Coil arrangement

Abstract

A coil device is provided which is small and thin. A coil device (10) has a coil (41 and 42), a bobbin (20) having a winding core portion (21) for arranging the coil (41 and 42), a flange portion (22a) formed at an end portion of the winding core portion (21) in an axial direction, and a first upper side protruding portion (31) protruding from the flange portion (22a), and a magnetic core (50v) mounted to the bobbin (20). The winding core portion (21) is arranged so that an axial core thereof is substantially parallel to a mounting surface. The magnetic core (50v) has a recessed portion (54) recessed in a direction substantially perpendicular to the mounting surface and capable of accommodating the first upper side protruding portion (31).

Description

Technical Field

[0001] This invention relates to coil devices used as transformers and the like. Background Technology

[0002] As a coil device used in transformers, etc., a coil device with the structure shown in Patent Document 1 is known, for example. The coil device described in Patent Document 1 has a spool and a magnetic core mounted on the spool. The spool has a core portion on which a first coil and a second coil are wound, and a flange portion provided at the axial end of the core portion. The core portion is arranged substantially parallel to the mounting surface, thereby achieving a thinner coil device.

[0003] Furthermore, the lower end of the flange bends (protrudes) axially outward, functioning as a terminal block. This protrusion extends significantly outward (below) the magnetic core. Therefore, in the coil device described in Patent Document 1, the increased vertical length of the flange and the increased protrusion of the protrusion make it difficult to fully achieve miniaturization and thinning of the coil device.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 11-111534 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] The present invention was made in view of the actual situation, and its object is to provide a small coil device with a low back.

[0009] Methods for solving problems

[0010] To achieve the above objectives, the coil device of the present invention includes:

[0011] coil;

[0012] A bobbin has a core portion for arranging the coil, a flange portion formed at an axial end of the core portion, and a protrusion extending from the flange portion; and

[0013] The magnetic core, which is mounted on the spool,

[0014] The shaft core of the winding core is arranged approximately parallel to the mounting surface.

[0015] The magnetic core has a recess that is recessed in a direction substantially perpendicular to the mounting surface and is capable of accommodating the protrusion.

[0016] In the coil device of the present invention, a recess is formed in the magnetic core, which is recessed in a direction substantially perpendicular to the mounting surface. Therefore, when the magnetic core is mounted on the spool, the protrusion is accommodated inside the recess, and the protrusion does not significantly protrude outward from the magnetic core. That is, in the coil device of the present invention, the amount of protrusion of the protrusion can be absorbed by the recess of the magnetic core, so the vertical length of the flange does not increase the amount of protrusion. Therefore, the coil device can be sufficiently miniaturized and thinned. In addition, in the coil device of the present invention, since the core of the winding portion is arranged substantially parallel to the mounting surface, further miniaturization and thinning of the coil device can be achieved.

[0017] Preferably, the protrusion has a bottom surface shape that follows the shape of the inner surface of the recess. By employing such a structure, the recess includes a shape adapted to accommodate the protrusion, or a shape specifically designed to accommodate the protrusion. Therefore, most of the protrusion can be accommodated within the recess, effectively enabling miniaturization and thinning of the coil device.

[0018] Preferably, the magnetic core has an outer leg extending axially along the core portion on its side, the upper surface of which is located above the bottom of the protrusion and protrudes in a direction substantially perpendicular to the mounting surface. This prevents the protrusion from protruding significantly from the upper surface of the outer leg, effectively achieving miniaturization and thinning of the coil device. Furthermore, the larger vertical length of the outer leg enhances the magnetic properties of the coil device.

[0019] Preferably, the device has a housing that accommodates the spool and the magnetic core, the interior of which is filled with a heat-dissipating resin, and the upper surface of the outer leg protrudes from the surface of the heat-dissipating resin filling the interior of the housing. With this structure, heat can be efficiently dissipated from the spool and the magnetic core via the heat-dissipating resin. Furthermore, the more the upper surface of the outer leg protrudes from the surface of the heat-dissipating resin, the more adequately the vertical length of the outer leg is ensured, thereby further improving the magnetic characteristics of the coil device.

[0020] Preferably, the magnetic core has a central foot disposed inside the winding core portion, a hole is formed on the outer peripheral surface of the winding core portion, and the heat-dissipating resin is filled between the central foot and the winding core portion. By employing this structure, heat from the magnetic core and the like can be efficiently dissipated via the heat-dissipating resin filled between the central foot and the winding core portion.

[0021] Preferably, the lead-out portion of the coil extends from the axial end of the core portion toward the protrusion through the interior of the recess, reverses inside the recess, and extends from the protrusion toward the axial end of the core portion. By extending and reversing the lead-out portion inside the recess, significant protrusion of the lead-out portion toward the outside of the magnetic core can be prevented, enabling a thinner coil assembly. Furthermore, by reversing the lead-out portion along the axial direction of the core portion from the first direction to the second direction and converging the lead-out portion at the second direction end of the spool, space-saving measures for the lead-out portion arrangement can be achieved, thereby enabling a smaller and thinner coil assembly. Additionally, unnecessary or difficult winding of the lead-out portion on the mounting substrate can be avoided, facilitating the winding of the lead-out portion.

[0022] Preferably, the lead-out portion of the coil extends from the axial end of the core portion toward the protrusion, and the protrusion has a guide path that reverses the lead-out direction of the coil lead-out portion. By guiding the lead-out portion to the guide path, the lead-out portion can be reversed from the first direction to the second direction along the axial direction of the core portion, thereby converging the lead-out portion at the second direction end of the spool. This allows for space-saving of the lead-out portion configuration space, and further enables miniaturization and thinning of the coil device.

[0023] Preferably, the protrusion has: a lower protrusion disposed at the lower part of the spool; and an upper protrusion disposed at the upper part of the spool, the upper protrusion having the guide path, and the lower protrusion having a heat sink. With this structure, heat can be efficiently dissipated from the spool and the like via the heat sink. Furthermore, since the protrusion (lower protrusion) can be accommodated within the recess, the enlargement of the coil assembly associated with the heat sink is prevented.

[0024] Preferably, the flange portion has a first flange portion formed at a first axial end of the winding core portion and a second flange portion formed at a second axial end of the winding core portion; the magnetic core has a first magnetic core and a second magnetic core combined with each other; the coil has a first coil disposed radially outside the winding core portion and a second coil disposed radially outside the first coil; the protrusion portion has a first protrusion portion protruding from the first flange portion and a second protrusion portion protruding from the second flange portion; the first lead-out portion of the first coil is led out to the second protrusion portion via the first protrusion portion; and the second lead-out portion of the second coil is led out to the second protrusion portion without passing through the first protrusion portion.

[0025] By adopting this structure, the first lead and the second lead can be converged on one side of the axial direction of the spool, saving space in the arrangement of the first and second leads, thereby achieving miniaturization and thinning of the coil device. Furthermore, by pulling the first lead towards the second protrusion via the first protrusion, defects such as loosening of the first lead can be prevented. As a result, the first lead can be drawn towards the second protrusion at a lower position (near the outer peripheral surface of the second coil), effectively achieving thinning of the coil device.

[0026] Preferably, the first protrusion has a first guide path that reverses the lead-out direction of the first lead-out portion of the first coil, and the second protrusion has a lead-out groove through which the first lead-out portion and the second lead-out portion pass. With this structure, the first pull-out portion, pulled from the first end of the core portion toward the first protrusion, can be reversed along the first guide path and pulled toward the second protrusion. Furthermore, by having the first lead-out portion and the second lead-out portion pass through the lead-out groove, effects such as fixing the positions of the first lead-out portion and the second lead-out portion and preventing them from contacting each other can be achieved.

