals 61a, 61b, 62a, 62b, and the cores 50a, 50b mounted on the winding frame 20.

[0148] By adopting this structure, the insulation ensuring component 80 can improve the insulation between the lead portions 43a1, 43a2, 43b1, 43b2 and the wiring portions 62b, 63b, 65b, 66 of the terminals 61a, 61b, 62a, 62b, and the outer feet 52a, 52b of the cores 50a, 50b mounted on the winding frame 20. Furthermore, the insulation ensuring component 80 can also improve the insulation between the lead portions 43a1, 43a2, 43b1, 43b2 and the wiring portions 67a, 67b, 68a, 68b of the terminals 61a, 61b, 62a, 62b, and the housing 90.

[0149] like Figure 3 As shown, in this embodiment, the insulation assurance component 80 has an intermediate portion 82 integrally formed with the insulating sheet portion 81. The intermediate portion 82 is sandwiched between the terminal support portion 91 and the terminal base 70. Figure 9AAs shown, the insulation securing component 80 has an intermediate engaging portion 86 that engages with the terminal block 70, and the intermediate engaging portion 86 has engaging claws 861. By engaging the intermediate engaging portion 86 with the terminal block 70, the terminal block 70 and the insulation securing component 80 can be easily installed while being positioned. Furthermore, the terminal block 70 and the insulation securing component 80 can be fixed without the use of adhesive. However, adhesive may also be used.

[0150] like Figure 4 As shown, in this embodiment, the intermediate portion 82 has intermediate protrusions 83a, 83b, 84a, and 84b that enter the support through holes 92a, 92b, 93a, and 93b formed in the terminal support portion 91. By allowing the intermediate protrusions 83a, 83b, 84a, and 84b to enter the support through holes 92a, 92b, 93a, and 93b, the positioning of the insulation assurance component 80 and the terminal support portion 91 becomes easier.

[0151] like Figure 9A As shown, the intermediate protrusions 83a, 83b, 84a, and 84b have receiving recesses 83a1, 83b1, 84a1, and 84b1 that open toward the terminal block 70. These receiving recesses 83a1, 83b1, 84a1, and 84b1 can accommodate metal debris and other debris generated during the threading of the threaded portions that mechanically and electrically connect the terminals 61a, 61b, 62a, and 62b to the substrate, etc. The threaded portions of the terminals 61a, 61b, 62a, and 62b, which are used to mount external terminals of a circuit board (not shown) to the terminal block, are configured to enter the receiving recesses 83a1, 83b1, 84a1, and 84b1.

[0152] like Figure 4 As shown, the terminal block 70 has engaging protrusions 75a and 75b. Additionally, as... Figure 9A As shown, intermediate through holes 85a and 85b are formed in the middle portion 82 of the insulation protection component 80. Figure 4 As shown, the engaging protrusions 75a and 75b pass through the central through hole of the middle portion and engage with the engaging holes 94a and 94b formed in the terminal support portion 91.

[0153] With this structure, the terminal block 70 and the insulation protection component 80 can be easily positioned, and the terminal block 70 and the terminal block support 91 can be installed simultaneously with positioning. Furthermore, the terminal block 70, the insulation protection component 80, and the terminal block 70 support can be fixed without the use of adhesive. However, adhesive can also be used.

[0154] like Figure 1A As shown, the housing 90 has a cover member 100. The cover member 100 has an opening portion 101. Figure 3The specified gap H1 shown covers at least a portion of the upper opening 90a of the housing 90. The specified gap H1 is greater than the protrusion height of the protrusion 33 of the winding frame 20 from the upper opening 90a of the housing 90, and greater than the protrusion height of the protective hooks 23a, 23b, 24a, 24b.

[0155] By covering a portion of the upper opening 90a of the housing 90 with a predetermined gap H1 by the mask part 101, the protrusions of the cores 50a and 50b, and the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b are protected. For example, when the terminals 61a, 61b, 62a, and 62b of the coil device 10 are connected to the substrate, it can effectively prevent damage from contact between the protrusions of the substrate, the substrate itself, and the protrusions of the cores 50a and 50b, and the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b.

[0156] like Figure 3 As shown, in this embodiment, the cover member 100 covers at least a portion of the wires 44 (41) of the winding frame 20 housed inside the housing 90. Preferably, the cover member 100 covers the entire winding portion of the wires 41a and 41b, excluding the lead portions 45 and 46 (42 and 43). By constructing the cover member 100 with metal or the like, the effect of shielding against leakage magnetic flux from the winding portions (coil portions) of the wires 41a and 41b is improved.

