Coil arrangement

Abstract

A coil device that can be assembled in a simple procedure and is advantageous for miniaturization and low profile, comprising: a core having a pair of core bases extending in a first direction and arranged with a prescribed interval left in a second direction, and core legs having a first core leg, a second core leg, a third core leg, a fourth core leg, and a fifth core leg arranged with intervals left from each other in the first direction in order from one end to the other end of the first direction of the core bases; a first winding having a first winding portion wound in a manner passing through the first gap and the third gap and surrounding the second core leg and the third core leg; a second winding having a second winding portion wound in a manner passing through the second gap and the third gap and surrounding the third core leg; a third winding having a third winding portion wound in a manner passing through the fourth gap and the third gap and surrounding the fourth core leg; and a bobbin wound by the first winding portion, the second winding portion, and the third winding portion.

Description

TECHNICAL FIELD

[0001] The present application relates to a composite coil device having three or more winding portions. BACKGROUND

[0002] There is a demand for a composite coil device such as a composite transformer having three or more winding portions, which has both functions of a transformer and an inductor. As a conventional composite coil device, there is proposed a technique in which an E core is further added to the back surface of an E core on one side of a transformer portion formed using an E-E core, thereby making a structure using three E cores, and a winding portion disposed in the added E core has a function of an inductor (see Patent Document 1 and the like).

[0003] However, in the conventional coil device shown in Patent Document 1, since the structure in which three E cores are overlapped in three stages, it is difficult to shorten the length in the axial direction, and there is a technical problem in terms of miniaturization and low profile. In addition, in the structure in which three E cores are overlapped, the assembly process of the core and the bobbin is complicated.

[0004] PRIOR ART DOCUMENTS

[0005] PATENT DOCUMENTS

[0006] Patent Document 1: Japanese Patent Application Publication No. 2012-54549 SUMMARY

[0007] Technical Problem to be Solved by the Invention

[0008] The present application has been achieved in view of such circumstances, and relates to a composite coil device having three or more winding portions, which is a coil device that can be assembled with a simple process and is advantageous in terms of miniaturization and low profile.

[0009] Means for Solving the Technical Problem

[0010] The coil device according to the first aspect of the present application includes:

[0011] a core having a pair of core base portions extending in a first direction and disposed in parallel with each other with a predetermined interval in a second direction perpendicular to the first direction, and a core leg portion having a first core leg portion, a second core leg portion, a third core leg portion, a fourth core leg portion, and a fifth core leg portion arranged in order from one end portion to the other end portion in the first direction of the core base portions with an interval between each other from at least either side of the pair of core base portions to the other side;

[0012] a first winding portion which is wound in a manner of passing through a first gap formed between the first leg portion and the second leg portion and a third gap formed between the third leg portion and the fourth leg portion and surrounding the second leg portion and the third leg portion;

[0013] a second winding portion which is wound in a manner of passing through a second gap formed between the second leg portion and the third leg portion and the third gap and surrounding the third leg portion;

[0014] a third winding portion which is wound in a manner of passing through a fourth gap formed between the fourth leg portion and a fifth leg portion and the third gap and surrounding the fourth leg portion; and

[0015] a bobbin which is wound by the first winding portion, the second winding portion and the third winding portion.

[0016] In the coil device according to the first aspect of the present application, by using the core having the first to fifth leg portions, the first to third winding portions of the winding are arranged at the prescribed positions in the first to fourth gaps, so that the coil device which is assembled with a simple procedure and is advantageous for the size reduction and the low profile can be realized. For example, since the first to fifth leg portions are all arranged between one core base portion, the coil device can be assembled with a simple procedure and is advantageous for the size reduction and the low profile. Further, since the first winding portion, the second winding portion and the third winding portion are all structures which pass through the third gap of the core, the size reduction of the core and the shortening of the length of the winding are advantageous.

[0017] Further, for example, the second winding portion and the third winding portion can be electrically connected.

[0018] By electrically connecting the second winding portion and the third winding portion, the coil device constitutes a compound coil device having the third winding portion as a resonance coil connected in series with the second winding portion of the transformer portion. However, the electrical connection of the second winding portion and the third winding portion can be realized by the outside of the coil device, for example, a substrate on which the coil device is mounted, differently from this.

[0019] Further, for example, the bobbin can have a first bobbin portion which winds the first winding portion, a second bobbin portion which winds the second winding portion, and a third bobbin portion which winds the third winding portion, and the first bobbin portion, the second bobbin portion and the third bobbin portion can be separable from each other.

[0020] By adopting the structure in which the three bobbins are formed respectively, the coil device can be manufactured by assembling the first to third winding portions which are formed in the respective bobbins after that, so that such a coil device is easily assembled.

[0021] Further, for example, the above-mentioned first bobbin portion can have a second hollow cylinder portion through which the above-mentioned third leg portion is inserted,

[0022] The above-mentioned first bobbin portion can have a first hollow cylinder portion through which the above-mentioned second bobbin portion and the above-mentioned second leg portion are inserted,

[0023] The above-mentioned third bobbin portion can have a third hollow cylinder portion through which the above-mentioned fourth leg portion is inserted.