[0027] Preferably, the first lead-out portion extends from the first protrusion to the second protrusion through the radially outer side of the second coil, and the passage area of ​​the first lead-out portion is formed radially inward beyond the upper end of the outer peripheral surface of the second coil and radially inward beyond the side end of the outer peripheral surface of the second coil. In this configuration, the first lead-out portion passes near the outer peripheral surface of the second coil. Therefore, it is possible to prevent the first lead-out portion from protruding significantly outward from the magnetic core, achieving a thinner coil assembly.

[0028] Preferably, the first coil has a first single-layer region formed in a single layer along its radial direction and a first multi-layer region formed in multiple layers along its radial direction, and the second coil has a second single-layer region formed in a single layer along its radial direction and a second multi-layer region formed in multiple layers along its radial direction, wherein the first single-layer region and the second single-layer region are stacked radially along the core portion at predetermined positions along the axial direction of the core portion. In this way, by stacking the first single-layer region and the second single-layer region, the leakage of the first coil and the second coil can be adjusted according to their stacking arrangement. Therefore, for example, when the coil assembly is used as a leakage transformer, the magnetic characteristics of the coil assembly can be improved. Furthermore, by stacking the first single-layer region and the second single-layer region, the number of layers of the first coil and the second coil can be minimized, effectively achieving miniaturization and thinning of the coil assembly. Attached Figure Description

[0029] Figure 1 This is a perspective view of a coil device according to one embodiment of the present invention.

[0030] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0031] Figure 3A yes Figure 2 A three-dimensional view of the spool shown.

[0032] Figure 3B It is a different perspective. Figure 3A A three-dimensional view of the spool shown.

[0033] Figure 4A Is Figure 2 A three-dimensional view of the first coil wound on the bobbin shown.

[0034] Figure 4B Is Figure 4A A three-dimensional view of the second coil being further wound onto the spool shown.

[0035] Figure 5 It involves winding the first coil and the second coil together. Figure 2 The side view of the spool shown.

[0036] Figure 6 It is along Figure 1 A cross-sectional view of the coil assembly along line VI-VI (the housing is omitted from the diagram).

[0037] Figure 7 It is along Figure 1 A cross-sectional view of line VII-VII of the coil assembly shown.

[0038] Figure 8 From Figure 1 The side view of the coil device shown, omitting the housing.

[0039] Explanation of reference numerals in the attached figures

[0040] 10...coil device

[0041] 20... spools

[0042] 21……Core Section

[0043] 210……Through Hole

[0044] 211, 212... Flow holes

[0045] 22a, 22b... flange portion

[0046] 23a~23c……Separating flange portion

[0047] 24a~24d……Wound fixing part

[0048] 25a~25c……Clamping protrusions

[0049] 26a~26c……gap

[0050] 27a~27d……Wound Sections

[0051] 31……First upper protrusion

[0052] 310...Bottom wall part

[0053] 310a……Bottom

[0054] 310b, 310c... tapered section

[0055] 311……Wrap-through path

[0056] 312……Side wall portion

[0057] 313……Thick-walled section

[0058] 314……Upper wall part

[0059] 315……Wound Rotary Section

[0060] 32……Second upper protrusion

[0061] 320...Bottom wall part

[0062] 321……Main Body

[0063] 322a~322d……lead-out slots

[0064] 323……Sliding hole

[0065] 33……Lower protrusion

[0066] 330……Upper wall

[0067] 330a……Top

[0068] 330b, 330c... tapered section

[0069] 331... Heatsink

[0070] 41……First Coil

[0071] 41a, 41b... Introduction

[0072] 41c……First winding

[0073] 41d……First Single-Layer Region

[0074] 41e……First Multi-Layer Area

[0075] 42……Second coil

[0076] 42a, 42b... Introduction

[0077] 42c……Second winding

[0078] 42d……Second Single-Layer Region

[0079] 42e……Second level area

[0080] 50V, 50W, 50X, 50Y... magnetic core

[0081] 51……Base section

[0082] 510a... Bottom of the magnetic core

[0083] 510b, 510c... Tapered section of the magnetic core

[0084] 52……Outer foot

[0085] 520……Outer leg bend

[0086] 53……Midfoot

[0087] 530……Middle leg bend

[0088] 54…concave

[0089] 60... hat

[0090] 70……shell

[0091] 90……Potting Resin Detailed Implementation

[0092] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0093] Figure 1 The coil device 10 shown in this embodiment functions as a transformer, for example, in vehicle chargers, power circuits for various electrical devices, etc. In the following description, the positive Z-axis direction side is designated as the upper side, and the negative Z-axis direction side is designated as the lower side. Furthermore, the side towards the center of the coil device 10 is designated as the inner side, and the side away from the center of the coil device 10 is designated as the outer side.

[0094] like Figure 2 As shown, the coil assembly 10 includes a first coil 41, a second coil 42, a bobbin 20, and magnetic cores 50v to 50y. One of the first coil 41 and the second coil 42 constitutes a primary coil, and the other constitutes a secondary coil. In addition to the aforementioned components, the coil assembly 10 also includes a housing 70 that accommodates the bobbin 20 and the magnetic cores 50v to 50y. The coil assembly 10 is a horizontal coil assembly in which the core of the bobbin 20 is arranged substantially parallel to the mounting base (not shown).

[0095] The housing 70 is made of a metal with excellent cooling properties, such as aluminum, and has a bottom 71, a side 72, and a boss 73. An opening for accommodating the spool 20 is formed on the top of the housing 70. Fasteners such as screws are fixed to the boss 73, thereby enabling the housing 70 to be mounted on a mounting base (not shown).

[0096] The housing 70 houses the spool 20, etc., and is capable of being filled with potting resin 90. Figure 7 The potting resin 90 is a heat-dissipating resin, composed of silicone resin, polyurethane resin, or epoxy resin, etc. The potting resin 90 fills to the vicinity of the opening of the housing 70, and more specifically, fills to about 70 to 80% of the height of the side portion 72. The upper surfaces of the magnetic cores 50V and 50W (the upper surfaces of the outer feet 52 or the base portion 51, described later) and a portion of the spool 20 are exposed from the upper surface of the cured potting resin 90.

[0097] In this embodiment, the heat generated by the spool 20 and the magnetic core 50v~50y can be efficiently dissipated to the outside through the housing 70 and the potting resin 90, thereby improving the cooling efficiency of the coil device 10.

[0098] Magnetic cores 50V and 50Y are E-shaped cores and are mounted on spool 20. Cores 50V and 50Y are designed to be assembled with each other; cores 50V and 50W are positioned above spool 20, while cores 50X and 50Y are positioned below spool 20. Alternatively, cores 50V and 50X can be integrated, as can cores 50W and 50Y.

[0099] The magnetic cores 50V to 50Y can be made of magnetic materials such as metals or ferrites, but there are no particular limitations. The magnetic cores 50V to 50Y have the same shape, having a base portion 51, a pair of pairs of feet 52, and a middle foot 53.

[0100] The base portion 51 has a plate shape and a predetermined thickness in the X-axis direction. An outer leg portion 52 and a middle leg portion 53 are connected to the inner surface of the base portion 51 in the X-axis direction. That is, the base portion 51 supports the outer leg portion 52 and the middle leg portion 53 extending in the X-axis direction. The outer surface of the base portion 51 in the X-axis direction is flat.

[0101] A recess 54 is formed on the outer surface of the base portion 51 in the Z-axis direction. The outer surface of the base portion 51 in the Z-axis direction is the upper surface of the base portion 51 for the magnetic core portions 50v and 50w, and the lower surface of the base portion 51 for the magnetic core portions 50x and 50y. That is, the recess 54 is formed on a surface orthogonal to the inner surface of the base portion 51 in the X-axis direction (the surface connecting the outer foot portion 52 and the middle foot portion 53) (a surface that defines the outer periphery or outer edge of the base portion 51 and is parallel to the XY plane). The recess 54 is composed of a recess recessed between a pair of feet 52 in the Z-axis direction (a direction substantially perpendicular to the mounting surface). Alternatively, the recess 54 may be formed spanning the base portion 51 and a pair of feet 52.

