Coil arrangement

Abstract

The present invention provides a coil device (1) having: a spool (20) having a winding core (21) for winding a conductor (41a); a core (50a) having a central leg (53a) inserted into a shaft hole in the winding core (21); and a housing (90) for accommodating the spool (20) on which the magnetic core (50a) is mounted. The middle leg (53a) has the following cross-sectional shape: when the middle leg (53a) is divided into an upper half (ML1) and a lower half (ML2) by a middle horizontal plane (P0), the cross-sectional area (CA2) of the lower half (ML2) is greater than the cross-sectional area (CA1) of the upper half (ML2). The middle horizontal plane (P0) is a horizontal plane with the midpoint (O) of the vertical line connecting the upper horizontal plane (P1) containing the upper end (E1) of the middle leg (53a) and the lower horizontal plane (P2) containing the lower end (E2) of the middle leg (53a) by the shortest distance.

Description

Technical Field

[0001] The present invention relates to coil devices suitably used, such as transformers. Background Technology

[0002] As a coil device for use in larger transformers, etc., a coil device as shown in Patent Document 1 below has been developed, for example. In this developed coil device, a spool (winding frame) with a wire wound around it is housed inside a housing, and the inside of the housing is filled with a resin with excellent thermal conductivity, such as potting resin, to improve heat dissipation.

[0003] However, in recent years, there has been a demand for lower height of coil devices such as transformers, as well as for miniaturization of coil devices and improved heat dissipation characteristics.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-93405 Summary of the Invention

[0007] The technical problem that the invention aims to solve

[0008] The present invention was made in view of this situation, and its object is to provide a coil device that can achieve low height, miniaturization of the device, and excellent heat dissipation.

[0009] Technical solutions for solving the problem

[0010] To achieve the above objectives, the coil device of the first aspect of the present invention comprises: a spool having a winding core for winding a conductor; a core having a central leg portion inserted into a shaft hole in the winding core; and a housing for housing the spool in which the magnetic core is mounted, wherein the central leg portion has a cross-sectional shape such that, when the central leg portion is divided into an upper half and a lower half by an intermediate horizontal plane, the cross-sectional area (CA2) of the lower half portion is greater than the cross-sectional area (CA1) of the upper half portion, wherein the intermediate horizontal plane is a horizontal plane formed by the midpoint of a vertical line connecting an upper horizontal plane containing the upper end of the central leg portion and a lower horizontal plane containing the lower end of the central leg portion with the shortest distance.

[0011] Furthermore, the coil device of the second aspect of the present invention comprises: a spool having a winding core for winding a conductor; a core having a central leg portion inserted into the shaft hole of the winding core; and a housing for housing the spool on which the magnetic core is mounted, wherein the central leg portion has a shape in which, when the central leg portion is divided into an upper half and a lower half by an intermediate horizontal plane, the volume (V2) of the lower half portion is greater than the volume (V1) of the upper half portion, wherein the intermediate horizontal plane is the horizontal plane formed by the midpoint of a vertical line connecting the upper horizontal plane containing the upper end of the central leg portion and the lower horizontal plane containing the lower end of the central leg portion with the shortest distance.

[0012] Furthermore, the coil device of the third aspect of the present invention comprises: a spool having a winding core for winding a conductor; a core having a central leg portion inserted into the shaft hole of the winding core; and a housing for housing the spool on which the magnetic core is mounted, wherein the central leg portion has a shape in which, when the central leg portion is divided into an upper half and a lower half by an intermediate horizontal plane, the area (OA2) of the outer peripheral surface of the lower half portion is greater than the area (OA1) of the outer peripheral surface of the upper half portion, wherein the intermediate horizontal plane is a horizontal plane at the midpoint of a vertical line connecting the upper horizontal plane containing the upper end of the central leg portion and the lower horizontal plane containing the lower end of the central leg portion with the shortest distance.

[0013] In the coil device of the present invention (first to third aspects), the spool is arranged inside the housing such that the winding axis of the conductor is substantially parallel to the bottom surface of the housing. That is, the coil device of the present invention is a horizontal coil device, which can be easily reduced in height compared to a vertical coil device in which the winding axis of the conductor is substantially perpendicular to the bottom surface of the housing.

[0014] In addition, by filling the inside of the housing with heat-dissipating resins such as potting resin, heat from the wire or spool (including the core) can be released to the bottom surface of the housing through the heat-dissipating resin, thereby improving heat dissipation.

[0015] Furthermore, in the coil device of the present invention, the cross-sectional area (CA2) of the lower half of the middle leg of the core is greater than the cross-sectional area (CA1) of the upper half. Alternatively, the volume (V2) of the lower half of the middle leg of the core is greater than the volume (V1) of the upper half. Alternatively, the area (OA2) of the outer peripheral surface of the lower half of the middle leg of the core is greater than the area (OA1) of the outer peripheral surface of the upper half.

[0016] In the coil device of the present invention, because it has a core with a middle leg having such a relationship, it is possible to further reduce the height and miniaturize the coil device compared to a coil device with a core having a typical middle leg shape (the upper and lower halves are the same), while also improving heat dissipation.

[0017] The interior of the housing is filled with a heat-dissipating resin, such as potting resin, to cool the core and conductor mounted on the spool. However, from the perspective of minimizing height, the height of the housing is limited to the necessary minimum. Therefore, the liquid level of the heat-dissipating resin inside the housing must be lower than the upper horizontal level of the upper end of the middle foot containing the core. Consequently, a portion of the upper end of the core, including the middle foot, does not contact the heat-dissipating resin.

[0018] In the coil device of the present invention, due to the above-described structure, the cross-sectional area, volume, and / or the area of ​​the outer peripheral surface of the core in the portion not in contact with the heat-dissipating resin can be minimized. Furthermore, the cross-sectional area, volume, and / or the area of ​​the outer peripheral surface of the core in contact with the heat-dissipating resin can be minimized. Therefore, in the coil device of the present invention, compared to a coil device having a core with a typical center leg shape (the upper and lower halves are the same), further reduction in height and miniaturization can be achieved, while simultaneously improving heat dissipation.

[0019] Alternatively, the core may have: a base portion connecting to the root end of the middle leg portion; and outer legs portion connected to the base portion and disposed on both sides of the middle leg portion. That is, the core may have a so-called E-type core, or a combination of E-type cores, or a combination of E-type cores and I-type cores, or a combination of cores of other shapes. In short, the core has at least a middle leg portion inserted into the axial hole of the wound core portion of the spool.

[0020] Preferably, the upper ends of the outer legs and the middle legs have substantially the same height. By employing this structure, the magnetic flux balance is improved, and the characteristics are enhanced.

[0021] Preferably, the lower end of the middle leg is positioned above the lower end of the outer leg. A gap is formed here because the wire is wound around the middle leg with respect to the core of the spool. Additionally, a notch is preferably formed at the base located below the middle leg. This allows a heat-dissipating resin, such as potting resin, to easily enter the axial center of the core near the bottom of the housing, improving heat dissipation.

[0022] Preferably, each of the outer legs has a shape in which, when the outer leg portion is divided into an upper outer leg portion and a lower outer leg portion by the intermediate horizontal plane, the volume (OV2) of the lower outer leg portion is larger than the volume (OV1) of the upper outer leg portion. Similar to the middle leg portion, the outer legs can also achieve a lower height and smaller size by making the volume of the lower outer leg portion larger than the volume of the upper outer leg portion, while simultaneously improving heat dissipation. Furthermore, the magnetic flux balance is improved, and the overall characteristics are enhanced.

[0023] Alternatively, a cover member may be provided in the housing to cover a portion of the upper opening of the housing with a predetermined gap. The cover member covers a portion of the upper opening of the housing with a predetermined gap, thereby effectively preventing damage from contact between protrusions from the substrate, the substrate itself, and protrusions of the core or lead portions of the wires when connecting the terminals of the coil device to the substrate, etc.

[0024] Preferably, the cover member covers at least a portion of the wire wound on the spool housed inside the housing. More preferably, the cover member covers the entire wound portion of the wire, excluding the lead portion. By constructing the cover member from metal or the like, the effect of shielding leakage magnetic flux from the wound portion (coil portion) of the wire is improved.

[0025] The cover component can be integrally formed with the housing, or it can be formed separately from the housing and installed by fitting or other means. By forming the cover component integrally with the housing by bending a metal sheet or the like, the manufacture of both the cover component and the housing becomes easier. Additionally, the housing may have a terminal support portion protruding outward from the edge of the upper opening of the housing.

[0026] Preferably, the terminal support portion is integrally formed with the housing. By forming the terminal support portion integrally with the housing using a metal plate or the like, the manufacturing of both the terminal support portion and the housing becomes easier.

[0027] In addition, the cover component can also function as a cooling mechanism. By making the cover component function as a heat sink or by having the cover component contact other cooling mechanisms, heat can be released from the heat-dissipating resin inside the housing to the outside through the cover component.

[0028] Alternatively, the housing may have a terminal support portion that protrudes outward from the edge of the upper opening of the housing. By adopting such a structure, it is possible to configure the housing horizontally without increasing the installation area corresponding to the area of ​​the terminal base, thereby reducing the installation area of ​​the housing.

[0029] Furthermore, a terminal block can also be disposed on the terminal block support portion, and the terminal block support portion formed by extending the outer wall of the housing can also support the terminal block. By adopting such a structure, the strength and reliability of the terminal block can be improved. In particular, when the terminals provided on the terminal block of the coil device are connected to the substrate disposed on the coil device, the terminal block support portion strengthens the terminal block, thus making the connection with the substrate easier and improving reliability.