[0024] The coil device having such a bobbin can be easily assembled by arranging the first to third hollow cylinder portions at portions corresponding to the leg portions. Further, the arrangement accuracy of the bobbin and the first to third winding portions with respect to the core is also good.

[0025] Further, for example, the above-mentioned first bobbin portion and the above-mentioned third bobbin portion can be adjacent to each other at the above-mentioned third gap.

[0026] In such a coil device, since the transformer portion and the resonance coil portion (inductor portion) are arranged adjacent to each other, it is advantageous in terms of miniaturization.

[0027] Further, for example, the distance of the core base portion along the above-mentioned first direction from the above-mentioned one end portion to the above-mentioned third leg portion can be shorter than the distance along the above-mentioned first direction from the above-mentioned other end portion to the above-mentioned third leg portion.

[0028] Such a coil device, with the third leg portion as a reference, the core becomes asymmetric, and the space required for the transformer portion and the space required for the resonance coil portion can be appropriately distributed, which is advantageous in terms of miniaturization.

[0029] Further, for example, with respect to the width along the above-mentioned first direction, the above-mentioned third gap can be wider than the above-mentioned second gap.

[0030] In the first to third winding portions, the second gap is passed only by the second winding portion, and the third gap is passed only by the first to third winding portions, so that by making the third gap wider than the second gap, the gap through which the winding portions pass can be appropriately formed, which is advantageous in terms of miniaturization.

[0031] Further, for example, with respect to the length of a third direction perpendicular to the above-mentioned first direction and the above-mentioned second direction, the above-mentioned first leg portion and the above-mentioned fifth leg portion can be substantially equal.

[0032] Such a core easily forms the first leg portion and the fifth leg portion of a size suitable for passing magnetic flux, which is advantageous in terms of miniaturization of the core.

[0033] Further, for example, with respect to a length in a third direction orthogonal to the above-mentioned first direction and the above-mentioned second direction, the above-mentioned third leg portion can be shorter than any of the above-mentioned first leg portion, the above-mentioned second leg portion, the above-mentioned fourth leg portion, and the above-mentioned fifth leg portion.

[0034] By shortening the length in the third direction of the third leg portion, in such a core, a shape in which a central portion of the core base portion in the first direction is tapered can be formed. Therefore, in a coil device having such a core, the lead-out portions of the first to third windings can be arranged at the tapered portion of the core base portion, and thus it is advantageous in terms of downsizing and low profile.

[0035] Further, for example, with respect to a cross-sectional area of a cross section orthogonal to the above-mentioned second direction, the above-mentioned first leg portion and the above-mentioned fifth leg portion can be substantially equal, and the above-mentioned third leg portion can be substantially equal to the sum of the above-mentioned first leg portion and the above-mentioned fifth leg portion.

[0036] Such a core easily forms the first leg portion, the third leg portion, and the fifth leg portion, which are suitable for passing magnetic flux, and is advantageous in terms of downsizing of the core.

[0037] Further, for example, a second slit can be formed in the above-mentioned second leg portion, a third slit can be formed in the above-mentioned third leg portion, a fourth slit can be formed in the above-mentioned fourth leg portion, and a length in the above-mentioned second direction of the above-mentioned third slit can be shorter than lengths in the above-mentioned second direction of the above-mentioned second slit and the above-mentioned fourth slit.

[0038] By forming such slits, a composite coil device that generates a relatively large predetermined leakage magnetic flux can be obtained.

[0039] Further, the coil device according to the second aspect of the present application includes:

[0040] a core having: a pair of core base portions extending in a first direction and arranged in parallel to each other at a predetermined interval in a second direction orthogonal to the above-mentioned first direction; and a first leg portion, a second leg portion, a third leg portion, a fourth leg portion, and a fifth leg portion protruding from at least either side of the pair of core base portions to the other side and arranged in the above-mentioned first direction from one end portion to the other end portion of the core base portion in the above-mentioned first direction in order with a predetermined interval therebetween, the core being separable into a first core portion including at least one of the core base portions and a second core portion including at least the other core base portion; and

[0041] A coil holder is disposed between the two core bases, and has a first coil holder portion wound with a first winding portion of the first winding, a second coil holder portion wound with a second winding portion of the second winding, and a third coil holder portion wound with a third winding portion of the third winding. The first coil holder portion, the second coil holder portion, and the third coil holder portion are separable from each other.

[0042] A coil device according to a second aspect of the present application has a core having first to fifth core leg portions disposed in a first direction and separable into a first core portion and a second core portion, and first to third coil holder portions disposed between the two core bases and separable from each other. Such a coil device can be assembled in a simple process, and is advantageous for size reduction and low profile. BRIEF DESCRIPTION OF DRAWINGS

[0043] Figure 1 is an external view of a coil device according to an embodiment of the present application.