[0102] The base portion 51 has a core bottom 510a and a pair of core tapered portions 510b and 510c. The core bottom 510a and the pair of core tapered portions 510b and 510c form a recess 54 that is generally V-shaped.

[0103] The core bottom 510a has a surface that is substantially parallel to the mounting surface (XY plane). The core bottom 510a is substantially coplanar with the surface of the middle leg 53 (the outer surface in the Z-axis direction). That is, the core bottom 510a is continuously connected to the outer surface of the middle leg 53 in the Z-axis direction along the X-axis direction. The outer surface of the middle leg 53 in the Z-axis direction refers to the upper surface of the middle leg 53 for cores 50v and 50w, and to the lower surface of the middle leg 53 for cores 50x and 50y. The width of the core bottom 510a in the Y-axis direction is smaller than the width of the middle leg 53 in the Y-axis direction.

[0104] A pair of core tapered portions 510b and 510c are formed on one side and the other side of the core bottom 510a in the Y-axis direction, respectively. The core tapered portions 510b and 510c connect the core bottom 510a to the outer surface of the outer foot portion 52 in the Z-axis direction. The outer surface of the outer foot portion 52 in the Z-axis direction refers to the upper surface of the outer foot portion 52 for cores 50v and 50w, and the lower surface of the outer foot portion 52 for cores 50x and 50y. The core tapered portions 510b and 510c each have a tapered surface, inclined at a predetermined angle relative to the core bottom 510a. The width of the core tapered portions 510b and 510c in the X-axis direction is the same as the thickness of the base portion 51 in the X-axis direction.

[0105] In the magnetic core 50v~50y, the inner surface shape of the recess 54 is similar to that of each protrusion of the spool 20. Figure 3A and Figure 3B The bottom or top surface shapes of the first upper protrusion 31, the second upper protrusion 32, or the lower protrusion 33 shown correspond to each other, as will be described in detail later. Therefore, each protrusion of the spool 20 can be accommodated inside the recess 54.

[0106] A pair of feet 52 are formed at each end of the base portion 51 in the Y-axis direction, protruding from the inner side of the base portion 51 in the X-axis direction. A pair of feet 52 are respectively disposed on the side of the core portion 21 of the spool 20 in the Y-axis direction, extending along the axial direction (X-axis direction) of the core portion 21. An outer foot bend 520 is formed on the inner surface of each pair of feet 52 (the surface opposite to the middle foot 53). The outer foot bend 520 bends along the outer peripheral surfaces of the first coil 41 and the second coil 42.

[0107] like Figure 7 As shown, the curvature of the outer curved portion 520 of the magnetic core 50v increases towards the top, while the curvature of the outer curved portion 520 of the magnetic core 50x increases towards the bottom. That is, the curvature of the outer curved portion 520 increases towards the outer side of the Z-axis direction of the magnetic core portion 50v or 50x. If the magnetic core 50v and magnetic core 50x are combined, a roughly C-shaped recess is formed from the inner surface of the outer foot portion 52 of the magnetic core 50v to the inner surface of the outer foot portion 52 of the magnetic core 50x. Furthermore, the outer curved portion 520 of the magnetic core 50v is not formed at the upper end of the inner surface of the outer foot portion 52, and the outer curved portion 520 of the magnetic core 50x is not formed at the lower end of the inner surface of the outer foot portion 52.

[0108] The upper surface of the outer foot 52 of the 50V magnetic core (and the same applies to the 50W magnetic core) is located at a position greater than... Figure 3A and Figure 3B The bottoms of the first upper protrusion 31 and the second upper protrusion 32 of the spool 20 shown are exposed in a direction approximately perpendicular to the mounting surface (Z-axis direction) further above the mounting surface. That is, no components such as potting resin 90 are disposed above the upper surface of the outer foot 52, and the upper surface of the outer foot 52 is exposed to the external space through the opening of the housing 70.

[0109] like Figure 2 As shown, the middle leg portion 53 is formed between a pair of pairs of legs 52 along the Y-axis direction, protruding from the inner side of the base portion 51 in the X-axis direction towards the inner side. The middle leg portion 53 is disposed inside the winding core portion 21 of the spool 20. More specifically, each middle leg portion 53 of the magnetic cores 50v to 50y is disposed inside the through hole 210 of the winding core portion 21 with its front ends joined together.

[0110] A middle leg bend 530 is formed on the outer surface of the middle leg portion 53 (the surface opposite to the outer leg portion 52). The middle leg bend 530 bends along the outer peripheral surfaces of the first coil 41 and the second coil 42, and the curvature of the middle leg bend 530 is approximately equal to the curvature of the outer leg bend 520. Therefore, the distance between the inner surface of the outer leg portion 52 and the outer surface of the middle leg portion 53 is approximately constant.

[0111] like Figure 7As shown, when the middle legs 53 of the magnetic cores 50v and 50x are combined, the cross-sectional shape of the combined body of each middle leg 53 is approximately elliptical. The ellipse formed by the combined body of each middle leg 53 has a long side in the Y-axis direction and a short side in the Z-axis direction. Thus, by setting the cross-sectional shape of the combined body of each middle leg 53 to approximately elliptical, its cross-sectional area is larger compared to setting it to a perfect circle. This allows for an increase in the size of the first coil 41 and the second coil 42, which are arranged radially outward from the combined body of each middle leg 53, thereby improving the magnetic properties of the coil device 10. Furthermore, compared to setting its cross-sectional shape to a quadrilateral shape, it is possible to suppress the bulging of the first coil 41 and the second coil 42, thereby improving the quality of the coil device 10.

[0112] The bottom surface of magnetic core 50x (and magnetic core 50y) is disposed at the bottom 71 of housing 70. The upper surface of magnetic core 50v (and magnetic core 50w) is disposed above the upper end of the side portion 72 of housing 70 and protrudes from the opening of housing 70. The gap between the outer feet 52 of each of magnetic cores 50v and 50x (and magnetic cores 50w and 50y) and the side portion 72 of housing 70 is filled with potting resin 90. Additionally, the gap between the outer feet 52 of each of magnetic cores 50v and 50x (and magnetic cores 50w and 50y) and the outer peripheral surface of the second coil 42 is filled with potting resin 90. The upper surface of the potting resin 90 is located between the upper surface of the middle foot 53 of magnetic core 50v (and magnetic core 50w) and the upper surface of the outer feet 52 of magnetic core 50v (and magnetic core 50w).

[0113] like Figure 3A As shown, the spool 20 has a core portion 21, flange portions 22a and 22b, a first upper protrusion 31, a second upper protrusion 32, and two lower protrusions 33. In addition to the above-mentioned portions, the spool 20 also has separating flange portions 23a to 23c, winding fixing portions 24a to 24d, engaging protrusions 25a to 25c, and gaps 26a to 26c. The spool 20 is made of plastics such as PPS, PET, PBT, and LCP, or other insulating materials (preferably heat-resistant materials).

[0114] The core section 21 is composed of a cylindrical body with a through hole 210. The intermediate legs 53 of the magnetic cores 50v to 50y are inserted inside the through hole 210. Figure 2 The first winding 41c and the second winding 42c are wound around the outer peripheral surface of the core portion 21. Figure 2 ), forming the first coil 41 and the second coil 42.