[0030] Preferably, a plurality of terminals are arranged in the terminal block, substantially parallel to the winding axis of the wire. By adopting such a structure, terminals that are easily connected to the lead portions of the plurality of wires wound on the spool can be arranged in a straight line along the opening edge of the housing in one or more rows, and the connection between each terminal and the substrate is also facilitated.

[0031] Furthermore, in the coil device of the present invention, the terminal base can also be mounted on the terminal base support portion with an insulating securing member in between. By employing such a structure, it becomes easier to connect the lead portions of multiple wires to multiple terminals at once after winding multiple wires on the spool and mounting multiple terminals on the terminal base. The connection between the lead portions of the wires and the terminals is achieved using, for example, thermoforming such as fusion welding.

[0032] When connecting the lead portion of the wire to the terminal, it is necessary to press the heat-pressing clamp or similar device from both sides of the lead portion. Before installing the insulation protection component on the terminal block, it is easy to press the heat-pressing clamp or similar device from both sides of the lead portion. Furthermore, after connecting the lead portion of the wire to the terminal, the insulation protection component is positioned on one side of the connection portion of the terminal and the lead portion of the wire, thus effectively ensuring the insulation of this connection portion and the core mounted on the spool. In addition, the insulation protection component also ensures the insulation of the lead portion and the connection portion of the terminal from the housing.

[0033] Preferably, the insulation ensuring component has an insulating sheet portion disposed between the lead portion of the conductor, the terminal connection portion, and the outer leg portion of the core mounted on the spool. By employing this structure, the insulation ensuring component can improve the insulation between the lead portion, the terminal connection portion, and the outer leg portion of the core mounted on the spool. Furthermore, the insulation ensuring component can also improve the insulation between the lead portion and the terminal connection portion and the housing.

[0034] Preferably, the insulation securing component further comprises an intermediate portion integrally formed with the insulating sheet portion and clamped between the terminal base support portion and the terminal base, the intermediate portion having an intermediate engaging portion that engages with the terminal base. By engaging the intermediate engaging portion, such as the engaging claw, with the terminal base, the terminal base and the insulation securing component can be easily installed while being positioned. Furthermore, the terminal base and the insulation securing component can be fixed without the use of adhesive. However, adhesive may also be used.

[0035] Preferably, the intermediate portion has a central protrusion that enters the support through hole formed in the terminal block support. By allowing the central protrusion to enter the support through hole, positioning of the insulation assurance component and the terminal block support becomes easier.

[0036] The intermediate protrusion may also have a receiving recess that opens toward the terminal block. It may also be configured such that the threaded portion for mounting the terminal to the terminal block enters the receiving recess. The receiving recess can accommodate metal debris or other debris generated during the threaded engagement of the terminal mounting portion to the terminal block.

[0037] The terminal block may also have an engaging protrusion that engages with an engaging hole formed in the terminal block support portion through a central through hole formed in the intermediate portion. By engaging the engaging protrusion through the central through hole with the engaging hole formed in the terminal block support portion, positioning of the terminal block and the insulation protection component can be achieved, and installation of the terminal block and the terminal block support portion during positioning becomes easier. Furthermore, the terminal block, the insulation protection component, and the terminal block support portion can be fixed without the use of adhesive. However, adhesive may also be used.

[0038] Preferably, the spool has a winding core for winding the conductor and a flange portion mounted on the end of the winding core. Preferably, the flange portion has a protective hook portion that protrudes upward from the upper opening of the housing to guide the lead of the conductor to the terminal block. By engaging the lead of the conductor with the protective hook portion, the lead portion of the conductor is easily guided to the terminal mounted on the terminal block.

[0039] Preferably, the protective hook portion has a height that is at or above the upper surface of the terminal, and the lead portion of the wire and the terminal connection portion are positioned lower than the upper surface of the terminal. With this configuration, the protective hook portion protects the connection portion, effectively preventing contact between the connection portion and protrusions from the substrate or the substrate itself.

[0040] In addition, it is preferable that the protective hook portion is lower than the lower surface of the cover component. With this configuration, the cover component and the protective hook portion together protect the wiring portion, effectively preventing contact between the protrusions from the substrate, the substrate itself, and the wiring portion.

[0041] Furthermore, the structure of the terminal and terminal block is not limited to the structure described above; the terminal block can also be mounted on the flange portion of the spool. For example, terminal block engaging portions can be integrally formed on each flange portion located on both sides of the spool. Alternatively, the spool engaging portions (e.g., arm portions) located at both ends of the terminal block in the longitudinal direction can be fitted with these terminal block engaging portions (e.g., engaging recesses), and the terminal block is mounted to the spool in a fitted manner.

[0042] By adopting such a structure, terminals that are easily connected to the lead portions of multiple wires wound on the spool can be arranged in a straight line along the opening edge of the housing in one or more rows, and the connection between each terminal and the substrate becomes easier.

[0043] Furthermore, the terminal blocks can be arranged in a straight line along the X-axis on only one side of the opening edge of the housing, or they can be arranged separately on both sides in the Y-axis direction of the housing. For example, a terminal block with two terminals arranged on one side can be arranged on the other side. Attached Figure Description

[0044] Figure 1A This is a schematic perspective view of a coil device according to an embodiment of the present invention.

[0045] Figure 1B This is a schematic perspective view of a coil device according to another embodiment of the present invention.

[0046] Figure 2 yes Figure 1A An exploded perspective view of the coil device shown.

[0047] Figure 3 yes Figure 1A Side view of the coil assembly shown.

[0048] Figure 4 From Figure 1A A simplified three-dimensional view of the coil device as viewed from a slightly lower angle.

[0049] Figure 5A yes Figure 1A A schematic perspective view of the spool portion of the coil assembly shown.

[0050] Figure 5B From Figure 5A A rough three-dimensional view of the spool section as seen from a slightly downward angle.

[0051] Figure 6A yes Figure 1A A schematic perspective view of the housing of the coil device shown.

[0052] Figure 6B yes Figure 1B A schematic perspective view of the housing of the coil device shown.

[0053] Figure 6C yes Figure 1B A schematic perspective view of the cover of the coil device shown.

[0054] Figure 7 yes Figure 1A The diagram shows a cross-sectional view of the core of the coil assembly.

[0055] Figure 8 yes Figure 1A A schematic perspective view of the terminal block of the coil device shown.

[0056] Figure 9A yes Figure 1AAn exploded perspective view of the terminal block and insulation protection components of the coil assembly shown.

[0057] Figure 9B It means Figure 9A The diagram shows a schematic perspective view of the assembled terminal block and insulation components.

[0058] Figure 10 yes Figure 1A A cross-sectional view of the coil device shown at line X-X.

[0059] Figure 11 This is an exploded perspective view showing the relationship between the terminal block and the spool in a coil device according to another embodiment of the present invention.

[0060] Explanation of reference numerals in the attached figures

[0061] 10-coil device (transformer)

[0062] 20 and 120 spools

[0063] 21, 121, 122a, 122b Winding core

[0064] 211 Through Hole

[0065] 22a, 22b flange portions

[0066] 220a, 220b flange body

[0067] 23a, 23b, 24a, 24b Protective hooks

[0068] 23a1, 23b1, 24a1, 24b1 hook support section

[0069] 25a, 25b, 26a, 26b core separation wall

[0070] 27a, 27b extended flange portion

[0071] 28a, 28b notches

[0072] 32a and 32b mounting sections

[0073] 33 and 34 protrusions

[0074] 35 and 36 through holes

[0075] 37a, 37b concave bottom

[0076] 123a, 123b Terminal block fixing part

[0077] 124a, 124b engagement recess (terminal seat engagement part)

[0078] 130a, 130b fixed convex parts

[0079] 41a and 41b wires

[0080] 42a, 42b coil sections

[0081] 43a1, 43a2, 43b1, 43b2 lead sections

[0082] 50a, 50b core

[0083] 51a, 51b base

[0084] 510a and 510b outer surfaces

[0085] 511a, 511b inner surfaces

[0086] 512a, 512b upper surface

[0087] 513a, 513b lower surfaces

[0088] 52a, 52b outer foot

[0089] 520a, 520b outer foot inner side

[0090] 521a, 521b outer foot end face

[0091] 522a, 522b outer foot upper surface

[0092] 523a, 523b outer foot surface

[0093] 53a, 53b Middle foot

[0094] 531a, 531b middle leg end face

[0095] 55a, 55b concave parts (notches)

[0096] 550a and 550b inner circumferential surfaces

[0097] 551a and 551b conical surfaces

[0098] 56a, 56b Thick-walled sections

[0099] 61a, 61b, 62a, 62b, 161a, 162a, 161b, 162b terminals

[0100] 63a, 63b, 64a, 64b terminal main part

[0101] Mounting claws for 63a1~63a4, 63b1~63b4, 64a1~64a4, and 64b1~64b4

[0102] 65a, 65b, 66a, 66b connecting holes

[0103] Wiring sections 67a, 67b, 68a, and 68b

[0104] 67a1, 67b1, 68a1, 68b1 foldback sheets

[0105] 163a, 164a, 163b, 164b terminal main part

[0106] Wiring sections for 167a, 168a, 167b, and 168b

[0107] 70, 170 terminal blocks

[0108] 701 terminal base

[0109] Fastener configuration holes 71a, 71b, 72a, 72b

[0110] Terminal fixing parts 71a1, 71b1, 72a1, 72b1

[0111] Mounting claw holes 73a1~73a4, 73b1~73b4, 74a1~74a4, 74B1~74b4

[0112] 75a, 75b engaging protrusions

[0113] 76-card combined gap

[0114] 77 terminal separation wall fitting groove

[0115] 78a, 78b, 79a, 79b fasteners

[0116] Arm section (spool engagement section) of 172a and 172b

[0117] 173a, 173b Hook section (spool engagement section)