[0044] Figure 2 is an exploded perspective view of the coil device shown in Figure 1

[0045] Figure 3 is a perspective view of a portion of the coil device shown in Figure 1

[0046] Figure 4 is a plan view of a portion of the coil device shown in Figure 1

[0047] Figure 5 is a perspective view of a coil holder of the coil device shown in Figure 1

[0048] Figure 6 is an exploded perspective view of the coil holder shown in Figure 5

[0049] Figure 7 is a cross-sectional view of the coil device shown in Figure 1

[0050] Figure 8 is a conceptual view of a winding structure of the coil device shown in Figure 1

[0051] Figure 9 is a conceptual view of a flow of magnetic flux in the coil device shown in Figure 1

[0052] Figure 10 is a conceptual view of a circuit of the coil device shown in Figure 1 ​​​​​​​​​

[0053] Explanation of symbols:

[0054] 10 Coil device

[0055] 20 Core

[0056] 20a First core portion

[0057] 20b Second core portion

[0058] 21 Core base

[0059] 21a First core base

[0060] 21ac One end portion

[0061] 21ad Other end portion

[0062] 21aa, 21ab Concave portion

[0063] 21b Second core base

[0064] 21bc One end portion

[0065] 21bd Other end portion

[0066] 22 Core foot portion

[0067] 22a First core foot portion

[0068] 22b Second core foot portion

[0069] 22ba Second slit

[0070] 22c Third core foot portion

[0071] 22ca Third slit

[0072] 22d Fourth core foot portion

[0073] 22da Fourth slit

[0074] 22e Fifth core foot portion

[0075] 24a First gap

[0076] 24b Second gap

[0077] 24c Third gap

[0078] 24d Fourth gap

[0079] D1 First direction

[0080] D2 Second direction

[0081] D3 …… 3rd direction

[0082] 31 …… 1st winding

[0083] 31a …… 1st winding portion

[0084] 31b …… 1st lead-out portion

[0085] 32 …… 2nd winding

[0086] 32a …… 2nd winding portion

[0087] 32b, 32c …… 2nd lead-out portion

[0088] 33 …… 3rd winding

[0089] 33a …… 3rd winding portion

[0090] 33b, 33c …… 3rd lead-out portion

[0091] 40 …… bobbin

[0092] 41 …… 1st bobbin portion

[0093] 41a …… 1st hollow cylinder portion

[0094] 41b …… 1st lead-out groove portion

[0095] 41c …… 1st cover portion

[0096] 42 …… 2nd bobbin portion

[0097] 42a …… 2nd hollow cylinder portion

[0098] 42b …… 2nd lead-out groove portion

[0099] 42c …… 2nd cover portion

[0100] 42d …… intermediate flange portion

[0101] 42e …… 2nd guide portion

[0102] 43 …… 3rd bobbin portion

[0103] 43a …… 3rd hollow cylinder portion

[0104] 43b …… 3rd lead-out groove portion

[0105] 43c …… 3rd cover portion

[0106] 50 …… housing DETAILED DESCRIPTION

[0107] Hereinafter, the present application will be described based on the embodiments shown in the drawings.

[0108] Figure 1 is a perspective view showing a coil device 10 according to an embodiment of the present application. The coil device 10 can be used as, for example, a vehicle-mounted power supply, a charging station, an energy storage system (ESS), or the like, but the use of the coil device 10 is not limited to these. As shown in Figure 1 , the coil device 10 has a core 20 and a first winding 31, a second winding 32 (see Figure 7 , 8 ), a third winding 33, a bobbin 40, and the like.

[0109] As shown in Figure 1 , the coil device 10 has a substantially rectangular parallelepiped outer shape. As shown in Figure 2 , the core 20 of the coil device 10 has a pair of plate-shaped core base portions 21a and 21b. Further, the core 20 has a first core portion 20a having at least the first core base portion 21a of the pair of core base portions 21a and 21b, and a second core portion 20b having at least the second core base portion 21b of the pair of core base portions 21a and 21b, and the first core portion 20a and the second core portion 20b are separable from each other.

[0110] Further, in the description of the coil device 10, as shown in Figure 1 and Figure 2 , a direction in which the plate-shaped core base portions 21a and 21b extend and a direction in which a core leg portion 22 described later is arranged are taken as an X-axis direction; a direction orthogonal to the pair of plate-shaped core base portions 21a and 21b arranged substantially parallel to each other is taken as a Z-axis direction; and a direction perpendicular to the X-axis direction and the Z-axis direction is taken as a Y-axis direction. Further, in the description of the coil device 10, the Z-axis direction is taken as a vertical direction, but the coil device 10 can be arranged with the first core portion 20a located upward as shown in Figure 1 , or can be arranged with another direction upward.

[0111] As shown in Figure 2 , the core 20 has the pair of core base portions 21a and 21b and the core leg portion 22 arranged between the pair of core base portions 21a and 21b. The first core base portion 21a as one of the pair of core base portions 21a and 21b and the second core base portion 21b as the other core base portion each extend in a first direction (see Figure 2 ) parallel to the X-axis direction. The first core base portion 21a and the second core base portion 21b are arranged substantially parallel to each other with a prescribed interval in a second direction (parallel to the Z-axis direction) orthogonal to the first direction (see Figure 2 ) D2).