[0115] Furthermore, the first conductor 41c and the second conductor 42c are each made of insulated wire, such as copper wire. The first winding 41c and the second winding 42c can each be made of a single wire, or they can be made of twisted wire. The wire diameter of the first winding 41c and the second winding 42c is preferably 1.0 to 3.0 mm, for example. The wire diameters of the first winding 41c and the second winding 42c can be equal or different. For example, the wire diameter of the winding carrying a larger current in the first winding 41c and the second winding 42c can be thicker than that of the other winding.

[0116] As described above, the coil device 10 in this embodiment is a horizontal coil device. Therefore, the core of the winding core 21 is arranged approximately parallel to the mounting surface and approximately parallel to the X-axis direction. As a result, the height of the coil device 10 can be suppressed, and the coil device 10 can be miniaturized and made thinner.

[0117] like Figure 4A As shown, flow holes 211 and 212 are formed at predetermined intervals along the X-axis on the lower portion of the outer peripheral surface of the core portion 21. Flow holes 211 and 212 are located at the center of the core portion 21 in the Y-axis direction. Flow holes 211 and 212 penetrate the outer peripheral surface of the core portion 21 and have generally elliptical openings. The length of the flow hole 211 in the X-axis direction is shorter than the length of the flow hole 212 in the X-axis direction.

[0118] like Figure 3B As shown, flow holes 211 and 212 are formed at predetermined intervals along the X-axis direction on the upper portion of the outer peripheral surface of the core portion 21. The positions of the flow holes 211 and 212 formed on the upper portion of the outer peripheral surface of the core portion 21 correspond in the Z-axis direction to the positions of the flow holes 211 and 212 formed on the lower portion of the outer peripheral surface of the core portion 21.

[0119] By forming flow holes 211 and 212 on the outer peripheral surface of the core portion 21, the potting resin 90 filling the housing 70 enters the inner side (through hole 210) of the core portion 21 through the flow holes 211 and 212. Therefore, as Figure 7 As shown, potting resin 90 is filled between the middle leg portion 53 and the winding core portion 21 of each of the magnetic cores 50v and 50x (and the same applies to magnetic cores 50w and 50y). This allows for efficient heat dissipation from the magnetic cores 50v to 50y via the potting resin 90 filled between the middle leg portion 53 and the winding core portion 21.

[0120] like Figure 3AAs shown, flange 22a is formed at one axial end of core portion 21, and flange 22b is formed at the other axial end of core portion 21. Flanges 22a and 22b extend circumferentially on the outer peripheral surface of core portion 21. Furthermore, flanges 22a and 22b protrude radially outward from the outer peripheral surface of core portion 21 by a predetermined length. The lower ends of flanges 22a and 22b (and similarly for separating flanges 23a to 23c) are flat surfaces, enabling the spool 20 to be stably mounted inside housing 70 (see reference). Figure 7 ).

[0121] The separating flanges 23a to 23c extend circumferentially on the outer peripheral surface of the core portion 21. Furthermore, the separating flanges 23a to 23c protrude radially outward from the outer peripheral surface of the core portion 21 by a predetermined length. The separating flanges 23a to 23c are arranged axially between flanges 22a and 22b along the core portion 21. Separating flanges 23a and 23b are arranged with a relatively wide interval along the axial direction of the core portion 21, while separating flanges 23b and 23c are arranged with a relatively narrow interval along the axial direction of the core portion 21.

[0122] like Figure 5 As shown, a portion of the second coil 42 is disposed in the winding partition 27a formed between the flange portion 22a and the separating flange portion 23a. Furthermore, a portion of the first coil 41 and a portion of the second coil 42 are disposed in the winding partition 27b formed between the separating flange portion 23a and the separating flange portion 23b. Additionally, a portion of the first coil 41 is disposed in the winding partition 27c formed between the separating flange portion 23b and the separating flange portion 23c. Furthermore, a portion of the first coil 41 is disposed in the winding partition 27d formed between the separating flange portion 23c and the flange portion 22b.

[0123] like Figure 3A As shown, gaps 26a to 26c are formed above the outer peripheral surface of the core portion 21 in such a way that they circumferentially separate the separating flange portions 23a to 23c. That is, the separating flange portions 23a to 23c do not reach the position of gaps 26a to 26c. Therefore, in winding sections 27a to 27d ( Figure 5 The first coil 41 and the second coil 42 can travel back and forth between each other.

[0124] The winding fixing portions 24a to 24c are formed at the upper ends of the separating flange portions 23a to 23c. The winding fixing portions 24a to 24c are all located at the lead-out portion 41a of the first coil 41 in the upper ends of the separating flange portions 23a to 23c. Figure 4AThe winding fixing portion 24d is formed on one side (negative Y-axis direction side) of the lead-out portion 41a of the first coil 41 in the upper end of the flange portion 22a. As shown... Figure 4A As shown, the lead-out portion 41a of the first coil 41 is fixed in the winding fixing portions 24a to 24d.

[0125] like Figure 3A As shown, engaging protrusions 25a to 25c are formed at the upper ends of winding fixing portions 24a to 24c. Engaging protrusions 25a and 25b are located at the lead-out portions 42a and 42b of the second coil 42 in the upper ends of winding fixing portions 24a and 24b. Figure 4B On one side (positive Y-axis direction side). The engaging protrusion 25c is located at the upper end of the winding fixing part 24c, at the lead-out parts 41a and 41b of the first coil 41. Figure 4B One side of the Y-axis (negative direction of the Y-axis).

[0126] like Figure 4B As shown, the lead-out portion 42b of the second coil 42 engages with the engaging protrusion 25a, the leads-out portions 42a and 42b of the second coil 42 engage with the engaging protrusion 25b, and the leads-out portions 41a and 41b of the first coil 41 engage with the engaging protrusion 25c. This prevents positional displacement of each lead-out portion. Alternatively, tension can be applied to each lead-out portion to prevent slackness.

[0127] like Figure 3B As shown, a first upper protrusion 31 is formed at the upper end of the flange portion 22a, protruding outward from the outer surface (outer end surface) of the flange portion 22a in the X-axis direction. The first upper protrusion 31 is integrally formed on the outer end surface of the flange portion 22a and has a bottom wall portion 310, a winding insertion path 311, a side wall portion 312, a thick wall portion 313, an upper wall portion 314, and a winding rotation portion 315.

[0128] The bottom wall portion 310 forms the bottom surface of the first upper protrusion 31 and has a generally V-shaped shape. The bottom wall portion 310 has a bottom portion 310a and a pair of tapered portions 310b and 310c. The bottom portion 310a has a surface that is generally parallel to the mounting surface (XY plane). The pair of tapered portions 310b and 310c are formed on one side and the other side of the bottom portion 310a in the Y-axis direction, respectively. The tapered portions 310b and 310c each have a tapered surface that is inclined at a predetermined angle relative to the bottom portion 310a.

[0129] The shape of the bottom wall portion 310 is similar to the recess 54 of the magnetic core 50v. Figure 2 The inner surface shape corresponds to that of the recess 54. That is, the first upper protrusion 31 has a bottom surface shape that follows the inner surface shape of the recess 54. Therefore, as... Figure 8As shown, the bottom 310a of the bottom wall portion 310 and the bottom 510a of the magnetic core of the recess 54 are arranged facing each other, the tapered portion 310b of the bottom wall portion 310 and the tapered portion 510b of the magnetic core of the recess 54 are arranged facing each other, and the tapered portion 310c of the bottom wall portion 310 and the tapered portion 510c of the magnetic core of the recess 54 are arranged facing each other. As a result, the entire bottom wall portion 310 or substantially the entire first upper protrusion 31 can be accommodated inside the recess 54. Furthermore, a portion of the bottom wall portion 310 or a portion of the first upper protrusion 31 can also extend outward from the recess 54.

