Coil device

Abstract

The invention provides a coil device which can adjust leakage and is excellent in heat dissipation performance. The spacer (10) has a predetermined thickness along the winding axis. The spacer (10) has: an outer flow path (11) that allows fluid to flow from the outer side in the radial direction of a first opposing end (42) of the first winding part (40) or a second opposing end (52) of the second winding part (50) to the inner side; and an inner flow path (12) that allows fluid to flow from the inner side in the radial direction of the first opposing end (42) or the second opposing end (52) to the outer side. And at least one of the axial flow paths (16) allowing flow of fluid from the first opposing end (42) towards the second opposing end (52).

Description

Technical Field

[0001] The present invention relates to a coil arrangement for use, for example, as a transformer or the like. Background Art

[0002] For example, as shown in Patent Document 1 listed below, there is known a coil device in which an insulating plate is arranged between a primary coil and a secondary coil to adjust leakage between the primary coil and the secondary coil.

[0003] In recent years, as the current of coil devices has increased, heat generated by windings constituting the primary coil and the secondary coil has become a technical problem.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2011-77255 Summary of the invention

[0007] The present invention has been developed in view of such actual circumstances, and an object of the present invention is to provide a coil device that can adjust leakage and has excellent heat dissipation properties.

[0008] In order to achieve the above-mentioned object, a coil device according to a first aspect of the present invention comprises:

[0009] a first winding coiling portion;

[0010] a second wire winding portion disposed adjacent to the first wire winding portion along a winding axis of the first wire winding portion;

[0011] a spacer disposed between a first opposite end of the first winding portion along the winding axis and a second opposite end of the second winding portion along the winding axis,

[0012] The spacer has a predetermined thickness along the winding axis, and

[0013] The spacer has:

[0014] At least one of an outer flow path allowing fluid to flow from the radially outer side to the inner side of the first relative end or the second relative end, an inner flow path allowing fluid to flow from the radially inner side to the outer side of the first relative end or the second relative end, and an axial flow path allowing fluid to flow from the first relative end to the second relative end.

[0015] In the coil device of the present invention, since a spacer having a predetermined thickness is disposed between the first winding portion and the second winding portion, the distance between the first opposite end of the first winding portion and the second opposite end of the second winding portion can be controlled by the thickness of the spacer. As a result, the leakage of the coil device can be adjusted.

[0016] In addition, in the coil device of the present invention, the spacer having a predetermined thickness has at least one of an outer flow path, an inner flow path, and an axial flow path. Therefore, through these flow paths, a cooling fluid (such as cooling wind, heat-dissipating resin, etc.) can be introduced between the first opposite end and the second opposite end, thereby improving the heat dissipation of the coil device.

[0017] Preferably, at least one of the outer flow path, the inner flow path, and the axial flow path is a plurality of flow path forming regions without components constituting the spacer and not in contact with the first opposite end and / or the second opposite end. In addition, preferably, the plurality of flow path forming regions exist at a plurality of positions along the circumferential direction of the spacer.

[0018] By providing a flow path forming area where there are no components constituting the spacer at multiple locations along the circumferential direction on the surface of the spacer, the cooling fluid can be introduced between the first opposite end and the second opposite end at multiple locations along the circumferential direction, and the heat dissipation of the coil device is further improved. In addition, even if the flow path forming area is formed at multiple locations along the circumferential direction, the leakage adjustment of the coil device is well maintained because the spacer has a specified thickness. In addition, the flow path forming area can be a groove formed only on a single side surface of the spacer, or it can be a groove formed on both sides of the spacer, or it can also be a cutout or through hole that passes through the front and back sides of the spacer.

[0019] At least one of the plurality of flow path forming areas may also have an outer recessed portion, which is recessed from the outer peripheral position toward the inner peripheral position of the spacer and does not contact the first relative end and / or the second relative end. Through the outer recessed portion, the cooling fluid can be introduced from the radial outer side of the winding portion toward the inner side, between the first relative end and the second relative end. In addition, the outer recessed portion only needs to be recessed from the radial outer side of the winding portion toward the inner side, and if it is a structure that does not contact at least one of the first relative end and the second relative end, it can be a cut or a groove. In addition, the outer recessed portion may also pass through from the radial outer side of the spacer to the inner side.