[0118] Steps 174a and 174b

[0119] Lower surfaces of steps 174a1 and 174b1

[0120] 175a, 175b fixed recessed parts

[0121] 178 Terminal Cover Mounting Section

[0122] 180 terminal cover (insulation protection component)

[0123] 181 terminal cover bottom

[0124] 183a, 183b terminal cover side

[0125] 184 Control Department

[0126] 184a upper arm

[0127] 184b lower arm

[0128] 80 insulation protection components

[0129] 81 Insulating Sheet Section

[0130] 82 Middle Section

[0131] The convex part in the middle of 83a, 83b, 84a, and 84b

[0132] Storage recesses of 83a1, 83b1, 84a1, and 84b1

[0133] 83a2, 83b2 fixed protrusions

[0134] Fastener mounting parts 83a3, 83b3, 84a3, and 84b3

[0135] 85a and 85b through holes

[0136] 86 intermediate card joint

[0137] 861 Card Claw

[0138] 87 terminal separation wall

[0139] 88 central convex part

[0140] 90, 190 housing

[0141] 90a upper opening

[0142] 90b bottom surface

[0143] 90c, 90d side view

[0144] 91 Terminal base support

[0145] Support through holes 92a, 92b, 93a, 93b

[0146] 94a, 94b locking holes

[0147] 95 central hole

[0148] 96 opening edge

[0149] 97a, 97b Position Adjustment Section

[0150] 198a, 198b stop holes

[0151] 100 and 200 cover components

[0152] 101, 201 Mask Department

[0153] 102, 202 Side Cover Sections (Side Cover Sections)

[0154] 203 Cover Support

[0155] 204 card stop film

[0156] 205 Cover Placement Section

[0157] 206 opening

[0158] 210 Potting resin. Detailed Implementation

[0159] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0160] First Implementation Method

[0161] Figure 1A The coil device 10 shown as an example of the coil device in this embodiment functions as a transformer, for example, for an on-board charger for EVs (Electric Vehicles), PHVs (Plug-in Hybrid Vehicles), or portable mobile devices (vehicles), or for power circuits of household or industrial electrical equipment, or for power circuits of computer equipment, etc.

[0162] The detailed structure of the coil device 10 will now be described. Furthermore, in the following description and in the accompanying drawings, the X-axis, Y-axis, and Z-axis are perpendicular to each other. Additionally, the side facing the center of the coil device 10 is referred to as the inner side or inner direction, and the side away from the center of the coil device 10 is referred to as the outer side or outer direction.

[0163] like Figure 2 As shown, the coil assembly 10 includes a bobbin 20, conductors 41a and 41b, cores 50a and 50b, terminals 61a, 61b, 62a, and 62b, a terminal block 70, an insulation protection component 80, and a housing 90. The coil assembly 10 is a horizontal (layout) coil assembly in which the winding axis C of the coil portions 42a and 42b of the conductors 41a and 41b is parallel to the bottom surface 90b of the housing 90.

[0164] Furthermore, in this embodiment, the X-axis is parallel to the winding axis C of the conductors 41a and 41b, and the Y-axis is approximately in the same direction as the lead-out directions of the lead portions 43a1, 43a2, 43b1, and 43b2 of the conductors 41a and 41b. The Z-axis corresponds to the height (thickness) direction of the coil device 10. In this embodiment, the upper part of the coil device 10 along the Z-axis becomes the mounting surface of the circuit board connected to the terminals 61a, 61b, 62a, and 62b of the coil device 10 (transformer).

[0165] like Figure 2 As shown, the coil portion 42a is formed by winding the wire 41a around... Figure 5AThe spool 20 shown is formed by winding the core 21 onto the outer peripheral surface. The coil portion 42b is formed by winding the wire 41b around the core. Figure 5A The bobbin 20 shown is formed by winding the core 21 around its outer periphery. The conductors 41a and 41b are wound around the outer periphery of the core 21, for example, using an automatic winding machine.

[0166] like Figure 10 As shown, the coil portion 42a (42b) formed by the conductors 41a (41b) has one or more layers in the direction orthogonal to its winding axis (radial). Furthermore, as... Figure 2 As shown, the winding axes C of coil sections 42a and 42b are approximately the same and are parallel to the X-axis.

[0167] like Figure 2 As shown, coil portion 42a is wound around one side of the winding core along the X-axis, and coil portion 42b is wound around 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 of the winding core can also be configured on either side of the winding core along the X-axis.

[0168] Conductors 41a and 41b are respectively composed of, for example, insulated wires, such as copper wires covered with an insulating layer. The conductors in conductors 41a and 41b can be 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 diameter of conductor 41a or 41b carrying a large current can be larger than the other conductors.

[0169] 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.

[0170] like Figure 2 As shown, cores 50a and 50b are so-called E-shaped cores, mounted on spool 20. The materials of cores 50a and 50b can include magnetic materials such as metals and ferrites, but there are no particular limitations.

[0171] 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, and 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.

[0172] 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 2 As shown, in base 51a, the surface along the outer side of the X-axis is called outer surface 510a, the surface along the inner side of the X-axis is called inner surface 511a, the surface above it is called upper surface 512a, and the surface below it is called lower surface 513a. Similarly, in base 51b, the surface along the outer side of the X-axis is called outer surface 510b, the surface along the inner side of the X-axis is called inner surface 511b, the surface above it is called upper surface 512b, and the surface below it is called lower surface 513b.

[0173] 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. For example... Figure 7 As shown, the upper surface 512a of the base 51a has the same height as the upper surface 522a of the outer foot of the outer foot 52a.

[0174] On the lower surface 513a of the base 51a, a recess (notch) 55a is formed, recessed upward along the Z-axis at the position of the middle foot 53a. The recess 55a is formed approximately at the center of the base 51a along the Y-axis, and has a defined width along both the X and Y axes. The width of the recess 55a along the Y-axis is smaller than the width of the middle foot 53a along the Y-axis. Figure 5B The concave bottoms 37a or 37b of the spool 20 shown are approximately equal in width along the Y-axis. Figure 7 The recess 55a shown is formed to extend from the inner surface of the base 51a to the outer surface.

[0175] like Figure 7 As shown, the recess 55a is recessed upward from the lower surface 513a to a predetermined depth. The upper end of the inner peripheral surface 550a of the recess 55a is located below the lower outer peripheral surface of the middle foot 53a, but it may also be on the same surface. In this embodiment, the inner peripheral surface 550a has a generally flat top surface, but it may also be curved, triangular, or polygonal.

[0176] The inner peripheral surface 550a of the recess 55a may also have tapered surfaces 551a on both sides along the Y-axis. The tapered surfaces 551a are formed such that the width of the recess 55a along the Y-axis narrows upward from the lower surface 513a. The shape of the recess 55a is similar to... Figure 5B The concave bottoms 37a or 37b of the spool 20 shown are generally similar in shape, but may also be different.

[0177] like Figure 2 As shown, the 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 spool 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 in contact. Alternatively, a gap may be formed along the X-axis between the end faces 531a and 531b of the middle legs 53a and 53b.

[0178] 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 bulging at the bottom. 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. The middle horizontal plane P0 is the midpoint of the vertical distance line connecting the upper horizontal plane P1 (which includes the upper end E1 of the middle foot 53a (53b) along the Z-axis) and the lower horizontal plane P2 (which includes the lower end E2 of the middle foot 53a (53b) along the Z-axis). The middle horizontal plane P0 is the plane containing the central axis (the center along the Z-axis) O of the middle foot 53a (53b).

[0179] 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.

[0180] In this embodiment, CA2 / CA1 is preferably 1.05 to 2.00, more preferably 1.09 to 1.50. Furthermore, V2 / V1 is preferably 1.05 to 2.00, more preferably 1.09 to 1.50. Moreover, OA2 / OA1 is preferably 1.30 to 2.00, more preferably 1.67 to 2.00. By employing these ranges, the device 10 can be made smaller and more compact, while simultaneously improving the heat dissipation of the potting resin.

[0181] Furthermore, in this embodiment, the liquid level S of the potting resin, described later, is a predetermined height T1 lower than the upper end E1 (along the Z-axis) of the middle foot 53a (53b). Therefore, it is possible to achieve the following: Figure 1A The coil assembly 10 of the housing 90 shown is reduced in height.

[0182] In this embodiment, T1 / T0 is preferably 0 to 1 / 3, more preferably 1 / 5 to 1 / 3. By adopting this range, the height of the device 10 can be reduced while improving the heat dissipation of the potting resin. Furthermore, from the viewpoint of improving heat dissipation at the expense of reducing the height, the liquid level P1 of the potting resin can also be located above the upper end E1 of the intermediate foot 53a (53b).