[0130] like Figure 4A As shown, the winding insertion path 311 is formed approximately at the center of the bottom wall portion 310 in the Y-axis direction and extends along the axial direction of the core portion 21. The winding insertion path 311 is formed in the side wall portion 312 and the thick wall portion 313. Figure 3B The path between the two coils is sandwiched between the side wall portion 312 and the thick wall portion 313. The lead-out portion 41a of the first coil 41 is inserted into the winding insertion path 311.

[0131] The side wall portion 312 extends upward from near the bottom of the bottom wall portion 310, and extends in the X-axis direction from one end of the bottom wall portion 310 to the other end. For example... Figure 3B As shown, the thick-walled portion 313 is formed on the side opposite to the sidewall portion 312 in the Y-axis direction, separated by the winding insertion path 311. The thick-walled portion 313 is integrally formed on the outer end face of the flange portion 22a, protruding outward from the outer end face of the flange portion 22a in the X-axis direction. Therefore, the thick-walled portion 313 occupies a portion of the upper surface of the tapered portion 310c of the bottom wall portion 310 (the inner region in the X-axis direction). The outer surface of the thick-walled portion 313 is curved, and a winding rotation portion 315 is formed around the thick-walled portion 313.

[0132] The winding rotation section 315 includes a path extending at a predetermined distance along the X-axis (winding insertion path 311) and a path extending at a predetermined distance along the Y-axis (a path extending along the tapered section 310c). For example... Figure 4A As shown, the lead-out portion 41a of the first coil 41 is inserted into the winding rotation portion 315. By inserting the lead-out portion 41a into the winding rotation portion 315, the lead-out direction of the lead-out portion 41a is reversed from the outside to the inside in the X-axis direction. That is, the winding rotation portion 315 functions as a guide path to reverse the lead-out direction of the lead-out portion 41a. Since the thick-walled portion 313 has a relatively large thickness, the lead-out portion 41a is inserted into the winding rotation portion 315 in a manner that it is wound around the thick-walled portion 313. Therefore, it is easy to reverse the lead-out direction of the lead-out portion 41a with a larger wire diameter.

[0133] like Figure 8As shown, the winding rotation section 315 is disposed inside the recess 54 of the magnetic core section 50v. Therefore, the lead-out direction of the lead-out section 41a is substantially reversed from the outside to the inside in the X-axis direction inside the recess 54. That is, the lead-out section 41a is led out from one axial end of the core section 21 to the first upper protrusion 31 through the interior of the recess 54 (more specifically, the winding insertion path 311). Moreover, the lead-out section 41a is reversed inside the recess 54 (more specifically, the winding rotation section 315) and is led out from the first upper protrusion 31 to one axial end of the core section 21.

[0134] In this way, by taking out and reversing the lead-out portion 41a inside the recess 54, it is possible to prevent the lead-out portion 41a from protruding significantly above the magnetic cores 50v and 50w, thereby achieving a thinner coil device 10. In addition, unnecessary or difficult winding of the lead-out portion 41a on the mounting substrate can be avoided, making the winding of the lead-out portion 41a easier.

[0135] By guiding the lead-out portion 41a to the winding rotation portion 315, the lead-out portion 41a can be gathered at the other end of the axial direction of the spool 20 (the side where the second upper protrusion 32 is disposed). That is, the lead-out portion 41a (and the lead-out portion 41b as well) is not gathered at one end of the axial direction of the spool 20 (the side where the first upper protrusion 31 is disposed), but is gathered together with the leads 42a and 42b at the other end of the axial direction of the spool 20. As a result, space-saving can be achieved in the arrangement space of the leads 41a and 41b, and thus the coil device 10 can be made smaller and thinner.

[0136] like Figure 3B As shown, an upper wall portion 314 is formed at the upper end of the thick-walled portion 313. The upper wall portion 314 extends substantially parallel to the XY plane and is positioned above the tapered portion 310c of the bottom wall portion 310. The upper wall portion 314 serves to prevent the lead-out portion 41a of the through-winding rotation portion 315 from shifting upwards.

[0137] like Figure 3A As shown, a second upper protrusion 32 is formed at the upper end of the flange portion 22b, protruding outward from the outer surface (outer end face) of the flange portion 22b in the X-axis direction. The protrusion direction of the second upper protrusion 32 is opposite to the protrusion direction of the first upper protrusion 31. The second upper protrusion 32 is integrally formed on the outer end face of the flange portion 22b and has a bottom wall portion 320, a main body portion 321, lead-out groove portions 322a to 322d, and a sliding hole 323.

[0138] The bottom wall portion 320 has a bottom portion 320a and a pair of tapered portions 320b and 320c. The bottom wall portion 320 has a shape corresponding to the bottom wall portion 310 of the first upper protrusion 31. That is, the bottom portion 320a has a shape corresponding to the bottom portion 310a, and the pair of tapered portions 320b and 320c have shapes corresponding to the pair of tapered portions 310b and 310c.

[0139] The shape of the bottom wall 320 is similar to the recess 54 of the magnetic core 50w. Figure 2 The inner surface shape corresponds to that of the recess 54. That is, the second upper protrusion 32 has a bottom surface shape that follows the inner surface shape of the recess 54. Therefore, the entire bottom wall portion 320 or substantially the entire second upper protrusion 32 can be accommodated inside the recess 54. Furthermore, a portion of the bottom wall portion 320 or a portion of the second upper protrusion 32 can also extend outward from the recess 54.

[0140] The main body 321 has a flat, generally rectangular shape and is integrally connected to the upper end of the bottom wall 320. Lead-out grooves 322a to 322d are formed on the upper surface of the main body 321, extending from one end of the main body 321 along the X-axis to the other end. Figure 4B As shown, the lead-out portion 42a of the second coil 42 is inserted into the lead-out slot 322a, the lead-out portion 42b of the second coil 42 is inserted into the lead-out slot 322b, the lead-out portion 41b of the first coil 41 is inserted into the lead-out slot 322c, and the lead-out portion 41a of the first coil 41 is inserted into the lead-out slot 322d. In this way, by having each lead-out portion pass through the lead-out slots 322a to 322d, the positions of each lead-out portion can be fixed, and contact between them can be prevented.

[0141] like Figure 3A As shown, a sliding hole 323 is formed approximately at the center of the main body 321 in the Y-axis direction. The sliding hole 323 is located between the lead-out grooves 322b and 322c, extending inward in the X-axis direction. Inside the sliding hole 323, the sliding portion 61 of the cap 60 (described later) can be slidably inserted. Figure 2 ).

[0142] One of the two lower protrusions 33 is formed at the lower end of the flange 22a, protruding outward in the X-axis direction from the outer surface (outer end face) of the flange 22a. The other of the two lower protrusions 33 is formed at the lower end of the flange 22b, protruding outward in the X-axis direction from the outer surface (outer end face) of the flange 22b. The lower protrusions 33 have the same shape except that their protrusion directions are opposite to each other. The lower protrusions 33 have an upper wall portion 330 and a heat sink 331.

[0143] The upper wall portion 330 has a top 330a and a pair of tapered portions 330b and 330c. For example... Figure 3B As shown, the upper wall portion 330 has a shape corresponding to the bottom wall portion 310 of the first upper protrusion 31. Furthermore, as... Figure 3A As shown, the upper wall portion 330 has a shape corresponding to the bottom wall portion 320 of the second upper protrusion 32. That is, the top 330a has a shape corresponding to the bottom 310a (or bottom 320a), and the pair of conical portions 330b and 330c have shapes corresponding to the pair of conical portions 310b and 310c (or the pair of conical portions 320b and 320c). The bottom wall portion 310 (or bottom wall portion 320) protrudes downward in a downward convex manner, while the upper wall portion 330 protrudes upward in an upward convex manner.