[0020] Preferably, a spiral concave portion continuous along the circumferential direction is formed at the first opposite end and the second opposite end of the winding portion in coordination with the spiral shape of the winding wire constituting the winding portion. The cooling fluid introduced into the inner side of the winding portion through the outer concave portion can also flow into the inner concave portion located next to the winding portion in the circumferential direction through the spiral concave portion.

[0021] The width of the outer recessed portion along the circumferential direction is wider at the outer circumferential position than at the inner circumferential position. With this configuration, it is easy to introduce the cooling fluid from the radially outer side of the winding portion toward the inner side between the first opposing end and the second opposing end.

[0022] At least one of the plurality of flow path forming regions may also have an inner recessed portion, which is recessed from the inner peripheral position toward the outer peripheral position of the spacer and does not contact the first relative end and / or the second relative end. Through the inner recessed portion, the cooling fluid can be introduced between the first relative end and the second relative end from the radial inner side of the winding portion toward the outer side or from the outer side toward the inner side. In addition, the inner recessed portion only needs to be recessed from the radial inner side of the winding portion toward the outer side, and if it is a structure that does not contact at least one of the first relative end and the second relative end, it can be a cutout or a groove. In addition, the inner recessed portion may also pass through from the radial inner side of the spacer to the outer side.

[0023] The width of the inner recessed portion along the circumferential direction may also be wider at the inner circumferential position than at the outer circumferential position. With such a configuration, it is easy to introduce the cooling fluid from the radial inner side of the winding portion toward the outer side between the first opposite end and the second opposite end. Alternatively, the cooling fluid may be introduced from the radial outer side of the winding portion toward the inner side between the first opposite end and the second opposite end along the inner recessed portion, and the cooling fluid may be stored at the inner circumferential position where the width of the inner recessed portion is wide, thereby improving the heat dissipation from the inner side of the winding portion and the outer circumferential surface of the mid-leg portion of the core.

[0024] At least one of the plurality of flow path forming regions may also have a through hole connected from the first opposite end to the second opposite end. Through the through hole, a cooling fluid can flow between the first opposite end and the second opposite end. In addition, the through hole is a flow path forming region that is not in contact with both the first opposite end and the second opposite end. If it is a structure that is not in contact with both ends, it may also be a cutout. In addition, the through hole may also be a structure that serves as an outer recess or an inner recess.

[0025] The plurality of flow path forming regions may also include:

[0026] an inner concave portion that is concave from an inner peripheral position toward an outer peripheral position of the spacer and does not contact the first opposite end and / or the second opposite end;

[0027] The outer recessed portion is disposed beside the inner recessed portion in the circumferential direction, is recessed from the outer circumferential position toward the inner circumferential position of the spacer, and does not contact the first opposing end and / or the second opposing end.

[0028] By arranging the inner recess and the outer recess adjacent to each other in the circumferential direction, the cooling fluid can be introduced between the first opposite end and the second opposite end from the radial inner side to the outer side and from the outer side to the inner side of the winding portion, and the heat dissipation is further improved. In addition, by, for example, providing a spiral recess at the first opposite end or the second opposite end, the cooling fluid can also flow between the adjacent inner recess and the outer recess.

[0029] The width of the outer recess along the circumferential direction may also be wider than the width of the inner recess along the circumferential direction. Sometimes, the middle leg of the core is closely arranged in the central opening of the spacer, so that the cooling fluid is easily circulated from the radially outer side to the inner side of the spacer, compared with the cooling fluid flowing from the radially inner side to the outer side of the spacer. Therefore, by making the width of the outer recess along the circumferential direction wider than the width of the inner recess along the circumferential direction, it is easy to introduce the cooling fluid between the first opposite end and the second opposite end.

[0030] A coil device according to a second aspect of the present invention includes:

[0031] a first winding coiling portion;

[0032] a second wire winding portion disposed adjacent to the first wire winding portion along a winding axis of the first wire winding portion;

[0033] a spacer disposed between a first opposite end of the first winding portion along the winding axis and a second opposite end of the second winding portion along the winding axis,

[0034] The spacer has a predetermined thickness along the winding axis, and

[0035] The spacer has:

[0036] At least one of an outer recess allowing fluid to flow from the radially outer side to the inner side of the first relative end or the second relative end, an inner recess allowing fluid to flow from the radially inner side to the outer side of the first relative end or the second relative end, and a through hole allowing fluid to flow from the first relative end to the second relative end.