[0112] The leg portion 22 of the core protrudes from at least one side of the pair of core base portions 21a, 21b to the other side. As shown in Figure 2 The leg portion 22 of the core in the coil device 10 is configured by combining a portion protruding from the first core base portion 21a toward the second core base portion 21b and a portion protruding from the second core base portion 21b toward the first core base portion 21a. That is, the core 20 is an E-E core in which a first core portion 20a having the first core base portion 21a and a portion of the leg portion 22 and a second core portion 20b having the second core base portion 21b and another portion of the leg portion 22 are substantially the same shape. However, the core 20 of the coil device 10 is not limited to the E-E core, and can be an E-I core in which one of the core base portions alone is provided, or the like.

[0113] As shown in Figure 2 The leg portion 22 has a first leg portion 22a, a second leg portion 22b, a third leg portion 22c, a fourth leg portion 22d, and a fifth leg portion 22e. The first leg portion 22a, the second leg portion 22b, the third leg portion 22c, the fourth leg portion 22d, and the fifth leg portion 22e are arranged in a first direction parallel to the X-axis direction in order from one end portion 21ac, 21bc to the other end portion 21ad, 21bd of the core base portions 21a, 21b.

[0114] The first leg portion 22a, the second leg portion 22b, the third leg portion 22c, the fourth leg portion 22d, and the fifth leg portion 22e are arranged with a space between each other in the first direction. As a result, as shown in Figure 2 a first gap 24a is formed between the first leg portion 22a and the second leg portion 22b, a second gap 24b is formed between the second leg portion 22b and the third leg portion 22c, a third gap 24c is formed between the third leg portion 22c and the fourth leg portion 22d, and a fourth gap 24d is formed between the fourth leg portion 22d and the fifth leg portion 22e.

[0115] As will be described later, the lengths of the first to fourth gaps 24a, 24b, 24c, 24d in the first direction formed between each of the first to fifth leg portions 22a, 22b, 22c, 22d, 22e are not all the same. However, the core can be configured by the first to fifth leg portions 22a, 22b, 22c, 22d, 22e arranged at intervals, or the like, differently from this.

[0116] Figure 7 is a cross-sectional view of the coil device 10 taken in a plane parallel to the XZ plane and passing through the center of the coil device 10. As shown in Figure 7As shown, the 2nd slit 22ba is formed in the 2nd leg portion 22b, the 3rd slit 22ca is formed in the 3rd leg portion 22c, and the 4th slit 22da is formed in the 4th leg portion 22d. The length of the 2nd direction (a direction parallel to the Z-axis) of the 3rd slit 22ca is shorter than the length of the 2nd direction of the 2nd slit 22ba and the 4th slit 22da. Thus, the coil device 10 can make the amount of leakage flux generated in the transformer portion and the resonance coil portion an appropriate value, for example, and can omit a choke coil or the like connected to the primary side (refer to Figure 10 ) of the coil device 10, thereby achieving miniaturization of the entire circuit.

[0117] In addition, as shown in Figure 7 , the 2nd to 4th slits 22ba to 22da are air gaps, but the 2nd to 4th slits 22ba to 22da are not limited to air gaps, and the 2nd to 4th slits 22ba to 22da can be formed of a non-magnetic material. Furthermore, a slit (1st slit and 2nd slit) can also be formed in the 1st leg portion 22a and the 5th leg portion 22e. In this case, the length of the 2nd direction of the slit formed in the 1st leg portion 22a and the 5th leg portion 22e is shorter than the length of the 2nd to 4th slits 22ba to 22da, which is preferable in terms of the characteristics of the composite transformer of the coil device 10.

[0118] Figure 8 is a conceptual view showing the arrangement state of the 2nd core portion 20b and the 1st winding 31, the 2nd winding 32, and the 3rd winding 33 in the coil device 10, and is a view when these members in the coil device 10 are viewed from above. In addition, in Figure 8 , the 1st core portion 20a and the bobbin 40 are omitted from the illustration.

[0119] As shown in Figure 8 and Figure 7 , the distance in the 1st direction (parallel to the X-axis direction) from one end portion 21ac, 21bc of the core base portions 21a, 21b to the center of the 3rd leg portion 22c is shorter than the distance in the 1st direction from the other end portion 21ad, 21bd to the center of the 3rd leg portion 22c. That is, the 1st to 5th leg portions 22a to 22e are not arranged at equal intervals in the 1st direction, and the core 20 is asymmetric with respect to the 1st direction. By arranging the leg portions 22 of the core 20 in the manner shown in Figure 7 and Figure 8 , it is possible to appropriately form the gap through which the 1st to 3rd windings 31, 32, 33 pass, and achieve miniaturization of the coil device 10.

[0120] As shown in Figure 2 and Figure 7As shown, a first gap 24a is formed between the first core leg 22a and the second core leg 22b, and the first winding portion 31a of the first winding 31 passes through the first gap 24a. Furthermore, a second gap 24b is formed between the second core leg 22b and the third core leg 22c, and the second winding portion 32a of the second winding 32 passes through the second gap 24b.

[0121] Furthermore, a fourth gap 24d is formed between the fourth core leg 22d and the fifth core leg 22e, and the third winding portion 33a of the third winding 33 passes through the fourth gap 24d. Further, a third gap 24c is formed between the third core leg 22c and the fourth core leg 22d, and the first to third winding portions 31a to 33a of the first to third windings 31 to 33 pass through the third gap 24c.