[0157] like Figure 3 As shown, in this embodiment, the cover member 100 and the housing 90 are integrally formed. By integrally forming the cover member 100 and the housing 90 with a bent metal plate or the like, the manufacturing of the cover member 100 and the housing 90 becomes easier. Furthermore, in this embodiment, the terminal support portion 91 is integrally formed with the housing 90. By integrally forming the terminal support portion 91 and the housing 90 with a bent metal plate or the like, the manufacturing of the terminal support portion 91 and the housing 90 becomes easier.

[0158] like Figure 5A As shown, in this embodiment, the winding frame 20 has a winding core 21 for winding the wire and flanges 22a and 22b installed at the ends of the winding core 21. In addition, the flanges 22a and 22b have protective hooks 23a, 23b, 24a and 24b.

[0159] Protective hooks 23a, 23b, 24a, and 24b protrude upwards from the upper opening 90a of the housing 90, as... Figure 1AAs shown, the lead portions 43a1, 43a2, 43b1, and 43b2 of wires 41a and 41b are guided to the terminal block 70. By engaging the lead portions 43a1, 43a2, 43b1, and 43b2 of wires 41a and 41b with the protective hook portions 23a, 23b, 24a, and 24b, the lead portions 43a1, 43a2, 43b1, and 43b2 of wires 41a and 41b are easily guided to the terminals 61a, 61b, 62a, and 62b installed on the terminal block 70.

[0160] like Figure 3 As shown, in this embodiment, the protective hook portions 23a, 23b, 24a, and 24b have a height h1 that is flush with or higher than the upper surfaces of the terminals 61a, 61b, 62a, and 62b. Furthermore, the wiring portions 67a, 67b, 68a, and 68b of the terminals 61a, 61b, 62a, and 62b, to which the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b are connected, are positioned at a height h2 lower than the upper surfaces of the terminals. This configuration effectively protects the wiring portions 67a, 67b, 68a, and 68b from the protective hook portions 23a, 23b, 24a, and 24b, effectively preventing contact between the wiring portions 67a, 67b, 68a, and 68b from protrusions from a substrate (not shown) or the substrate itself.

[0161] Furthermore, in this embodiment, the opening mask portion 101 is positioned H1 higher than the opening 90a of the housing 90, and the protective hook portions 23a, 23b, 24a, and 24b are disposed between the opening mask portion 101 and the opening 90a. With this configuration, the opening mask portion 101 and the protective hook portions 23a, 23b, 24a, and 24b together protect the wiring portions 67a, 67b, 68a, and 68b, effectively preventing contact between the protrusions from the substrate, the substrate itself, and the wiring portions 67a, 67b, 68a, and 68b.

[0162] Second embodiment

[0163] like Figure 1B , Figure 6B and Figure 6C As shown, the coil device 20 of this embodiment is the same as the coil device 10 of the first embodiment, except for the different structures of the housing 190 and the cover member 200, and the same effect can be expected. In the following description, the parts that are the same as those in the first embodiment are omitted.

[0164] like Figure 6B and Figure 6C As shown, in this embodiment, the housing 190 and the cover component 200 are respectively formed separately from metal plates, such as... Figure 1B Assemble as shown.

[0165] The housing 190 has a pair of locking tabs 90c1 and 90c2 integrally formed on the upper side of the two opposite sides 90c, 90c along the Z-axis. Locking holes 198a and 198b are formed in each locking tab 90c1 and 90c2 respectively.

[0166] like Figure 6C As shown, in this embodiment, the cover member 200 has an opening cover portion 201, a side cover portion 202, and a pair of cover support portions 203, 203. The side cover portion 202 is formed such that it protrudes downward along the Z-axis from one end of the opening cover portion 201 along the Y-axis. Figure 1B As shown, the side cover 202 may also have an outer surface that is substantially perpendicular to the Y-axis. The outer surface of the side cover 202 is substantially in the same plane as the side surface 90d of the housing 90, or is introduced into the inside compared to the side surface 90d, or protrudes slightly.

[0167] The cover support portions 203 and 203 protruding downward from both ends of the cover portion 201 along the X-axis and along the Z-axis respectively have the same shape.

[0168] In each cover support portion 203, a locking piece 204 with an engaging protrusion at its front end is formed such that it extends upward along the Z-axis in an inverted U-shaped groove. The engaging protrusion is formed by bending the upper front end of the locking piece 204 so as to protrude outward along the X-axis. The cover support portions 203 located on the upper side along the Z-axis and on both sides along the Y-axis of the locking piece 204 are cut to form inverted U-shaped grooves.