[0037] At least one of the first winding wire constituting the first winding winding part and the second winding wire constituting the second winding winding part is composed of a conductor, and the conductor is covered with an insulating layer having at least a heat-welding layer. With such a structure, it is easy to join parts of the winding wires that are in contact with each other by heat-welding, and it is easy to form an air-core coil in which the winding wires are wound into a coil shape. In addition, in a state where the first winding winding part, the spacer, and the second winding winding part are combined, by heat-pressing them along the winding axis direction, it is easy to manufacture a coil body that integrates the first winding winding part, the spacer, and the second winding winding part.

[0038] The first opposite ends of the first winding portion or the second opposite ends of the second winding portion may be bonded to the surface of the spacer. The bonding method may be thermal compression bonding using a heat-sealing layer of the winding or a method using an adhesive.

[0039] The spacer may also be made of an insulating component and / or a metal component. When the spacer is made of an insulating component, the insulation between the first winding portion and the second winding portion is also improved. When the spacer is made of a metal component, the heat transfer characteristics of the spacer itself are good, and the heat dissipation is further improved. In addition, the winding is preferably a winding covered with an insulating film.

[0040] Preferably, the coil device further includes a core. Also, preferably, the spacer includes a central opening extending through the spacer along the winding axis, and the core includes a middle leg portion disposed in the central opening through the first winding portion or the second winding portion.

[0041] The core may also include a side foot portion covering at least a portion of the outer periphery of the first winding portion or the outer periphery of the second winding portion, and a predetermined gap may be provided between the outer peripheral end of the spacer and the inner peripheral surface of the side foot portion. The outer peripheral end of the spacer may also contact the inner peripheral surface of the side foot portion, but it is preferred that the inner peripheral surface of the side end portion of the core is not damaged.

[0042] It is also possible to further include a housing for accommodating at least a portion of the first winding portion and the second winding portion. In this case, it is preferred that the interior of the housing is filled with a heat-dissipating resin until the spacer between the first winding portion and the second winding portion is at least immersed. With such a configuration, the heat-dissipating resin as the cooling fluid enters between the first opposite end of the first winding portion and the second opposite end of the second winding portion, thereby particularly improving heat dissipation. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a schematic perspective view of a coil device according to a first embodiment of the present invention.

[0044] Figure 2A It has been removed Figure 1 A schematic perspective view of the coil device in the housing shown.

[0045] Figure 2B yes Figure 2A A schematic exploded perspective view of the coil device shown.

[0046] Figure 2C yes Figure 2B A schematic exploded perspective view of the terminal block shown.

[0047] Figure 2D yes Figure 2B A portion of the coil body is omitted in the perspective view.

[0048] Figure 3 Observe from different angles Figure 2C A perspective view of the terminal block body shown.

[0049] Fig.4A1 yes Figure 1 A schematic cross-sectional view of the coil device shown along line IVA-IVA.

[0050] Figure 4A2 yes Figure 1 The coil device shown is a schematic cross-sectional perspective view taken along line IVA-IVA.

[0051] Figure 4B yes Fig.4A1 A schematic cross-sectional view of the coil device shown along line IVB-IVB.

[0052] Figure 5 Yes means Figure 4A2 A schematic perspective view showing the flow direction of the heat dissipating resin in the spacer shown.

[0053] Fig. 6A yes Figure 4A2 A schematic perspective view of the spacer is shown.

[0054] Figure 6B Yes means Fig. 6A A schematic perspective view of a modified example of the spacer shown.

[0055] Figure 6C Yes means Fig. 6A A schematic perspective view of another modified example of the spacer shown.

[0056] Fig.6D Yes means Fig. 6A A schematic perspective view of yet another modified example of the spacer shown.

[0057] Fig. 6E Yes means Fig. 6AA schematic perspective view of yet another modified example of the spacer shown.

[0058] Fig. 6F Yes means Fig. 6A A schematic perspective view of yet another modified example of the spacer shown.

[0059] Figure 6G Yes means Fig. 6A A schematic perspective view of yet another modified example of the spacer shown.

[0060] Figure 6H Yes means Fig. 6A A schematic perspective view of yet another modified example of the spacer shown.

[0061] Fig.6I Yes means Fig. 6A A schematic perspective view of yet another modified example of the spacer shown.