[0122] like Figure 7 As shown, regarding the width along the first direction (width in the first direction), the third gap 24c is wider than the second gap 24b. Furthermore, regarding the width along the first direction, the third gap 24c is wider than the first gap 24a and the fourth gap 24d. By making the width of the third gap 24c, through which all the first to third winding portions 31a to 33a pass, wider than the first gap 24a, the second gap 24b, and the fourth gap 24d, it is possible to make the first to fourth gaps 24a to 24d formed between the core feet 22 an appropriate width corresponding to the first to third winding portions 31a to 33a passing through these first to fourth gaps 24a to 24d, and this contributes to the miniaturization of the coil assembly 10.

[0123] like Figure 8 As shown, regarding the third direction (parallel to the Y-axis direction) which is perpendicular to the first and second directions, refer to the third direction D3. Figure 8 The lengths of the first core leg 22a (length L1) and the fifth core leg 22e (length L5) are approximately equal. Furthermore, regarding the length in the third direction, the third core leg 22c (length L3) is shorter than any of the first core leg 22a, the second core leg 22b (length L2), the fourth core leg 22d (length L4), and the fifth core leg 22e.

[0124] By making the length of the third direction of the first to fifth core feet 22a to 22e be... Figure 8 As shown, Figure 2 As shown, recesses 21aa and 21ab, narrower in the third direction than one end 21ac and the other end 21ad, are formed in the middle portion of the first core base 22a in the first direction. These recesses 21aa and 21ab can be configured with... Figure 4The first lead-out groove portion 41b, the second lead-out groove portion 42b, and the third lead-out groove portion 43b of the bobbin 40 are shown. In this way, by forming the recesses 21aa, 21ab in the first core base portion 21a, and disposing the first to third lead-out groove portions 41b to 43b therein, it is possible to suppress the protrusion of the lead-out portions of the first to third windings 31 to 33, and to achieve the downsizing of the coil device 10.

[0125] As shown in Figure 8 , the first core leg portion 22a (cross-sectional area S1) is substantially equal to the fifth core leg portion 22e (cross-sectional area S5), and the third core leg portion 22c (cross-sectional area S3) is substantially equal to the sum of the first core leg portion 22a and the fifth core leg portion 22e (cross-sectional area S1+S3) with respect to the cross-sectional area obtained by the cross section orthogonal to the second direction (Z-axis parallel). By achieving such a relationship, it is possible to appropriately ensure the magnetic characteristics of the core 20. However, each core leg portion 22a to 22e can be different from the embodiment shown in Fig. 8.

[0126] Figure 6 is Figure 1 an exploded perspective view of the bobbin 40 included in the coil device 10 shown in Figure 6 . As shown in , the bobbin 40 has a first bobbin portion 41, a second bobbin portion 42, and a third bobbin portion 43, and the first bobbin portion 41, the second bobbin portion 42, and the third bobbin portion 43 can be separated from each other.

[0127] Figure 2 As shown in Figure 3 , the first to third bobbin portions 41 to 43 are disposed between the first core base portion 21a as one core base portion and the second core base portion 21b as another core base portion. As can be understood from Figure 7 , the first winding portion 31a of the first winding 31 is wound around the first bobbin portion 41. Further, the second winding portion 32a of the second winding 32 is wound around the second bobbin portion 42 (see Figure 7 ). Further, the third winding portion 33a of the third winding 33 is wound around the third bobbin portion 43.

[0128] As shown in Figure 8 , the first to third winding portions 31a to 33a of the first to third windings 31 to 33 of the coil device 10 are disposed between the first core base portion 21a and the second core base portion 21b in a manner of surrounding the periphery of at least one of the second to third core leg portions 22b to 22c.

[0129] As shown in Figure 7 and Figure 8As shown, the first winding portion 31a of the first winding 31 is wound in a manner passing through the first gap 24a and the third gap 24c of the core 20 and surrounding the second leg portion 22b and the third leg portion 22c of the core 20.

[0130] Further, the second winding portion 32a of the second winding 32 is wound in a manner passing through the second gap 24b and the third gap 24c of the core 20 and surrounding the third leg portion 22c of the core 20. Further, the third winding portion 33a of the third winding 33 is wound in a manner passing through the fourth gap 24d and the third gap 24c of the core 20 and surrounding the fourth leg portion 22d.

[0131] Figure 3 is a perspective view of the first to third windings 31 to 33 and the bobbin 40 included in the coil device 10, Figure 4 is a plan view when the first to third windings 31 to 33 and the bobbin 40 are viewed from the positive direction of the Z-axis. As shown in Figures 2-4 The first winding 31 has a pair of first lead portions 31b drawn from the first winding portion 31a. The first lead portions 31b, which are both end portions of the first winding 31, are drawn outside from the first bobbin portion 41 through the first lead groove portions 41b of the first bobbin portion 41.

[0132] Further, the second winding 32 has a pair of second lead portions 32b, 32c drawn from the second winding portion 32a. The second lead portion 32b, which is one of the second lead portions 32b, 32c, both end portions of the second winding 32, is drawn outside from the second bobbin portion 42 through the second lead groove portion 42b of the second bobbin portion 42. The second lead portion 32c, which is the other of the second lead portions 32b, 32c, is connected to the third lead portion 33c of the third winding 33 as described later.