[0183] Furthermore, in this embodiment, it is preferable that the Z-axis position of the upper end E1 of the outer peripheral surface of the middle foot 53a is approximately the same as the Z-axis position of the upper surface 512a of the base 51a, and the upper vertex of the middle foot 53a along the Z-axis is connected to the upper surface 512a of the base 51a without steps. However, the Z-axis position of the upper end E1 of the outer peripheral surface of the middle foot 53a may also be different from the Z-axis position of the upper surface 512a of the base 51a. In addition, the lower portion of the middle foot 53a, including the lower end E2 of the outer peripheral surface, is positioned near the inner peripheral surface 550a of the recess 55a, preferably above the inner peripheral surface 550a, but is not limited thereto.

[0184] like Figure 2 As shown, a pair of feet 52a are arranged at predetermined intervals along the Y-axis and connected to the inner surface 511a of the base 51a. One of the pairs of feet 52a is disposed at one end of the inner surface 511a along the Y-axis, and the other of the pairs of feet 52a is disposed at the other end of the inner surface 511a along the Y-axis.

[0185] like Figure 7 As shown, the inner surface 520a of the outer foot portion 52a bends inward along the Y-axis from the intermediate horizontal plane P0 toward the upper and lower sides of the outer foot portion 52a. Furthermore, the curved portion of the inner surface 520a bends approximately along the outer peripheral surface of the middle foot portion 53a at predetermined intervals. Additionally, the curved portion of the inner surface 520a bends approximately along... Figure 5AThe outer periphery of the flange portion 22a (flange body 220a) of the spool 20 shown is bent.

[0186] Furthermore, along the Y-axis located at... Figure 7 The outer side of the outer foot portion 52a, opposite to the inner side 520a of the outer foot shown, has a plane perpendicular to the Y-axis, and its shape is different from the curved shape of the inner side 520a. Furthermore, on each pair of outer foot portions 52a (52b), a thick-walled portion 56a, thicker in the Y-axis direction than the upper end of the outer foot portion 52a, is formed at the lower end along the Z-axis. The inner side 520a (520b) of the thick-walled portion 56a protrudes inward along the Y-axis, and is a plane perpendicular to the Y-axis.

[0187] In this embodiment, by forming a thick-walled portion 56a in the outer foot portion 52a, the area of ​​the outer foot portion 52 covered by the potting resin can be sufficiently ensured, and a coil device 10 with good inductance characteristics can be obtained.

[0188] In addition, in this embodiment, when each outer leg portion 52a (52b) is divided into an upper outer leg portion OL1 and a lower outer leg portion OL2 by the intermediate horizontal plane P0, the outer leg portion 52a (52b) has a shape in which the volume (OV2) of the lower outer leg portion OL2 is greater than the volume (OV1) of the upper outer leg portion OL1.

[0189] Similar to the middle legs 53a (53b), the outer legs 52a (52b) can also achieve a lower height and smaller size by making the volume of the lower half of the outer legs OL2 larger than the volume of the upper half of the outer legs OL1, while also improving heat dissipation. In addition, the magnetic flux balance is also improved, resulting in enhanced characteristics.

[0190] In this embodiment, OV2 / OV1 is preferably within the same range as V2 / V1 described above, and may be slightly larger than V2 / V1 or smaller than V2 / V1. Furthermore, similar to the middle leg portion 53a (53b), the volume of the outer leg portion may also be replaced by the cross-sectional area of ​​the outer leg portion or the area of ​​its outer peripheral surface.

[0191] like Figure 2 As shown, a pair of outer legs 52a and a middle leg 53a extend along the X-axis from the inner surface 511a for a predetermined length and are disposed on the outside of the winding core 21 of the spool 20. In addition, the middle leg 53a is inserted into the through hole 211 of the spool 20.

[0192] like Figure 5A and Figure 5BAs shown, the spool 20 has a winding core 21 and flanges 22a and 22b. The winding core 21 of the spool 20 extends along the X-axis, and flanges 22a and 22b are formed at both ends of the winding core 21 along the X-axis. At the center of the winding core 21 along the X-axis, protrusions 33 and 34 protruding outward along the Z-axis are formed on opposite sides of the Z-axis.

[0193] Winding the outer peripheral surface of the winding core 21 Figure 2 The wires 41a and 41b shown are used to form coil portions 42a and 42b. Coil portion 42a is... Figure 5A The wound core 21 shown is positioned along the X-axis between the flange 22a and the protrusion 33 (34). Additionally, Figure 2 The coil section 42b shown is in Figure 5A The winding core 21 shown is positioned on the other side of the X-axis between the flange 22b and the protrusion 33 (34).

[0194] like Figure 2 As shown, one end of the coil portion 42a along the winding axis is positioned adjacent to the flange portion 22a, and the other end of the coil portion 42a along the winding axis is positioned adjacent to the protrusions 33 and 34. Similarly, one end of the coil portion 42b along the winding axis is positioned adjacent to the flange portion 22b, and the other end of the coil portion 42b along the winding axis is positioned adjacent to the protrusions 33 and 34.

[0195] like Figure 5B As shown, the wound core 21 is a cylindrical body, and the cross-section of the through hole 211 of the wound core 21 has the same cross-section as... Figure 7 The lower bulge 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. The middle legs 53a and 53b of the cores 50a and 50b can be housed inside the through hole 211 with a predetermined gap (or locally zero) on their outer peripheral surfaces.

[0196] 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 along the X and Y axes (directions), and is situated between the protrusions 33 and 33. The through hole 35 has an opening of approximately elliptical shape with a major axis along the X-axis. The cross-sectional shape of the through hole 35 corresponds to the cross-sectional shape of the intermediate legs 53a and 53b, which can be inserted into the interior of the through hole 35 with a predetermined gap.

[0197] like Figure 5BAs 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 along the X and Y axes, and is situated between the protrusions 34 and 34. The through hole 36 has an opening of approximately elliptical shape with a major axis along the X axis. Along the Z axis, the through hole 36 is formed at the opposite position to the through hole 35.

[0198] By forming through holes 35 and 36 in the winding core 21, the potting resin 210 (refer to) can be potted. Figure 10 Through these through holes 35 and 36, the potting resin 210 can be distributed throughout the housing 90 by circulating inside and outside the spindle 20 (winding core 21).

[0199] 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.

[0200] The flange body 220a is composed of a plate having a predetermined thickness in the X-axis direction 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.

[0201] like Figure 5B As shown, a pair of mounting portions 32a are formed below the flange body 220a, protruding downwards from the 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 on the same plane. The pair of mounting portions 32a are mounted on... Figure 2 The bottom surface 90b of the shell 90 shown.

[0202] like Figure 5BAs 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 spool 20.

[0203] A concave bottom 37a is formed between a pair of mounting portions 32a, and a concave bottom 37b is formed between 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.

[0204] Preferably, the inner circumferential surface shape of the concave bottoms 37a and 37b is similar to... Figure 7 The inner circumferential surface shape of the recess 55a (55b) formed in the core 50a (50b) is corresponding to that of the core 50a (50b), and is substantially the same, but may be larger or smaller. Furthermore, as shown... 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.

[0205] By forming concave bottoms 37a and 37b in the flange bodies 220a and 220b, and filling them with potting resin 210 ( Figure 10 When the concave bottoms 37a and 37b are in use, they function as flow paths for the potting resin 210. The potting resin 210 flows, for example, from the inner (outer) side of the concave bottoms 37a (37b) along the X-axis toward the outer (inner) side, and in particular, it enables the potting resin 310 to be distributed all over the underside of the spool 20.

[0206] From the viewpoint of improving heat dissipation by ensuring good flow of the potting resin in the X-axis direction, the larger the dimensions of the concave bottoms 37a and 37b, the better; however, the dimensions are determined based on a balance with the strength of the mounting portions 32a and 32b. This is for Figure 7 The recess 55a (55b) formed in the core 50a (50b) shown is the same.

[0207] like Figure 5A As shown, protective hook portions 23a and 24a are formed side-by-side along the Y-axis above the flange body 220a. The protective hook portions 23a and 24a are connected to the upper portion of the flange body 220a via protective hook retaining portions 23a1 and 24a1. Core separation walls 25a and 26a are formed in the protective hook retaining portions 23a1 and 24a1. The core separation walls 25a and 26a protrude outwards along the X-axis, facing the protective hook portions 23a and 24a.

[0208] An extended flange portion 27a is formed above the flange body 220a. The extended flange portion 27a is integrally connected to the upper portion of the flange body 220a and extends substantially parallel to the flange body 220a along the YZ plane. That is, the extended flange portion 27a has a shape that extends the flange body 220a upward and constitutes a part of the flange body 220a. The extended flange portion 27a has a predetermined thickness along the X-axis and has a surface substantially parallel to the YZ plane.

[0209] A notch 28a is formed between each of the protective hook portions 23a and 24a. This allows for... Figure 2 The lead portions 43a1 and 43a2 of the conductor 41a shown are inserted into the notch portion 28a. Additionally, it can be inserted between the core separation wall 25a and the protective hook portion 23a. Figure 2 The lead wire portion 43a1 is shown. Additionally, the lead wire portion 43a2 can be inserted between the core separation wall 26a and the protective hook portion 24a.

[0210] In this embodiment, such as Figure 2 As shown, the lead portion 43a1 of the lead portions 43a1 and 43a2 is inserted through. Figure 5A The notch 28a shown extends towards the terminal 61a through the space between the core separation wall 25a and the protective hook portion 23a. Additionally, Figure 2 The lead wire 43a2 shown is inserted through the notch 28a, passes between the core separation wall 26a and the protective hook 24a, and is led out along the outer side of the protective hook 24a along the Y-axis toward the terminal 62a. The lead wires 43a1 and 43a2 are able to ensure good insulation from the core 50a through the core separation walls 25a and 26a.