[0144] The shape of the upper wall portion 330 is similar to the recess 54 of the magnetic core 50x (or magnetic core 50y). Figure 2 The inner surface shape corresponds to that of the recess 54. That is, the lower protrusion 33 has an upper surface shape that follows the inner surface shape of the recess 54. Therefore, as Figure 8 As shown, the entirety of the upper wall portion 330 or substantially the entirety of the lower protrusion 33 can be accommodated inside the recess 54 of the magnetic core 50x. Furthermore, a portion of the upper wall portion 330 or a portion of the lower protrusion 33 may extend outward from the recess 54.

[0145] like Figure 3A As shown, a heat sink 331 is disposed on the back side of the upper wall 330 and has concave and convex (heat sink) features. The heat sink 331 has the function of efficiently dissipating heat from the spool 20. Figure 8 As shown, with the lower protrusion 33 accommodated inside the recess 54 of the magnetic core 50x (or magnetic core 50y), the heat sink 331 is disposed inside the recess 54. Therefore, it is possible to prevent the coil assembly 10 associated with the placement of the heat sink 331 from becoming too large. Compared to potting resin 90, the heat sink 331 can inexpensively function as a heat dissipation mechanism.

[0146] like Figure 6 As shown, the first coil 41 and the second coil 42 are arranged on the radially outer side of the core portion 21. More specifically, the first coil 41 is wound on winding sections 27b to 27d of the core portion 21, and the second coil 42 is wound on winding sections 27a and 27b of the core portion 21.

[0147] The first coil 41 is wound in one layer on the outer peripheral surface of the core portion 21 in winding section 27b, and in two layers on the outer peripheral surface of the core portion 21 in winding sections 27c and 27d. That is, the first coil 41 has a first single-layer region 41d formed in a single layer along its radial direction and a first multi-layer region 41e formed in multiple layers (two layers in this embodiment) along its radial direction.

[0148] The second coil 42 is wound in two layers on the outer peripheral surface of the core portion 21 in winding section 27a, and wound in one layer on the radially outer side (outer peripheral surface of the first coil 41) of winding section 27b. That is, the second coil 42 has a second single-layer region 42d formed in a single layer along its radial direction and a second multi-layer region 42e formed in multiple layers (two layers in this embodiment) along its radial direction.

[0149] The first single-layer region 41d and the second single-layer region 42d are arranged along the axial direction of the core portion 21 between the first multi-layer region 41e and the second multi-layer region 42e. The number of layers in the X-axis direction of the first single-layer region 41d and the number of layers in the X-axis direction of the second single-layer region 42d are both 6, with each layer number corresponding to the other in a 1:1 ratio. The first single-layer region 41d and the second single-layer region 42d are stacked radially along the core portion 21 at approximately the center of the axial direction.

[0150] In this way, by stacking the first single-layer region 41d and the second single-layer region 42d, the leakage of the first coil 41 and the second coil 42 can be adjusted according to their stacking arrangement. Therefore, for example, when the coil device 10 is used as a leakage transformer, the magnetic characteristics of the coil device 10 can be improved. Furthermore, by stacking the first single-layer region 41d and the second single-layer region 42d, the number of layers of the first coil 41 and the second coil 42 can be minimized, effectively achieving miniaturization and thinning of the coil device 10. Additionally, by appropriately changing the number of layers in the X-axis direction of the first single-layer region 41d and the second single-layer region 42d, the leakage characteristics of the coil device 10 can be adjusted.

[0151] like Figure 7 As shown, the upper portion of the outer peripheral surface of the second coil 42 protrudes into the external space from the opening of the housing 70 between a pair of legs 52 of the magnetic core 50v (and the same applies to the magnetic core 50w). Although detailed illustrations are omitted, the upper portion of the outer peripheral surface of the first coil 41 also protrudes into the external space from the opening of the housing 70 between a pair of legs 52 of the magnetic core 50w.

[0152] Furthermore, the lower portion of the outer peripheral surface of the second coil 42 is positioned between a pair of pairs of legs 52 of the magnetic core 50x (and the same applies to the magnetic core 50y) in a manner opposite to the bottom 71 of the housing 70. Although detailed illustrations are omitted, the lower portion of the outer peripheral surface of the first coil 41 is also positioned between a pair of pairs of legs 52 of the magnetic core 50y in a manner opposite to the bottom 71 of the housing 70. In this way, by positioning the lower portions of the outer peripheral surfaces of the first coil 41 and the second coil 42 near the bottom 71, their cooling efficiency can be improved.

[0153] like Figure 4AAs shown, the lead-out portion 41a of the first coil 41 extends from the first upper protrusion 31 to the second upper protrusion 32. More specifically, the lead-out portion 41a extends from... Figure 6 The winding section 27b (first single-layer region 41d) shown traverses the winding section 27a and extends into the winding insertion path 311 of the first upper protrusion 31. At this time, the lead-out portion 41a extends into the winding insertion path 311 through the radially inner side of the second coil 42 (second multi-layer region 42e). Furthermore, the lead-out portion 41a changes direction along the winding rotation portion 315, is fixed to the winding fixing portions 24a-24c and the engaging protrusion 25c, and extends through the lead-out slot 322d of the second upper protrusion 32. The lead-out portion 41a extends from the first upper protrusion 31 to the second upper protrusion 32 through the radially outer side of the first coil 41 and the second coil 42.

[0154] Thus, via the winding rotation section 315 (or fixed to) Figure 3B The thick-walled portion 313 (shown) leads the lead-out portion 41a toward the second upper protrusion 32, thereby preventing defects such as loosening of the lead-out portion 41a. As a result, the lead-out portion 41a can be led toward the second upper protrusion 32 at a low position (near the outer peripheral surface of the first coil 41 or the second coil 42), effectively achieving a thinner coil device 10.

[0155] Furthermore, the lead-out portion 41b of the first coil 41 extends to the second upper protrusion 32 without passing through the first upper protrusion 31. More specifically, the lead-out portion 41b is fixed to the engaging protrusion 25c, and extends from... Figure 6 The winding section 27c (the second layer of the first multilayer region 41e) is shown as an extension. Additionally, the extension portion 41b traverses... Figure 6 The winding section 27d is shown, and the lead-out section 322c is through the second upper protrusion 32. The lead-out section 41b is led out from the winding section 27c to the second upper protrusion 32 through the radially outer side of the first coil 41.

[0156] like Figure 4B As shown, the leads 42a and 42b of the second coil 42 extend to the second upper protrusion 32 without passing through the first upper protrusion 31. More specifically, the lead 42a is fixed to the engaging protrusion 25b and extends from... Figure 6 The winding section 27b (second single-layer region 42d) shown is led out. Additionally, the lead-out portion 42a traverses... Figure 6 The winding sections 27c and 27d are shown, and the lead-out groove 322a of the second upper protrusion 32 is provided. The lead-out portion 42a extends from the winding section 27b to the second upper protrusion 32 through the radially outer side of the first coil 41.

[0157] Additionally, the lead-out portion 42b is fixed to the engaging protrusion 25a, and from... Figure 6 The winding section 27a (the second layer of the second multilayer region 42e) is shown as the lead-out point. Additionally, the lead-out portion 42b traverses... Figure 6 The winding sections 27b to 27d are shown, and the lead-out groove 322b of the second upper protrusion 32 is also present. The lead-out portion 42b extends from the winding section 27a to the second upper protrusion 32 through the radially outer side of the first coil 41 and the second coil 42.

[0158] like Figure 7 As shown, the passage area of ​​the lead-out portion 41a to the second upper protrusion 32 is formed at a position that is radially inward beyond the upper end of the outer peripheral surface of the second coil 42 and radially inward beyond the side end of the outer peripheral surface of the second coil 42 in the Y-axis direction. That is, if the line segment passing through the upper end of the outer peripheral surface of the second coil 42 and parallel to the Y-axis is designated as L1, and the line segment passing through the side end of the outer peripheral surface of the second coil 42 and parallel to the Z-axis is designated as L2, then the passage area of ​​the lead-out portion 41a becomes the area surrounded by the outer peripheral surface of the second coil 42, line segment L1, and line segment L2. However, as long as at least a portion of the lead-out portion 41a is located inside this passage area, a portion of the lead-out portion 41a may also extend outward beyond line segment L1 or L2.