[0133] Further, as shown in Figure 4 The third winding 33 has a pair of third lead portions 33b, 33c drawn from the third winding portion 33a. One third lead portion 33b is drawn outside from the third bobbin portion 43 through the third lead groove portion 43b of the third bobbin portion 43. The other third lead portion 33c in the third winding 33 is connected to the other second lead portion 32c of the second winding 32 through the third lead groove portion 43b of the third bobbin portion 43. Thus, the second winding 32 and the third winding 33 are electrically connected via the other second lead portion 32c of the second winding 32 and the other third lead portion 33c of the third winding 33.

[0134] Figure 10 is a conceptual view showing a circuit of the coil device 10. As shown in Figure 10As shown, in the coil device 10, the portion including the first winding portion 31a and the second winding portion 32a constitutes the transformer portion, and the portion including the third winding portion 33a constitutes the resonant coil (secondary resonant coil) portion. Figure 9 This is a conceptual diagram showing the direction of magnetic flux flow caused by the transformer portion formed within the core 20 of the coil device 10 (arrow 61) and the direction of magnetic flux flow caused by the resonant coil portion (arrow 62).

[0135] like Figure 9 As shown, in the coil device 10, the common magnetic circuit between the transformer section and the resonant coil section is generated more than in existing composite coil devices, which is advantageous from the viewpoint of miniaturization. In the coil device 10, even without forming a magnetic circuit separating the transformer section and the resonant coil section, the gaps between the first core leg 22a and the fifth core leg 22e are made smaller than the gaps between the other second to fourth core legs 22b to 22d, thereby preventing the magnetic flux from interfering with each other's operation.

[0136] Furthermore, in the coil device 10, by means of... Figure 10 As shown, adjusting the current direction increases the number of portions where the magnetic flux flow caused by the transformer (arrow 61) and the magnetic flux flow caused by the resonant coil (arrow 62) are in opposite directions. Specifically, in coil assembly 10, at the first core leg 22a and the fifth core leg 22e, the magnetic flux flow caused by the transformer (arrow 61) and the magnetic flux flow caused by the resonant coil (arrow 62) are in opposite directions. In coil assembly 10, by generating magnetic flux in opposite directions, the magnetic flux is canceled out, and the cross-sectional area of ​​each part of the core 20 can be narrowed.

[0137] However, in the coil assembly 10, it can also be configured such that the direction of magnetic flux flow (arrow 61) caused by the transformer portion and the direction of magnetic flux flow (arrow 62) caused by the resonant coil portion are in the same direction at the first core leg 22a and the fifth core leg 22e. The cross-sectional area of ​​each part of the core 20 and the direction of the current can be determined by taking into account the operating conditions of the coil assembly 10 or various losses.

[0138] like Figure 6 As shown, the second winding frame portion 42 has a second hollow cylindrical portion 42a and a pair of second lead-out slots 42b. On the outer periphery of the second hollow cylindrical portion 42a, a second winding portion 32a of the second winding 32 is arranged (see reference). Figure 7 The second winding frame portion 42 has a central flange portion 42d and a second guide portion 42e formed near the lower end of the second hollow cylinder portion 42a. The central flange portion 42d and the second guide portion 42e guide the second winding portion 32a as a layer of winding and prevent the second winding portion 32a from being misaligned or deformed in the second direction.

[0139] As shown in Figure 7 , the 2nd hollow cylinder portion 42a allows the 3rd leg portion 22c to pass therethrough. As shown in Figure 9 , the 3rd leg portion 22c that passes through the 2nd hollow cylinder portion 42a functions as a leg portion of a transformer portion in the coil device 10. Further, as shown in Figure 7 , at a portion of the 2nd hollow cylinder portion 42a that is disposed in the 2nd gap 24b, a 2nd cover portion 42c that ensures an insulation distance of the 2nd winding portion 32a with respect to the 2nd leg portion 22b is installed.

[0140] Figure 6 The 1st bobbin portion 41 shown in Figure 3 and Figure 7 has a 1st hollow cylinder portion 41a and a pair of 2nd lead groove portions 41b. The 1st winding portion 31a of the 1st winding 31 is disposed on the outer periphery of the 1st hollow cylinder portion 41a (refer to Figure 7 ).

[0141] As shown in Figure 5 and Figure 7 , the 1st hollow cylinder portion 41a of the 1st bobbin portion 41 allows the 2nd bobbin portion 42 and the 2nd leg portion 22b to pass therethrough. As shown in Figure 7 , the 3rd leg portion 22c, the 2nd hollow cylinder portion 42a, the 2nd winding portion 32a, and at least a portion of the 2nd leg portion 22b are housed inside the 1st hollow cylinder portion 41a.