[0211] like Figure 5A As shown, protective hook portions 23b and 24b are formed side-by-side along the Y-axis above the flange body 220b. The protective hook portions 23b and 24b are connected to the upper portion of the flange body 220b via protective hook retaining portions 23b1 and 24b1. Core separation walls 25b and 26b are formed in the protective hook retaining portions 23b1 and 24b1. The core separation walls 25b and 26b protrude outwards along the X-axis, facing (opposite to) the protective hook portions 23b and 24b.

[0212] An extended flange portion 27b is formed at the upper portion of the flange body 220b. The extended flange portion 27b is integrally connected to the upper portion of the flange body 220b and extends substantially parallel to the flange body 220b along the YZ plane. That is, the extended flange portion 27b has a shape that extends the flange body 220b upward and constitutes a part of the flange body 220b. The extended flange portion 27b has a predetermined thickness along the X-axis and has a surface substantially parallel to the YZ plane.

[0213] A notch 28b is formed between each of the protective hook portions 23b and 24b. A wire 41b can be inserted through the notch 28b. Figure 2 The lead portions 43b1 and 43b2 are respectively. Additionally, lead portion 43b1 can be inserted between core separating wall 25b and protective hook portion 23b. Additionally, lead portion 43b2 can be inserted between core separating wall 26b and protective hook portion 24b.

[0214] In this embodiment, such as Figure 2 As shown, lead wire 43b1 of lead wires 43b1 is inserted through notch 28b, passes between core separating wall 25b and protective hook 23b, and is led out toward terminal 61b. Lead wire 43b2 is inserted through notch 28b, passes between core separating wall 26b and protective hook 24b, wraps around the outer side of protective hook 24b along the Y-axis, and is led out toward terminal 62b. Lead wires 43b1 and 43b2 are well insulated from core 50b by core separating walls 25b and 26b.

[0215] like Figure 6A As 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 in the Z-axis direction, plate-shaped components forming two sides 90c and 90c in the X-axis direction, and plate-shaped components forming two sides 90d and 90d in the Y-axis direction. Along the Z-axis, the upper side has an upper opening 90a. There are gaps between the plate-shaped components on the side surfaces 90c, and there are also gaps between the plate-shaped components between the side surfaces 90c and the bottom surface 90b.

[0216] The housing 90 has a terminal support portion 91. The terminal support portion 91 is disposed on the upper side of a side surface 90d in the Y-axis direction in the Z-axis direction, and protrudes outward along the X-axis from the opening edge 96 of the upper opening 90a. Support through holes 92a, 92b, 93a, 93b, engagement holes 94a, 94b and a central hole 95 are formed in the terminal support portion 91.

[0217] 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 another side 90d of the housing 90 in the Y-axis direction. The opening cover portion 101 of the cover member 100 is connected to the side cover portion 102, covering a portion of the upper side of the upper opening 90a in the Z-axis direction.

[0218] like Figure 2As shown, the terminal block 70 is separately formed from the spool 20 and is 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 be made of the same insulating member as the spool 20, but is more preferably made of an insulating member with excellent formability (or heat resistance or insulation). Similarly, the insulation protection member 80 may also be made of the same insulating member as the spool 20, but is more preferably made of an insulating member with excellent insulation properties. Furthermore, the spool 20 is made of plastics such as PPS, PET, PBT, LCP, or other insulating members (preferably materials with heat resistance).

[0219] 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 in the terminal block base 701 along the X-axis. Fasteners 78a, 78b, 79a, and 79b can be embedded in the fastener mounting holes 71a, 71b, 72a, and 72b, respectively.

[0220] Fasteners 78a, 78b, 79a, and 79b may also be integrally formed with the terminal base 701. Bolts and the like for securing external terminals from circuit boards, etc., are detachably mounted on each of the fasteners 78a, 78b, 79a, and 79b. Fastener mounting holes 71a, 71b, 72a, and 72b extend from the upper surface of the terminal base 701 along the Z-axis to the lower surface.

[0221] 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 along the Z-axis downwards from the upper surface of the terminal base 701. By inserting the mounting claws of the terminal (described later) into the mounting claw holes 73a1–73a4, 73b1–73b4, 74a1–74a4, and 74b1–74b4, the terminal and terminal base 70 can be secured.

[0222] like Figure 9AAs 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 87 is formed such that it is embedded in the terminal separation wall fitting groove 77. Furthermore, a locking notch 76 is formed on the outer surface of the terminal base 701 along the Y-axis, between the fastener mounting holes 72a and 72b. By engaging the locking claw 861 of the intermediate locking portion 86 of the insulation protection member 80 with the locking notch 76, the terminal base 70 and the insulation protection member 80 can be fixed.

[0223] 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.

[0224] 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 4 As shown, the terminal block 70, the insulation protection member 80, and the terminal block support 91 are attached to the lower side along the Z-axis. This allows the terminal block 70, the insulation protection member 80, and the terminal block support 91 to be secured.

[0225] like Figure 2 As shown, the insulation assurance component 80 has an intermediate portion 82 disposed between the terminal base 70 and the terminal base support portion 91, and an insulating sheet portion 81 disposed between the outer legs 52a, 52b of the cores 50a, 50b and the terminals 61a, 61b, 62a, 62b. The intermediate portion 82 and the insulating sheet portion 81 are integrally formed as a sheet along a plane perpendicular to the Z-axis. The intermediate portion 82 is connected to the outer portion of the insulating sheet portion 81 along the Y-axis.

[0226] like Figure 9A As shown, a terminal separation wall 87 extending upward along the Z-axis is formed in the middle portion of the insulation protection component 80 in the X-axis direction. Figure 1A As shown, the terminal separation wall 87 is disposed between terminals 62a and 62b, which can ensure insulation between terminals 62a and 62b when the voltage difference tends to increase.

[0227] As mentioned above, in Figure 9AThe insulation protection component 80 shown has intermediate through holes 85a and 85b in its middle portion 82, through which the engaging protrusions 75a and 75b of the terminal block 70 can be inserted. In addition, as described above, an intermediate engaging portion 86 is formed in the middle portion 82 at a position corresponding to the engaging notch 76 of the terminal block 70.

[0228] In addition, although Figure 9A The image is not shown, but as Figure 9B As shown, a central protrusion 88 protruding downward along the Z-axis is integrally formed at the center position of the lower surface of the middle portion 82 in the X-axis direction. Figure 4 As shown, the central protrusion 88 of the insulation protection component 80 is inserted into the central hole 95 of the terminal support portion 91 to position the insulation protection component 80 and the housing 90.

[0229] like Figure 9B As shown, intermediate protrusions 83a, 83b, 84a, and 84b are formed in the intermediate portion 82 of the insulation protection component 80. The intermediate protrusions 83a, 83b, 84a, and 84b protrude downwards along the Z-axis. Each intermediate protrusion 83a, 83b, 84a, and 84b... Figure 4 The support through holes 92a, 92b, 93a, and 93b of the terminal support portion 91 shown are formed side by side along the X-axis.

[0230] Figure 9B The intermediate protrusions 83a, 83a, 84a, and 84b of the insulation protection component 80 shown can also be inserted into Figure 6A The support through holes 92a, 92b, 93a, and 93b shown are used to align the insulation protection component 80 and the terminal support portion 91.

[0231] like Figure 9B As shown, fixing protrusions 83a2 and 83b2 with a reduced lower end outer diameter in the Z-axis direction can also be formed on the outer peripheral surface of the intermediate protrusions 83a and 83b. By forming such intermediate protrusions 83a and 83b, the intermediate protrusions 83a, 83a, 84a, and 84b of the insulation protection component 80 can be easily positioned and inserted into the corresponding support through holes 92a, 92b, 93a, and 93b. In addition, their connection becomes more secure.

[0232] like Figure 9A As shown, the intermediate protrusions 83a, 83a, 84a, and 84b are respectively formed with receiving recesses 83a1, 83b1, 84a1, and 84b1 that are recessed downward along the Z-axis and open upward. The receiving recesses 83a1, 83b1, 84a1, and 84b1 correspond to the positions of the fastener mounting holes 71a, 71b, 72a, and 72b of the terminal block 70.

[0233] The threaded portions of bolts used to connect external terminals of circuit boards (not shown) to terminals 61a, 61b, 62a, 62b of terminal block 70 are inserted into the respective receiving recesses 83a1, 83b1, 84a1, 84b1. Additionally, the receiving recesses 83a1, 83b1, 84a1, 84b1 can accommodate metal debris and other debris generated during the threaded connection of the bolts (not shown) to fasteners 78a, 78b, 79a, 79b.

[0234] like Figure 1A As shown, terminal 61a has a terminal body 63a and a wiring portion 67a. Terminal 61b has a terminal body 63b and a wiring portion 67b. Terminal 62a has a terminal body 64a and a wiring portion 68a. Terminal 62b has a terminal body 64b and a wiring portion 68b. The structure of terminal 61a will be described below; this description also applies to terminals 61b, 62a, and 62b. Therefore, unless specifically required, the description of the structure of terminals 61b, 62a, and 62b will be omitted.