[0169] By employing this structure, the locking tab 204 maintains a cantilevered support beam shape relative to the main part of the cover support 203, allowing for flexible and elastic deformation. The engaging protrusion can move elastically outward and inward along the X-axis. Therefore, when the cover component 200 is inserted into the interior through the upper opening of the housing 190, Figure 6C The engaging protrusion of the locking tab 204 shown can easily engage with the locking hole 198a (198b), which can connect the cover component 200 to the housing 190.

[0170] Furthermore, each cover support portion 203 has a wide portion with an opening 206 extending through its front and back sides on both sides of the inverted U-shaped groove along the Y-axis. A cover mounting portion 205 is formed on the lower side of the wide portion of each cover support portion 203 along the Z-axis, and a recessed notch is formed at approximately the center of the cover mounting portion 205 along the Y-axis.

[0171] Including the notch, both the opening 206 and the U-shaped groove serve as pathways for the potting resin to fill the interior of the housing 190, allowing the interior of the housing 190 to be easily filled with potting resin. In the coil device 20 of this embodiment, since the cover member 200 is separated from the housing 190, the cover member does not become an obstacle when storing the winding frame with the coil wound inside the housing 190. In addition, there is no need to bend the cover member relative to the housing.

[0172] 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. For example, the heat-dissipating resin is not limited to potting resin, but can also be other resins with excellent heat dissipation properties. As a heat-dissipating resin, it is composed of, for example, silicone resin, polyurethane resin, epoxy resin, etc., which are soft after injection, and the longitudinal modulus (longitudinal elastic modulus) of the resin is preferably 0.1 to 100 MPa, and the Shore A hardness is 100 or less, preferably 60 or less. In addition, in order to improve heat dissipation, fillers with high thermal conductivity can also be filled into the resin.

[0173] Furthermore, in the above-described embodiments, such as Figure 7 As shown, the liquid level S of the potting resin is lower than the upper end (along the Z-axis) E1 of the middle foot 53a (53b) by a specified height T1, but is not limited to this. For example, if the height is increased... Figure 1A The height of the housing 90 along the Z-axis can be such that the liquid surface S of the potting resin is either flush with or above the upper end (along the Z-axis) E1 of the middle foot 53a (53b).

[0174] Moreover, in the above-described embodiments, such as Figure 6A or Figure 6B As shown, the terminal support portion 91 is formed only on one side of the upper opening 90a of the housing 90 or 190 in the Y-axis direction, but it is not limited to this. Similarly to the embodiments described above, for example... Figure 6A or Figure 6B Multiple terminal block support portions 91 may be formed at two or more locations on both sides of the upper opening 90a of the housing 90 or 190 in the Y-axis direction, or at two or more locations on both sides of the upper opening 90a of the housing 90 or 190 in the X-axis direction. Alternatively, another terminal block support portion may be formed separately from the aforementioned terminal block support portions 91 at any location on the upper opening 90a of the housing 90 or 190, facing outward from the opening, and multiple terminal block support portions 91 may be formed in the same manner as in the above embodiment.

[0175] In any case, if the housing forms multiple terminal support portions, multiple such... Figure 9A The terminal block 70 and insulation protection component 80 are shown and are installed on each terminal block support.

[0176] Explanation of reference numerals in the attached figures

[0177] 10. Coil assembly (transformer)