[0142] As shown in Figure 4 , the center of the 2nd hollow cylinder portion 42a housed inside the 1st hollow cylinder portion 41a does not coincide with the center of the 1st hollow cylinder portion 41a as viewed from the Z-axis direction, but is disposed closer to the 3rd bobbin portion 43 than the center of the 1st hollow cylinder portion 41a. Thus, a larger gap is formed between the inner wall of the 1st hollow cylinder portion 41a and the outer periphery of the 2nd hollow cylinder portion 42a on the X-axis negative direction side that is farther from the 3rd bobbin portion 43 than the center of the 2nd hollow cylinder portion 42a. At least a portion of the 2nd leg portion 22b is inserted into the gap formed between the inner wall of the 1st hollow cylinder portion 41a and the outer periphery of the 2nd hollow cylinder portion 42a.

[0143] As shown in Figure 9 , the 2nd leg portion 22b that passes through the 1st hollow cylinder portion 41a functions as a leg portion for adjusting the leakage flux of the transformer portion in the coil device 10. When the length of the 2nd gap 22ba of the 2nd leg portion 22b is shortened, the leakage flux of the transformer portion increases, and when the length of the 2nd gap 22ba is lengthened, the leakage flux decreases. Further, as shown in Figure 7As shown, a portion of the third hollow cylinder portion 43a disposed in the fourth gap 24d is provided with a third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the fifth leg portion 22e. Further, another portion of the third hollow cylinder portion 43a disposed in the third gap 24c is provided with the third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the first winding portion 31.

[0144] Figure 6 The third bobbin portion 43 has a third hollow cylinder portion 43a and a pair of third lead-out groove portions 43b. The third winding portion 33a of the third winding portion 33 is disposed on the outer periphery of the third hollow cylinder portion 43a (see FIG. 3). Figure 3 and Figure 7 The third winding portion 33a is wound in two layers, and the number of turns and the number of layers of the third winding portion 33a are not limited to those of the embodiment shown. Figure 7

[0145] As shown, the third hollow cylinder portion 43a of the third bobbin portion 43 allows the fourth leg portion 22d to pass therethrough. As shown, the fourth leg portion 22d that passes through the third hollow cylinder portion 43a functions as a leg portion of a resonance coil portion of the coil device 10. Further, as shown, a portion of the third hollow cylinder portion 43a disposed in the fourth gap 24d is provided with a third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the fifth leg portion 22e. Further, another portion of the third hollow cylinder portion 43a disposed in the third gap 24c is provided with the third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the first winding portion 31. Figure 4 and Figure 7 The first bobbin portion 41 and the third bobbin portion 43 are disposed so as to be adjacent to each other in the third gap 24c of the core 20. As shown, the other of the third lead-out groove portions 43b (the other end) of the third bobbin portion 43 extends toward the first bobbin portion 41 in the first direction. Further, the second lead-out groove portion 42b and the third lead-out groove portion 43b are disposed on the negative side of the Y axis with respect to the first core base portion 21a. Figure 9 Figure 7

[0146] As shown, the third hollow cylinder portion 43a of the third bobbin portion 43 allows the fourth leg portion 22d to pass therethrough. As shown, the fourth leg portion 22d that passes through the third hollow cylinder portion 43a functions as a leg portion of a resonance coil portion of the coil device 10. Further, as shown, a portion of the third hollow cylinder portion 43a disposed in the fourth gap 24d is provided with a third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the fifth leg portion 22e. Further, another portion of the third hollow cylinder portion 43a disposed in the third gap 24c is provided with the third cover portion 43c that ensures an insulation distance of the third winding portion 33a with respect to the first winding portion 31. Figure 4 and Figure 7 The first bobbin portion 41 and the third bobbin portion 43 are disposed so as to be adjacent to each other in the third gap 24c of the core 20. As shown, the other of the third lead-out groove portions 43b (the other end) of the third bobbin portion 43 extends toward the first bobbin portion 41 in the first direction. Further, the second lead-out groove portion 42b and the third lead-out groove portion 43b are disposed on the negative side of the Y axis with respect to the first core base portion 21a. Figure 4

[0147] As the material of the core 20 of the coil device 10, there is no particular limitation, and a soft magnetic material such as ferrite or metal can be cited. For example, the first core portion 20a and the second core portion 20b can be manufactured by molding a powder of ferrite or metal into a predetermined shape or the like. Further, as the material of the bobbin 40, there is no particular limitation, and an insulating resin or the like can be cited. For example, the first to third bobbin portions 41 to 43 can be manufactured by molding a material such as a resin by injection molding or the like.

[0148] ​​​​In addition, in the description of the core 20 of the coil device 10 and the bobbin 40, "separable" means that the core 20 and the bobbin 40 can be assembled from a state in which they are not integrated but separated in the assembly process of the coil device 10, and the core 20 and the bobbin 40 are not limited to being fixed to other members by adhesion or the like. As components pertaining to the relationship of "separable", components that are assembled from a state in which they are separated and fixed to other members by adhesion or the like at the time of assembly or after assembly are also included.

[0149] The first to third windings 31 to 33 of the coil device 10 are not particularly limited, and covered conductors having a conductive wire portion of copper or the like can be cited. As the first to third windings 31 to 33, either a single wire or a stranded wire such as a Litz wire can be used.