[0235] Figure 1A As shown, the terminal main portion 63a is mounted on the upper surface along the Z-axis of the terminal base portion 701. A connecting hole 65a and mounting claws 63a1 to 63a4 are formed in the terminal main portion 63a of the terminal 61a. The connecting hole 65a is positioned to... Figure 9A The 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 The mounting claw holes 73a1 to 73a4 shown can be used to fix the terminal 61a to the terminal block 70.

[0236] Figure 1A The terminal main portion 63a shown is connected to the wiring portion 67a along the Y-axis on its 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.

[0237] 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.

[0238] In this embodiment, such as Figure 1AAs 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.

[0239] The coil device 10 of this embodiment can be assembled, for example, as described below.

[0240] First, such as Figure 2 As shown, for example, an automatic winding machine is used to wind wires 41a and 41b onto the winding core 21 of the bobbin 20. Before, during, or simultaneously with this, the mounting claws 63a1 to 63a4 (63b1 to 63b4, 64a1 to 64a4, 64b1 to 64b4) of the terminals 61a (61b, 62a, 62b) are inserted into the mounting claw holes 73a1 to 73a4 (73b1 to 73b4, 74a1 to 74a4, 74b1 to 74b4), and the terminals 61a (61b, 62a, 62b) are mounted on the terminal block 70.

[0241] Next, the lead wires 43a1 (43a2, 43b1, 43b2) are temporarily fixed between the wiring portions 67a (67b, 68a, 68b) of terminals 61a (61b, 62a, 62b) and the foldback tabs 67a1 (67b1, 68a1, 68b1). Then, electrodes are used to press the wiring portions 67a (67b, 68a, 68b) from above along the Z-axis, and other electrodes are used to press the foldback tabs 67a1 (67b1, 68a1, 68b1) from below along the Z-axis. Voltage is applied between the electrodes, thereby electrically and mechanically connecting the terminals 61a (61b, 62a, 62b) and the lead wires 43a1 (43a2, 43b1, 43b2) by welding.

[0242] In this embodiment, during welding, there are no components above or below the Z-axis direction of the wiring portions 67a (67b, 68a, 68b), and the wiring portions 67a (67b, 68a, 68b) and the foldback pieces 67a1 (67b1, 68a1, 68b1) can be pressed from above and below by electrodes.

[0243] Next, the insulation protection component 80 is installed on the terminal block 70. Prior to this, fasteners 78a, 78b, 79a, and 79b are installed on the terminal block 70. When installing the insulation protection component 80 on the terminal block 70, as follows... Figure 9A As shown, the engaging claw 861 of the intermediate engaging portion 86 engages with the engaging notch 76, so that the terminal separating wall 87 is fitted into the terminal separating wall fitting groove 77.

[0244] Next, as Figure 2As shown, the middle legs 53a and 53b of the cores 50a and 50b are inserted into the through hole 21 of the spool 20, and the spool 20 and the cores 50a and 50b are fixed with, for example, an adhesive. A thermosetting adhesive can be used as the adhesive.

[0245] Next, the spool 20, in which the cores 50a and 50b are assembled, is housed in a housing 90 pre-filled (or injected with) potting resin (a resin with excellent heat dissipation). At this time, as... Figure 4 As shown, the insulation protection component 80, on which the terminal block 70 is mounted, is installed on the terminal block support 91. Alternatively, potting resin can be injected through the opening 90a after the spool 20 and cores 50a and 50b are housed in the housing 90.

[0246] When the insulation protection component 80, on which the terminal block 70 is mounted, is installed on the terminal block support 91, the intermediate protrusions 83a (83b, 84a, 84b) are inserted into the support through holes 92a (92b, 93a, 93b). Additionally, the central protrusion 88 is inserted into the central hole 95. Furthermore, the engaging protrusions 75a and 75b are inserted into the intermediate through holes 85a and 85b, and the claws formed on the engaging protrusions 75a and 75b are engaged with the terminal block support 91. Thus, the terminal block 70 and the insulation protection component 80 are fixed to the terminal block support 91.

[0247] After the spool 20 is housed in the housing 90, as Figure 2 As shown, the cover component 100 of the bent housing 90 forms Figure 1A The opening mask portion 101 is shown. By forming the opening mask portion 101 in this way, it is not necessary to form the cover component 100 and the housing 90 separately for installation, which simplifies assembly.

[0248] In this embodiment, such as Figure 2 As shown, in the coil device 10, the bobbin 20 is positioned inside the housing 90 such that the winding axis C of the wires 41a and 41b is substantially parallel to the bottom surface 90b of the housing 90. That is, the coil device 10 of this embodiment is a horizontal coil device, and is also substantially parallel to the mounting surface of the coil device 10 or the mounting surface of the mounting substrate (not shown). Compared to vertical coil devices where the winding axis of the wires 41a and 41b is substantially perpendicular to the bottom surface 90b of the housing 90, this coil device 10 can be easily made to have a lower height.

[0249] In addition, such as Figure 1AAs shown, in the coil device 10 of this embodiment, the terminal block 70 is supported on a terminal block support 91 that protrudes outward along the Y-axis from the opening edge 96 of the upper opening 90a of the housing 90. Therefore, it is not necessary to increase the installation area of ​​the housing 90 corresponding to the area of ​​the terminal block 70, and the installation area of ​​the housing 90 can be reduced while maintaining a horizontal orientation. Moreover, compared with the case where the terminal blocks are provided on both sides in the X-axis direction, the installation area of ​​the housing in the X-axis direction can also be reduced.

[0250] Furthermore, since the terminal support portion 91, formed by extending the outer wall of the housing 90, supports the terminal base 70, the strength and reliability of the terminal base 70 can be improved. In particular, when connecting the terminals 61a, 61b, 62a, 62b of the terminal base 70 of the coil device 10 to a substrate (not shown) disposed on the coil device 10, the terminal support portion 91 strengthens the terminal base 70, thus making the connection to the substrate easier and improving reliability.

[0251] In addition, in this embodiment, such as Figure 2 As shown, in the terminal block 70, a plurality of terminals 61a, 62a, 61b, and 62b are arranged substantially parallel to the winding shaft C of the wires 41a and 41b. By adopting such a structure, the terminals 61a, 62a, 61b, and 62b that connect to the lead portions 43a1, 43a2, 43b1, and 43b2 can be easily arranged in a straight line along the opening edge 96 of the housing 90 in one or more rows, and the connection between each terminal and the substrate (circuit board) becomes easier.

[0252] In addition, such as Figure 10 As shown, by filling the interior of the housing 90 with a heat-dissipating resin (potting resin 210) or similar operations, heat from the wires 42, 44 or the spool 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.

[0253] In addition, such as Figure 1A As shown, because the terminal block 70 is supported on the terminal block support portion 91 that protrudes outward from the opening edge 96 of the upper opening 90a of the housing 90, the terminal block 70 allows a large portion of the spool 20 (including the wires and core) with the winding axis of at least the wires 41a and 41b to contact the potting resin 210 inside the housing 90 without obstruction. Therefore, heat dissipation can be effectively improved using the minimum amount of potting resin required.

[0254] 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 10As shown, the position adjustment part 97a (97b) protrudes inward along the Y-axis inside the housing 90.

[0255] When the spool 20 and cores 50a and 50b are housed in the housing 90, they may be pressed against the side surface 90d of the housing 90 on the side opposite to the terminal block 70 in the Y-axis direction due to the elasticity of the lead portion of the wire. By abutting the position adjustment portion 97a (97b) against the outer foot portion 52a (52b) of the core 50a (50b), a gap can be formed between the side surface 90d and the core 50a for the potting resin 210 to enter.

[0256] 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 with an insulation protection member 80 in between. Therefore, after winding the wires 41a and 41b on the spool 20 and mounting the terminals 61a, 61b, 62a, and 62b on the terminal base 70, 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 go 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 can be appropriately performed, for example, by heat-pressing such as fusion welding.

[0257] 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 heat-pressing clamps 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 onto the terminal block 70, it is easy to press heat-pressing clamps or the like from both sides of the lead portions 43a1, 43a2, 43b1, 43b2.

[0258] Furthermore, after the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 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 wires 41a and 41b. Therefore, the insulation between the connection portions 67a, 67b, 68a, and 68b and the cores 50a and 50b mounted on the spool 20 can be effectively ensured.

[0259] 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 from the housing 90.

[0260] 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 spool 20.

[0261] By employing this structure, the insulation ensuring component 80 can 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 outer feet 52a, 52b of the cores 50a, 50b mounted on the spool 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.

[0262] 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 9A As shown, the insulation protection component 80 has an intermediate engagement portion 86 that engages with the terminal block 70, and the intermediate engagement portion 86 has engagement claws 861. By engaging the terminal block 70 with the intermediate engagement portion 86, installation can be easily performed while positioning the terminal block 70 and the insulation protection component 80. Furthermore, the terminal block 70 and the insulation protection component 80 can be fixed without the use of adhesive. However, adhesive can also be used.

[0263] like Figure 4 As shown, in this embodiment, the intermediate portion 82 has intermediate protrusions 83a, 83b, 84a, 84b that enter the support through holes 92a, 92b, 93a, 93b formed in the terminal support portion 91. By allowing the intermediate protrusions 83a, 83b, 84a, 84b to enter the support through holes 92a, 92b, 93a, 93b, the positioning of the insulation assurance component 80 and the terminal support portion 91 becomes easier.