[0159] In this case, the lead-out portion 41a passes near the outer peripheral surface of the second coil 42. Therefore, it is possible to prevent the lead-out portion 41a from protruding significantly above the magnetic core 50v (or magnetic core 50w), and to achieve a thinner coil device 10.

[0160] like Figure 2 As shown, cover 60 is installed on Figure 3A The upper part of the second upper protrusion 32 shown prevents the leads of the first coil 41 and the second coil 42 from shifting upwards. The cover 60 has a sliding part 61 and engaging parts 62 and 63. The sliding part 61 slides freely into place. Figure 3A The interior of the sliding hole 323 of the second upper protrusion 32 shown. Engaging portions 62 and 63 respectively engage with... Figure 3A The ends of the main body portion 321 of the second upper protrusion 32 shown engage in the Y-axis direction. Thus, the cover 60 can be fixed to the main body portion 321 via the sliding portion 61 and the engaging portions 62 and 63.

[0161] Next, the manufacturing method of the coil device 10 will be described. First, prepare... Figure 2 The components are shown. Next, the first coil 41 and the second coil 42 are wound around the core portion 21 of the spool 20. Regarding the first winding 41c, for example from... Figure 6The winding begins at the position of the winding section 27c shown, via α winding. That is, with respect to one end (side) of the first winding 41c, it is wound in one layer from winding section 27c to winding section 27b on the outer peripheral surface of the core portion 21. Then, it is pulled out from winding section 27b to the winding insertion path 311 of the first upper protrusion 31. Figure 4A Furthermore, it turns at the winding turning section 315 and extends to the outer side of the second upper protrusion 32 in the X-axis direction.

[0162] On the other hand, for the other end (side) of the first winding 41c, it is made to be in Figure 6 Two layers are reciprocally wound between the winding section 27c and the winding section 27d shown. Then, it is pulled out from the winding section 27c to the outer side of the second upper protrusion 32 in the X-axis direction. Figure 4A ).

[0163] Furthermore, regarding the second winding 42c, it is wound, for example, on the outer peripheral surface of the first coil 41 or the outer peripheral surface of the core portion 21 by normal winding. That is, in winding section 27b, the second winding 42c is wound in one layer on the outer peripheral surface of the first coil 41, and in winding section 27a, it is wound in two layers on the outer peripheral surface of the core portion 21. Also, one end (side) of the second winding 42c is led out from winding section 27a to the outer side of the second upper protrusion 32 in the X-axis direction (…). Figure 4B Regarding the other end (side) of the second winding 42c, it extends from the winding section 27b to the outer side of the second upper protrusion 32 in the X-axis direction. Figure 4B ).

[0164] like Figure 2 As shown, terminals 80 are installed as needed at each end (lead-out portions 41a and 41b) of the first winding 41c and each end (lead-out portions 42a and 42b) of the second winding 42c. Additionally, a cover 60 is installed on the upper part of the main body portion 321 of the second upper protrusion 32 as needed.

[0165] Next, magnetic cores 50V to 50Y are installed on the spool 20. If necessary, adhesives or similar materials can be used to secure the magnetic cores 50V to 50Y together.

[0166] Next, the spool 20 with a magnetic core of 50V to 50Y is placed inside the housing 70, and the interior of the housing 70 is filled with potting resin 90 (see reference). Figure 7 As described above, it is capable of manufacturing Figure 1 The coil device 10 shown.

[0167] As explained above, in the coil device 10 of this embodiment, such as Figure 2As shown, recesses 54 are formed in the magnetic cores 50v to 50y in a direction approximately perpendicular to the mounting surface (Z-axis direction). Therefore, when the magnetic cores 50v to 50y are mounted on the spool 20, each protrusion (first upper protrusion 31, second upper protrusion 32, and lower protrusion 33) is accommodated inside each recess 54, and each protrusion does not significantly protrude outward in the Z-axis direction of the magnetic cores 50v to 50y. That is, in the coil device 10 of this embodiment, since the protrusion amount (length in the Z-axis direction) of each protrusion can be absorbed by each recess 54 of the magnetic cores 50v to 50y, the vertical length of the flanges 22a and 22b does not increase the protrusion amount of each protrusion. Therefore, the miniaturization and thinning of the coil device 10 can be fully realized.

[0168] In addition, the recess 54 includes a shape suitable for accommodating the protrusions of the spool 20, or a shape specifically for accommodating the protrusions (conical shape). Therefore, most of the protrusions can be accommodated inside the recess 54, and the miniaturization and thinning of the coil device 10 can be effectively achieved.

[0169] In addition, such as Figure 8 As shown, the upper surface of the outer leg portion 52 protrudes in a direction approximately perpendicular to the mounting surface (Z-axis direction) at a position higher than the bottom of the first upper protrusion 31. Therefore, the first upper protrusion 31 does not protrude significantly from the upper surface of the outer leg portion 52, effectively enabling the miniaturization and thinning of the coil device 10. In addition, the vertical length of the outer leg portion 52 becomes relatively large, which improves the magnetic properties of the coil device 10.

[0170] In addition, such as Figure 7 As shown, in this embodiment, the more the upper surface of the outer foot 52 protrudes from the upper surface of the potting resin 90, the longer the length of the outer foot 52 in the vertical direction becomes. Therefore, the magnetic properties of the coil device 10 can be improved.

[0171] 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.

[0172] In the above embodiments, an application example of the transformer of the present invention has been described, but the present invention can be applied not only to transformers, but also to other coil devices.

[0173] In the above embodiments, it can also be constructed using an E-shaped magnetic core. Figure 2The magnetic cores 50V and 50X (or 50W and 50Y) shown are constructed from I-shaped magnetic cores. Alternatively, magnetic cores 50V to 50Y can be constructed from U-shaped magnetic cores.

[0174] In the above embodiments, such as Figure 2 As shown, four magnetic cores 50v to 50y are installed on the online shaft 20, but two magnetic cores (a combination of magnetic core 50v and magnetic core 50x, or a combination of magnetic core 50w and magnetic core 50y) can also be installed on the online shaft 20.

[0175] In the above embodiments, Figure 6 The sum of the radial layers of the first coil 41 and the second coil 42 shown is 2 layers, but it can also be 3 or more layers. However, in the winding section 27b, in order to lead the lead-out portion 41a of the first coil 41 to the first upper protrusion 31, it is preferable that the radial number of layers of the first coil 41 is odd. For example, in the winding section 27b, the first coil 41 consisting of 3 layers and the second coil 42 consisting of 3 layers can also be stacked.

[0176] In the above embodiments, such as Figure 2 As shown, the leads 41a and 41b of the first coil 41, together with the leads 42a and 42b of the second coil 42, are led out from one side of the axial direction of the spool 20. However, the leads 41a and 41b of the first coil 41 may also be led out from the side opposite to the leads 42a and 42b of the second coil 42 in the X-axis direction.

[0177] In the above embodiment, the lower protrusions 33 formed on the lower part of the bobbin 20 shown in FIG. 3 may also be omitted. In this case, the magnetic cores 50x and 50y disposed below the coil assembly 10 may also be omitted. Figure 2 ) of each recessed portion 54.

[0178] In the above embodiments, Figure 3B The bottom wall portion 310 of the first upper protrusion 31 shown has a tapered shape, but the shape of the bottom wall portion 310 is not limited to this and can be changed to various shapes. The same applies to the bottom wall portion 320 of the second upper protrusion 32 and the upper wall portion 330 of the lower protrusion 33. In this case, the shape of the recess 54 of the magnetic core 50v to 50y can also be changed according to the shape of each protrusion.