[0150] The coil device 10 described above can connect the second winding 32 and the third winding 33 compactly inside the coil device 10. However, the second winding 32 and the third winding 33 can also be considered to be connected in a manner other than inside the coil device 10 as shown in the embodiment. Figure 8 In this case, the second winding 32 and the third winding 33 can be connected by being connected via a substrate or the like on which the coil device 10 is mounted, thereby constituting a circuit similar to the circuit shown in Figure 10

[0151] The coil device 10 can be assembled in a simple process and is advantageous for size reduction and low profile by using the core 20 having the first to fifth leg portions 22a to 22e and arranging the first to third winding portions 31a to 33a in a manner that passes from the prescribed positions in the first to fourth gaps 24a to 24d. That is, since all of the first to fifth leg portions 22a to 22e are arranged between the pair of core base portions 21a, 21b, the coil device 10 can be assembled in a simple process and is advantageous for size reduction and low profile. Furthermore, since all of the first winding portion 31a, the second winding portion 32a, and the third winding portion 33a pass through the third gap 24c of the core 20, the coil device 10 is advantageous in terms of size reduction of the core 20 and shortening of the winding length.

[0152] Furthermore, the coil device 10 has a structure in which the first to third bobbin portions 41 to 43 that can be separated from each other are arranged between the pair of core base portions 21a, 21b, and thus the coil device 10 can be assembled in a simple process and is advantageous for size reduction and low profile.

[0153] The above describes the coil device 10 according to the embodiment, but the scope of the technology of the present application is not limited to the above-described embodiment, and the present application certainly includes many other embodiments or modifications. For example, the coil device 10 can have a housing 50 (refer to FIG. 2) that accommodates the core 20 and the bobbin 40 or the like. Figure 8 ​) can also have a filling resin or the like fixed to the housing 50, the core 20, the bobbin 40, and the like.

[0154] Further, in the coil device 10 shown in the embodiment, as shown in Figure 10 the second winding portion 32a and the third winding portion 33a constitute the secondary side. However, unlike this, a coil device in which the first winding portion 31a and the third winding portion 33a are connected in series, the first winding portion 31a and the third winding portion 33a constitute the primary side, and the second winding portion 32a constitutes the secondary side is also one of the embodiments of the present application. In such an embodiment, for example Figure 8 the third lead 33c and one of the first lead 31b are electrically connected as shown in

Claims

1. A coil device characterized by comprising: a core having a pair of core bases extending in a first direction and arranged substantially in parallel with each other at a prescribed interval in a second direction perpendicular to the first direction, and a core leg having a first core leg, a second core leg, a third core leg, a fourth core leg, and a fifth core leg arranged in order from one side to the other side of the pair of core bases and from one end to the other end of the core bases in the first direction with intervals therebetween; a first winding having a first winding portion wound so as to pass through a first gap formed between the first core leg and the second core leg and a third gap formed between the third core leg and the fourth core leg and enclose the second core leg and the third core leg; a second winding having a second winding portion wound so as to pass through a second gap formed between the second core leg and the third core leg and the third gap and enclose the third core leg; a third winding having a third winding portion wound so as to pass through the fourth gap formed between the fourth core leg and the fifth core leg and the third gap and enclose the fourth core leg; and a bobbin wound with the first winding portion, the second winding portion, and the third winding portion.

2. The coil device according to claim 1, characterized in that: the second winding and the third winding are electrically connected.

3. The coil device according to claim 1 or 2, characterized in that: the bobbin has a first bobbin portion wound with the first winding portion, a second bobbin portion wound with the second winding portion, and a third bobbin portion wound with the third winding portion, and the first bobbin portion, the second bobbin portion, and the third bobbin portion are separable from each other.

4. The coil device according to claim 3, characterized in that: the second bobbin portion has a second hollow cylinder portion through which the third core leg is inserted, the first bobbin portion has a first hollow cylinder portion through which the second bobbin portion and the second core leg are inserted, and the third bobbin portion has a third hollow cylinder portion through which the fourth core leg is inserted.

5. The coil device according to claim 3, characterized in that: the first bobbin portion and the third bobbin portion are adjacent to each other in the third gap.

6. The coil device according to claim 1 or 2, characterized in that: a distance of the core bases in the first direction from the one end to the third core leg is shorter than a distance of the core bases in the first direction from the other end to the third core leg.

7. The coil device according to claim 1 or 2, characterized in that: the third gap is wider than the second gap in width in the first direction.

8. The coil device according to claim 1 or 2, characterized in that: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ The first leg portion and the fifth leg portion are substantially equal in length in a third direction perpendicular to the first direction and the second direction.

9. The coil device according to claim 1 or 2, wherein: The third leg portion is shorter than the first leg portion, the second leg portion, the fourth leg portion, and the fifth leg portion in length in a third direction perpendicular to the first direction and the second direction.

10. The coil device according to claim 1 or 2, wherein: The first leg portion and the fifth leg portion are substantially equal in cross-sectional area of a cross section orthogonal to the second direction, and the third leg portion is substantially equal to the sum of the first leg portion and the fifth leg portion.

11. The coil device according to claim 1 or 2, wherein: A second slit is formed in the second leg portion, a third slit is formed in the third leg portion, and a fourth slit is formed in the fourth leg portion, and the second slit and the fourth slit are longer than the third slit in the second direction.

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