[0264] like Figure 9AAs 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 can accommodate metal debris and other debris generated during the threading of the terminals 61a, 61b, 62a, and 62b, which are mechanically and electrically connected to the substrate. The threaded portions of terminals 61a, 61b, 62a, and 62b (not shown) that are mounted to the terminal block on an external terminal of a circuit board are inserted into the receiving recesses 83a1, 83b1, 84a1, and 84b1.

[0265] 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 engage with the engaging holes 94a and 94b formed in the terminal support portion 91 through the intermediate through hole in the middle portion.

[0266] With this structure, the terminal block 70 and the insulation protection component 80 can be easily positioned, and their installation can be performed simultaneously with the positioning of the terminal block 70 and the terminal block support 91. 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.

[0267] like Figure 1A As shown, the housing 90 has a cover member 100. The cover member 100 has an opening portion 101 that... Figure 3 The 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 spool 20 from the upper opening 90a of the housing 90, and greater than the protrusion height of the protective hooks 23a, 23b, 24a, 24b.

[0268] By covering a portion of the upper opening 90a of the housing 90 with the opening part 101 at a predetermined gap H1, 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 is possible to effectively prevent the protrusions from the substrate, the substrate itself, etc., from contacting the protrusions of the cores 50a and 50b, and the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b, thus preventing them from being damaged.

[0269] like Figure 3As shown, in this embodiment, the cover member 100 covers at least a portion of the wire 44 (41) wound on the spool 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 from metal or the like, the effect of shielding against leakage magnetic flux from the winding portion (coil portion) of the wires 41a and 41b is improved.

[0270] like Figure 3 As shown, in this embodiment, the cover member 100 and the housing 90 are integrally formed. By bending a metal plate or the like integrally with the housing 90 to form the cover member 100, the manufacturing of both 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 bending a metal plate or the like integrally with the housing 90 to form the terminal support portion 91, the manufacturing of both the terminal support portion 91 and the housing 90 becomes easier.

[0271] like Figure 5A As shown, in this embodiment, the spool 20 has a winding core 21 for winding a conductor and flanges 22a and 22b mounted on the ends of the winding core 21. Additionally, the flanges 22a and 22b have protective hooks 23a, 23b, 24a, and 24b.

[0272] Protective hooks 23a, 23b, 24a, and 24b protrude upwards from the upper opening 90a of the housing 90, as... Figure 1A As 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 can be easily guided to the terminals 61a, 61b, 62a, and 62b mounted on the terminal block 70.

[0273] like Figure 3As shown, in this embodiment, the protective hooks 23a, 23b, 24a, 24b (upper surfaces) are on the same plane as or higher than the upper surfaces of the terminals 61a, 61b, 62a, 62b by a height h1. Furthermore, the wiring portions 67a, 67b, 68a, 68b of the terminals 61a, 61b, 62a, 62b to which the lead portions 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b are connected are positioned at a height h2 lower than the upper surfaces of the terminals. With this configuration, the protective hooks 23a, 23b, 24a, 24b can effectively protect the wiring portions 67a, 67b, 68a, 68b, and can effectively prevent contact between the wiring portions 67a, 67b, 68a, 68b and any protrusions from a substrate (not shown) or the substrate itself.

[0274] 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, together with the protective hook portions 23a, 23b, 24a, and 24b, protects the wiring portions 67a, 67b, 68a, and 68b, effectively preventing contact between the protrusions from the substrate (circuit board) or the substrate itself and the wiring portions 67a, 67b, 68a, and 68b.

[0275] Furthermore, in this embodiment, Figure 1A The cover component 100 shown can also function as a cooling mechanism. By making the cover component 100 function as a heat sink, or by making the cover component 100 contact with other cooling mechanisms, heat can be released from the heat-dissipating resin inside the housing 90 to the outside through the cover component 100.

[0276] Furthermore, in this embodiment, since the middle leg portion 53a (53b) of the core 50a (50b) has the above-described relationship, compared with a coil device having a core with a typical middle leg shape (the upper and lower halves are the same), it is possible to further reduce the height and miniaturize the coil, while also improving heat dissipation.

[0277] The interior of the housing 90 is filled with a heat-dissipating resin such as potting resin to cool the cores 50a (50b) and wires 41a and 41b mounted on the spool 20. However, from the viewpoint of minimizing height, the height of the housing 90 is limited to the minimum required. Therefore, as Figure 7 As shown, the liquid level S of the heat-dissipating resin housed inside the housing 90 must be lower than the upper horizontal plane P1 of the upper end E1 of the middle leg portion 53a (53b) containing the core 50a (50b). Therefore, a portion of the upper end of the core portion E1 containing the middle leg portion 53a (53b) (including the coil / hereinafter the same) is not in contact with the heat-dissipating resin.

[0278] In the coil device 10 of the present invention, because of the above-described structure, the cross-sectional area, volume, and / or the area of ​​the outer peripheral surface of the core 50a (50b) in the portion not in contact with the heat-dissipating resin can be minimized. Furthermore, the cross-sectional area, volume, and / or the area of ​​the outer peripheral surface of the core 50a (50b) in the portion in contact with the heat-dissipating resin can also be minimized. Therefore, in the coil device 10 of this embodiment, compared to a coil device having a core with a typical center leg shape (the upper and lower halves are the same), it is possible to further achieve lower height and miniaturization, while simultaneously improving heat dissipation.

[0279] In addition, in this embodiment, such as Figure 7 As shown, the upper ends of the outer legs 52a (52b), i.e., the upper surfaces 522a (522b) of the outer legs, and the upper ends E1 of the middle legs 53a (53b) have substantially the same height. By adopting this structure, the magnetic flux balance is improved, and the characteristics are enhanced.

[0280] Furthermore, in this embodiment, the lower end E2 of the middle foot 53a (53b) is located above the lower end of the outer foot 52a (52b), i.e., the upper surface 523a (523b) of the outer foot. Figure 10 As shown, the gap is formed because the conductor 41a (41b) is wound around the middle foot 53a (53b) through the winding core 21 of the spool.

[0281] In addition, such as Figure 7 As shown, in this embodiment, a lower recess (notch) 55a (55b) is formed in the base 51a (51b) located below the middle foot 53a (53b). Heat-dissipating resins such as potting resin can easily enter the axial center of the core 50a (50b) near the bottom 90b of the housing 90 through the recess 55a (55b), thus improving heat dissipation.

[0282] Furthermore, in this embodiment, similar to the middle leg portion 53a (53b), the outer leg portion 52a (52b) is also configured such that the volume of the lower half of the outer leg portion OL2 is larger than the volume of the upper half of the outer leg portion OL1, thereby achieving a lower height and miniaturization, while also improving heat dissipation. In addition, the magnetic flux balance is also improved, resulting in enhanced characteristics.

[0283] Second Implementation Method

[0284] like Figure 1B , Figure 6B and Figure 6CAs 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 component 200, and can be expected to have the same effect. In the following description, the description of the parts common to the first embodiment is omitted.

[0285] 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.

[0286] On the upper side of the two opposite sides 90c, 90c in the Z-axis direction of the housing 190, a pair of locking tabs 90c1 and 90c2 are integrally formed. Locking holes 198a and 198b are formed on each locking tab 90c1 and 90c2 respectively.

[0287] 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 by protruding downward along the Z-axis from one end of the opening cover portion 201 in the Y-axis direction. Figure 1B As shown, the side cover portion 202 can also be configured such that the side cover portion 202 has an outer surface that is approximately perpendicular to the Y-axis, and the outer surface of the side cover portion 202 is approximately in the same plane as the side surface 90d of the housing 90, or is located inward of the side surface 90d, or protrudes slightly.

[0288] The cover support portions 203 and 203, which protrude downwards along the Z-axis from both ends of the cover portion 201 in the X-axis direction, have the same shape.

[0289] In each cover support portion 203, a locking piece 204 with an engaging protrusion at its front end is formed to extend 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 in a manner that protrudes outward along the X-axis. The cover support portion 203 is cut out at the upper side in the Z-axis direction and on both sides in the Y-axis direction of the locking piece 204 to form an inverted U-shaped groove.

[0290] 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 elastically move 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 and the housing 190.

[0291] Furthermore, each cover support portion 203 has a wide portion with an opening 206 extending through its surface and back surface on both sides of the inverted U-shaped groove in the Y-axis direction. A cover mounting portion 205 is formed on the lower side of the wide portion of each cover support portion 203 in the Z-axis direction, and a notch recessed from bottom to top is formed approximately at the center of the cover mounting portion 205 in the Y-axis direction.

[0292] Including the notch, the opening 206 and the U-shaped groove both 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 separate from the housing 190, the cover member does not become an obstacle when storing a spool or the like with the coil wound inside the housing 190. Furthermore, there is no need to perform the operation of bending the cover member into shape on the housing.

[0293] Third Implementation Method

[0294] like Figure 11 As shown, the coil device of this embodiment includes a bobbin 120, terminals 161a, 162a, 161b, 162b, a terminal block 170, and an insulating cover 180 provided as needed. Except that the terminal block 170 can be mounted on the bobbin 120 in a one-touch manner, it is the same as in the first embodiment. In the following description, the description of parts common to the first embodiment is omitted.

[0295] like Figure 11 As shown, the spool 120 has a terminal block fixing portion 123a (123b) above the flange portions 122a and 122b on both sides in the Z-axis direction. A locking recess 124a (124b) is formed further above the terminal block fixing portion 123a (123b) along the Z-axis. Additionally, a fixing protrusion 130a (130b) is formed on the terminal block fixing portion 123a (123b).