Claims

1. A coil device, wherein: have: coil; A bobbin has a core portion for arranging the coil, a flange portion formed at an axial end of the core portion, and a protrusion portion protruding from the flange portion; as well as The magnetic core, which is mounted on the spool, The shaft core of the winding core is arranged approximately parallel to the mounting surface. The magnetic core has a recess that is recessed in a direction substantially perpendicular to the mounting surface and is capable of accommodating the protrusion. The protrusion has a bottom wall portion that protrudes from the flange portion. At least a portion of the bottom wall extends along the inner surface of the recess and is inclined relative to the mounting surface. Viewed from the axial direction, the lead-out portion of the coil extends obliquely along the bottom wall portion toward the bottom away from the bottom of the bottom wall portion.

2. The coil device as claimed in claim 1, wherein: The protrusion has a bottom surface shape that follows the shape of the inner surface of the recess.

3. The coil device as claimed in claim 1 or 2, wherein: The magnetic core has an outer leg extending axially along the side of the winding core portion. The upper surface of the outer foot is located above the bottom of the protrusion and protrudes in a direction substantially perpendicular to the mounting surface.

4. The coil device as claimed in claim 3, wherein: It has a housing that accommodates the spool and the magnetic core. The interior of the housing is filled with a heat-dissipating resin. The upper surface of the outer foot protrudes from the surface of the heat-dissipating resin filling the interior of the housing.

5. The coil device as claimed in claim 4, wherein: The magnetic core has a central leg portion disposed inside the winding core portion. A hole is formed on the outer peripheral surface of the core portion. The heat-dissipating resin is filled between the middle foot portion and the core portion.

6. The coil device as claimed in claim 1 or 2, wherein: The lead-out portion of the coil extends from the axial end of the core portion to the protrusion through the interior of the recess, and then reverses inside the recess to extend from the protrusion to the axial end of the core portion.

7. The coil device as claimed in claim 1 or 2, wherein: The lead-out portion of the coil extends from the axial end of the winding core portion toward the protrusion. The protrusion has a guide path that reverses the lead-out direction of the coil's lead-out portion.

8. The coil device as claimed in claim 7, wherein: The protrusion has a lower protrusion located at the lower part of the spool and an upper protrusion located at the upper part of the spool. The upper protrusion has the guide path. The lower protrusion has heat sinks.

9. The coil device as claimed in claim 1 or 2, wherein: The flange portion has a first flange portion formed at a first end in the axial direction of the core portion, and a second flange portion formed at a second end in the axial direction of the core portion. The magnetic core has a first magnetic core and a second magnetic core that are combined with each other. The coil has a first coil disposed radially outward of the core portion and a second coil disposed radially outward of the first coil. The protrusion has a first protrusion protruding from the first flange portion and a second protrusion protruding from the second flange portion. The first lead-out portion of the first coil extends to the second lead-out portion via the first protrusion. The second lead of the second coil is led out to the second protrusion without passing through the first protrusion.

10. The coil device as claimed in claim 9, wherein: The first protrusion has a first guide path that reverses the lead-out direction of the first lead-out portion of the first coil. The second protrusion has an outlet groove through which the first outlet and the second outlet pass.

11. The coil device as claimed in claim 9, wherein: The first lead-out portion extends from the first protrusion to the second protrusion via the radially outer side of the second coil. The passage area of ​​the first lead is formed radially inward from the upper end of the outer peripheral surface of the second coil, and radially inward from the side end of the outer peripheral surface of the second coil.

12. The coil device as claimed in claim 9, wherein: The first coil has a first single-layer region formed in a single layer along its radial direction, and a first multi-layer region formed in multiple layers along its radial direction. The second coil has a second single-layer region formed in a single layer along its radial direction, and a second multi-layer region formed in multiple layers along its radial direction. The first single-layer region and the second single-layer region are stacked radially along the core at predetermined positions along the axial direction of the core.

13. A coil device, wherein: have: coil; A bobbin has a core portion for arranging the coil, a flange portion formed at an axial end of the core portion, and a protrusion portion protruding from the flange portion; as well as The magnetic core, which is mounted on the spool, The shaft core of the winding core is arranged approximately parallel to the mounting surface. The magnetic core has a recess that is recessed in a direction substantially perpendicular to the mounting surface and is capable of accommodating the protrusion. The flange portion has a first flange portion formed at a first end in the axial direction of the core portion, and a second flange portion formed at a second end in the axial direction of the core portion. The magnetic core has a first magnetic core and a second magnetic core that are combined with each other. The coil has a first coil disposed radially outward of the core portion and a second coil disposed radially outward of the first coil. The protrusion has a first protrusion protruding from the first flange portion and a second protrusion protruding from the second flange portion. The first lead-out portion of the first coil extends to the second lead-out portion via the first protrusion. The second lead of the second coil is led out to the second protrusion without passing through the first protrusion. The first protrusion has a first guide path that reverses the lead-out direction of the first lead-out portion of the first coil. The second protrusion has an outlet groove through which the first outlet and the second outlet pass.

14. A coil device, wherein: have: coil; A bobbin has a core portion for arranging the coil, a flange portion formed at an axial end of the core portion, and a protrusion portion protruding from the flange portion; as well as The magnetic core, which is mounted on the spool, The shaft core of the winding core is arranged approximately parallel to the mounting surface. The magnetic core has a recess that is recessed in a direction substantially perpendicular to the mounting surface and is capable of accommodating the protrusion. The flange portion has a first flange portion formed at a first end in the axial direction of the core portion, and a second flange portion formed at a second end in the axial direction of the core portion. The magnetic core has a first magnetic core and a second magnetic core that are combined with each other. The coil has a first coil disposed radially outward of the core portion and a second coil disposed radially outward of the first coil. The protrusion has a first protrusion protruding from the first flange portion and a second protrusion protruding from the second flange portion. The first lead-out portion of the first coil extends to the second lead-out portion via the first protrusion. The second lead of the second coil is led out to the second protrusion without passing through the first protrusion. The first lead-out portion extends from the first protrusion to the second protrusion via the radially outer side of the second coil. The passage area of ​​the first lead is formed radially inward from the upper end of the outer peripheral surface of the second coil, and radially inward from the side end of the outer peripheral surface of the second coil.

15. A coil device, wherein: have: coil; A bobbin has a core portion for arranging the coil, a flange portion formed at an axial end of the core portion, and a protrusion portion protruding from the flange portion; as well as The magnetic core, which is mounted on the spool, The shaft core of the winding core is arranged approximately parallel to the mounting surface. The magnetic core has a recess that is recessed in a direction substantially perpendicular to the mounting surface and is capable of accommodating the protrusion. The flange portion has a first flange portion formed at a first end in the axial direction of the core portion, and a second flange portion formed at a second end in the axial direction of the core portion. The magnetic core has a first magnetic core and a second magnetic core that are combined with each other. The coil has a first coil disposed radially outward of the core portion and a second coil disposed radially outward of the first coil. The protrusion has a first protrusion protruding from the first flange portion and a second protrusion protruding from the second flange portion. The first lead-out portion of the first coil extends to the second lead-out portion via the first protrusion. The second lead of the second coil is led out to the second protrusion without passing through the first protrusion. The first coil has a first single-layer region formed in a single layer along its radial direction, and a first multi-layer region formed in multiple layers along its radial direction. The second coil has a second single-layer region formed in a single layer along its radial direction, and a second multi-layer region formed in multiple layers along its radial direction. The first single-layer region and the second single-layer region are stacked radially along the core at predetermined positions along the axial direction of the core.

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