[0178] 20 Winding stand

[0179] 21. Winding core

[0180] 211 Through hole

[0181] 22a, 22b Flange portions

[0182] 220a, 220b Flange body

[0183] 23a, 23b, 24a, 24b Protective hooks

[0184] Hook support parts 23a1, 23b1, 24a1, 24b1

[0185] 25a, 25b, 26a, 26b core separation wall

[0186] 27a, 27b Extended flange portion

[0187] 28a, 28b Notch

[0188] 32a, 32b mounting sections

[0189] 33, 34 Protrusions

[0190] Through holes 35 and 36

[0191] 37a, 37b Concave bottom

[0192] 41a and 41b wires

[0193] 42a, 42b Coil Section

[0194] 43a1, 43a2, 43b1, 43b2 Lead sections

[0195] 50a, 50b core

[0196] 51a, 51b base

[0197] 510a, 510b outer surface

[0198] 511a, 511b inner surfaces

[0199] 512a, 512b upper surface

[0200] 513a, 513b lower surface

[0201] 52a, 52b Outer foot

[0202] 520a, 520b Inner side of the outer foot

[0203] 521a, 521b outer foot end face

[0204] 53a, 53b Middle foot

[0205] 531a, 531b middle leg end face

[0206] 55a, 55b concave portion

[0207] Inner circumferential surfaces of 550a and 550b

[0208] 551a, 551b conical surfaces

[0209] 56a, 56b wall thickness sections

[0210] 61a, 61b, 62a, 62b terminals

[0211] 63a, 63b, 64a, 64b terminal main part

[0212] Mounting claws 63a1~63a4, 63b1~63b4, 64a1~64a4, 64b1~64b4

[0213] 65a, 65b, 66a, 66b connecting holes

[0214] Wiring sections 67a, 67b, 68a, and 68b

[0215] 67a1, 67b1, 68a1, 68b1 foldback sheets

[0216] 70 terminal block

[0217] 701 Terminal Base

[0218] Fastener mounting holes 71a, 71b, 72a, 72b

[0219] Terminal fixing parts 71a1, 71b1, 72a1, 72b1

[0220] Mounting claw holes 73a1~73a4, 73b1~73b4, 74a1~74a4, 74B1~74b4

[0221] 75a, 75b engaging protrusions

[0222] 76-card combo gap

[0223] 77 Terminal Separation Wall Fitting Groove

[0224] Fasteners 78a, 78b, 79a, 79b

[0225] 80 Insulation Protection Components

[0226] 81 Insulating sheet section

[0227] 82 Middle section

[0228] 83a, 83b, 84a, 84b Middle convex part

[0229] Storage recesses for 83a1, 83b1, 84a1, and 84b1

[0230] 83a2, 83b2 fixed protrusions

[0231] Fastener mounting parts 83a3, 83b3, 84a3, 84b3

[0232] 85a and 85b through holes

[0233] 86. Intermediate engagement part

[0234] 861 Claw Engagement

[0235] 87 Terminal Separation Wall

[0236] 88 Central convex part

[0237] 90, 190 housing

[0238] 90a Top opening

[0239] 90b bottom surface

[0240] 90C and 90D side views

[0241] 91 Terminal support portion

[0242] Support through holes 92a, 92b, 93a, 93b

[0243] 94a, 94b engagement holes

[0244] 95 Central Hole

[0245] 96 Opening edge

[0246] 97a, 97b Position Adjustment Section

[0247] 198a, 198b locking holes

[0248] 100 and 200 cover components

[0249] 101, 201 Mask Department

[0250] 102, 202 Side Cover Section

[0251] 203 Cover support section

[0252] 204 locking clip

[0253] 205 Cover mounting section

[0254] 206 Opening

[0255] 210 Encapsulating resin.

Claims

1. A coil device, comprising: a bobbin for winding a wire; a terminal of electric conductivity connecting a lead portion of the wire; a terminal holder of insulation mounting the terminal; a case housing the bobbin; and a core mounted to the bobbin, the bobbin is arranged inside the case in a manner that an axis of winding of the wire is substantially parallel to a bottom surface of the case, the case has a terminal holder support portion protruding outward from a rim of an upper opening of the case, the terminal holder is mounted on the terminal holder support portion via an insulation ensuring member, the insulation ensuring member has an insulation sheet portion, and a wiring portion of the terminal connects the lead portion of the wire.

2. The coil device according to claim 1, wherein the insulation ensuring member further has an intermediate portion integrally formed with the insulation sheet portion and sandwiched between the terminal holder support portion and the terminal holder, and the intermediate portion has an intermediate engaging portion engaging with the terminal holder.

3. The coil device according to claim 2, wherein the intermediate portion has an intermediate protrusion entering a support through-hole formed in the terminal holder support portion.

4. The coil device according to claim 3, wherein the intermediate protrusion has a housing recess opening toward the terminal holder.

5. The coil device according to any one of claims 2 to 4, wherein the terminal holder has an engaging protrusion engaging with an engaging hole formed in the terminal holder support portion through an intermediate through-hole formed in the intermediate portion.

6. The coil device according to any one of claims 1 to 4, wherein a heat dissipation resin can be filled inside the case.

7. The coil device according to any one of claims 1 to 4, wherein the case has a cover member covering at least a portion of the upper opening of the case with a prescribed gap, and the cover member covers at least a portion of the wire wound on the bobbin housed inside the case.

8. The coil device according to claim 7, wherein the cover member is integrally formed with the case.

9. The coil device according to any one of claims 1 to 4, wherein the terminal holder support portion is integrally formed with the case.

10. The coil device according to any one of claims 1 to 4, wherein the bobbin has a winding core portion for winding the wire and a flange portion mounted at an end portion of the winding core portion, and the flange portion has a protection hook portion protruding upward from the upper opening of the case to guide the lead of the wire to the terminal holder. The insulating sheet portion is arranged between the wiring portion of the terminal and the core.

11. The coil device according to claim 10, wherein the protection hook portion has a height which is flush with or higher than an upper surface of the terminal, and a wiring portion of the terminal to which a lead portion of the wire is connected is arranged at a position lower than the upper surface of the terminal. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

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