[0296] Furthermore, the terminal block 170 has arm portions 172a (172b) at both ends along the X-axis, each arm having a hook portion 173a (173b) that engages with the engaging recess 124a (124b). Additionally, the terminal block 170 has a fixing recess 175a (175b) with a shape corresponding to the fixing protrusion 130a (130b). Furthermore, step portions 174a (174b) are formed at both ends of the terminal block 170 along the X-axis. The lower surface 174a1 (174b1) of the step portion 174a (174b) is formed as a lower surface in the Z-axis direction supporting the terminal block fixing portion 123a (123b) below.

[0297] In this embodiment, the engaging recess 124a (124b) and the arm portion 172a (172b) are fitted together, the fixing protrusion 130a (130b) and the fixing recess 175a (175b) are combined, and the lower surface of the step 174a1 (174b1) extends from the lower surface of the lower supporting terminal base fixing portion 123a (123b) in the Z-axis direction, thereby fixing the terminal base 170 to the spool 120.

[0298] Additionally, the terminal cover (corresponding to the insulation protection component) 180 has a terminal cover bottom 181, which ensures insulation between the terminals 161a, 162a, 161b, 162b mounted on the terminal block 170 and the housing (not shown). Furthermore, terminal cover sides 183a and 183b are formed on the outer side of the terminal cover 180 along the Y-axis.

[0299] In addition, in this embodiment, a holding portion 184 is formed in the terminal cover 180. The terminal cover 180 is fixed to the terminal base 170 by the upper arm 184a and the lower arm 184b of the holding portion 184 gripping the terminal cover mounting portion 178 of the terminal base 170 from above and below along the Z-axis.

[0300] By adopting such a structure, the terminals 161a, 162a, 161b, 162b that are connected to the lead portions of the multiple wires wound on the spool 120 can be easily arranged in a straight line along the opening edge of the housing in one or more rows, and the connection between each terminal and the substrate becomes easier.

[0301] Furthermore, the terminal block 170 can be arranged in a straight line along the X-axis on only one side of the opening edge of the housing, or it can be arranged in a split configuration on both sides of the housing in the Y-axis direction. For example, a terminal block with two terminals arranged on one side can be arranged on the other side, and a terminal block with two other terminals arranged on the other side can be arranged on the other side.

[0302] 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.

[0303] For example, the heat-dissipating resin is not limited to potting resin, but can also be other resins with excellent heat dissipation properties. Preferably, the heat-dissipating resin is composed of, for example, silicone resin, polyurethane resin, epoxy resin, etc., which remain soft after injection. 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. Furthermore, to improve heat dissipation, fillers with high thermal conductivity can be added to the resin.

[0304] Moreover, in the first or second embodiment described above, such as Figure 6A or Figure 6BAs shown, the terminal support portion 91 is formed only at one location on one side of the upper opening 90a of the housing 90 or 190 in the Y-axis direction, but it is not limited thereto. For example, it can also be formed in the same manner as in the embodiment described above. Figure 6A or Figure 6B Multiple terminal support portions 91 are 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, in addition to the aforementioned terminal support portions 91, another terminal support portion may be formed at any location of the upper opening 90a of the housing 90 or 190 facing outward from the opening, and multiple terminal support portions 91 may be formed in the same manner as in the embodiment described above.

[0305] In summary, when the housing forms multiple terminal support portions, multiple corresponding terminal support portions can also be prepared. Figure 9A The terminal block 70 and insulation protection component 80 are shown and are installed on each terminal block support.

[0306] Furthermore, cores 50a and 50b are not limited to E-type cores; they can also be combinations of E-type cores, combinations of E-type cores and I-type cores, or combinations of cores of other shapes. In short, each core 50a and 50b has at least a middle leg 53a and 53b that is inserted into the shaft hole 211 of the winding core 21 of the bobbin 20.

Claims

1. A coil arrangement, characterized by Having: A spool having a winding core for winding a wire; A core having a middle leg portion inserted into a shaft hole of the winding core; and A case that houses the spool on which the core is mounted, The spool is arranged inside the case in a manner that the winding axis of the wire is substantially parallel to the bottom surface of the case, The middle leg portion has a cross-sectional shape in which, in the case where the middle leg portion is divided into an upper half portion and a lower half portion by an intermediate horizontal plane, the area of the cross section of the lower half portion (CA2) is larger than the area of the cross section of the upper half portion (CA1), wherein the intermediate horizontal plane is a horizontal plane passing through the midpoint of a perpendicular line connecting between an upper horizontal plane including the upper end of the middle leg portion and a lower horizontal plane including the lower end of the middle leg portion at the shortest distance, The core has a base portion that links the root end portion of the middle leg portion, and an outer leg portion that is arranged on both sides of the middle leg portion in connection with the base portion, The outer leg inner side surface of the outer leg portion is curved along the outer peripheral surface of the middle leg portion across the intermediate horizontal plane in the up-down direction, The width of the end portion on the lower side of the outer leg portion is wider than the end portion on the upper side along a first axis perpendicular to the winding axis, The outer leg upper surface of the outer leg portion and the upper end of the middle leg portion are arranged at substantially the same height.

2. A coil arrangement, characterized by Having: A spool having a winding core for winding a wire; A core having a middle leg portion inserted into a shaft hole of the winding core; and A case that houses the spool on which the core is mounted, The spool is arranged inside the case in a manner that the winding axis of the wire is substantially parallel to the bottom surface of the case, The middle leg portion has a shape in which, in the case where the middle leg portion is divided into an upper half portion and a lower half portion by an intermediate horizontal plane, the volume of the lower half portion (V2) is larger than the volume of the upper half portion (V1), wherein the intermediate horizontal plane is a horizontal plane passing through the midpoint of a perpendicular line connecting between an upper horizontal plane including the upper end of the middle leg portion and a lower horizontal plane including the lower end of the middle leg portion at the shortest distance, The core has a base portion that links the root end portion of the middle leg portion, and an outer leg portion that is arranged on both sides of the middle leg portion in connection with the base portion, The outer leg inner side surface of the outer leg portion is curved along the outer peripheral surface of the middle leg portion across the intermediate horizontal plane in the up-down direction, The width of the end portion on the lower side of the outer leg portion is wider than the end portion on the upper side along a first axis perpendicular to the winding axis, The outer leg upper surface of the outer leg portion and the upper end of the middle leg portion are arranged at substantially the same height.

3. A coil arrangement, characterized by Having: A spool having a winding core for winding a wire; A core having a middle leg portion inserted into a shaft hole of the winding core; and A case that houses the spool on which the core is mounted, The spool is arranged inside the case in a manner that the winding axis of the wire is substantially parallel to the bottom surface of the case, The middle leg portion has a shape in which, in the case where the middle leg portion is divided into an upper half portion and a lower half portion by an intermediate horizontal plane, the area of the outer peripheral surface of the lower half portion (OA2) is larger than the area of the outer peripheral surface of the upper half portion (OA1), wherein the intermediate horizontal plane is a horizontal plane passing through a midpoint of a perpendicular line connecting an upper horizontal plane including the upper end of the middle leg portion and a lower horizontal plane including the lower end of the middle leg portion at the shortest distance therebetween, the core has a base portion connecting root end portions of the middle leg portions, and outer leg portions disposed on both sides of the middle leg portions in connection with the base portion, an outer leg inner side surface of the outer leg portion is curved along an outer peripheral surface of the middle leg portion across the intermediate horizontal plane in the vertical direction, an end portion on the lower side of the outer leg portion is wider than an end portion on the upper side in a width along a first axis perpendicular to the winding axis, an outer leg upper surface of the outer leg portion and the upper end of the middle leg portion are disposed at substantially the same height.

4. The coil device according to any one of claims 1 to 3, characterized in that: the upper end of the outer leg portion and the upper end of the middle leg portion have substantially the same height, the lower end of the middle leg portion is located higher than the lower end of the outer leg portion, a notch is formed in the base portion below the middle leg portion.

5. The coil device according to any one of claims 1 to 3, characterized in that: each of the outer leg portions has a shape in which, in a case where the outer leg portion is divided into an outer leg upper half portion and an outer leg lower half portion with the intermediate horizontal plane, a volume (OV2) of the outer leg lower half portion is larger than a volume (OV1) of the outer leg upper half portion.

6. The coil device according to any one of claims 1 to 3, characterized in that: a thermally conductive resin can be filled in an interior of the housing.

7. The coil device according to claim 6, characterized in that: a height from a surface of the thermally conductive resin to an upper horizontal plane including the upper end of the middle leg portion is 1 / 5 to 1 / 3 of a distance between the upper horizontal plane including the upper end of the middle leg portion and a lower horizontal plane including the lower end of the middle leg portion.

8. The coil device according to any one of claims 1 to 3, characterized in that: a cover member covering a portion of an upper opening of the housing with a prescribed gap is provided in the housing, the cover member covers at least a portion of the wire wound on the bobbin housed in the interior of the housing.

9. The coil device according to claim 8, characterized in that: the cover member is integrally formed with the housing.

10. The coil device according to any one of claims 1 to 3, characterized in that: the housing has a terminal seat support portion protruding outward from an edge of an upper opening of the housing, a terminal seat is disposed on the terminal seat support portion.

11. The coil device according to claim 10, characterized in that: a plurality of terminals are disposed on the terminal seat substantially in parallel with a winding axis of the wire.

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