[0062] Explanation of symbols

[0063] 1…Coil device

[0064] 2…core

[0065] 21…First Core

[0066] 21a…Base

[0067] 21b…Midfoot

[0068] 21b1…Front End

[0069] 21c…lateral foot

[0070] 21c1…Front End

[0071] 22…Second core

[0072] 22a…base part

[0073] 22a1…concave part

[0074] 22b…Midfoot

[0075] 22b1…Front End

[0076] 22c…lateral foot

[0077] 22c1…Front End

[0078] 22c2…side end face

[0079] 3…Coil core assembly

[0080] 30…Coil body

[0081] 4…First winding

[0082] 40 ... first winding section

[0083] 41a, 41b…lead portion

[0084] 42…first opposite end

[0085] 45…Spiral recess

[0086] 5…Second winding

[0087] 50...Second winding section

[0088] 51a, 51b…lead portion

[0089] 52…Second opposite end

[0090] 55…spiral recess

[0091] 6…terminal

[0092] 60…Terminal base

[0093] 61…Connection

[0094] 62…External connection

[0095] 7…Terminal block

[0096] 70…Hood

[0097] 70a…Handle piece

[0098] 70b…claw

[0099] 70c…Through hole

[0100] 71…Mounting slot

[0101] 72…Base plate

[0102] 72a…Inner surface

[0103] 72b…Inner concave part

[0104] 73… Flat sheet

[0105] 73a…Inner surface

[0106] 74…Bending piece

[0107] 74a…Inner surface

[0108] 8…Housing

[0109] 80…base plate

[0110] 81…Side panels

[0111] 82…Heat dissipation resin

[0112] 9…Heat Radiator

[0113] 90…Top plate

[0114] 91…Side

[0115] 10…Spacer

[0116] 11...Outside concave part

[0117] 12...inside concave part

[0118] 13…Peripheral part

[0119] 14…Inner circumference

[0120] 16…Through hole. DETAILED DESCRIPTION

[0121] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the contents shown in the drawings are merely schematic and exemplary for understanding the present invention, and the appearance and dimensional ratios may be different from the actual objects. In addition, the present invention is not limited to the following embodiments.

[0122] (First Embodiment)

[0123] Figure 1 The coil device 1 of the embodiment of the present invention shown functions as a leakage transformer, for example, and is used in a vehicle charger and a power supply circuit of various electrical equipment. The coil device 1 has a core 2, a first winding 4, a second winding 5, a terminal block 7, and a housing 8. In addition, in the accompanying drawings, the X-axis, the Y-axis, and the Z-axis are perpendicular to each other, and the Z-axis is parallel to the height direction of the coil device 1 (the winding direction of the coil). In the following description, with respect to each of the X-axis, the Y-axis, and the Z-axis, the direction toward the center of the coil device 1 is referred to as the inner side, and the direction away from the center of the coil device 1 is referred to as the outer side.

[0124] like Figure 2A As shown in FIG. 2 , the coil core assembly 3 includes a core 2, a first winding 4, a second winding 5, and a terminal block 7 having a terminal 6. Figure 1 FIG. 9 is a diagram of the heat sink 9 shown in FIG. Figure 2B As shown, in the present embodiment, the core 2 can be decomposed into a first core 21 arranged on the lower side along the Z axis and a second core 22 arranged on the upper side along the Z axis of the first core 21 .

[0125] In the present embodiment, the first core 21 and the second core 22 are respectively formed of an E-shaped core whose cross section parallel to the plane containing the Z axis and the Y axis is substantially E-shaped, and have the same shape, but may be different from each other. For example, one core may be an E-shaped core and the other core may be an I-shaped core. In addition, in the present embodiment, the core 2 is formed by combining the cores 21 and 22 divided into two, but is not limited to being divided into two, and may be formed by combining, for example, three or more cores divided into four.

[0126] In the present embodiment, the first core 21 includes a base portion 21a having a bottom surface parallel to a plane including the X-axis and the Y-axis, a middle leg portion 21b extending from the center of the base portion 21a toward the upper side along the Z-axis, and a pair of side leg portions 21b extending from both ends of the base portion 21a along the Y-axis toward the upper side along the Z-axis. In addition, the second core 22 includes a base portion 22a having an upper surface parallel to a plane including the X-axis and the Y-axis, a middle leg portion 22b extending from the center of the base portion 22a toward the lower side along the Z-axis, and a pair of side leg portions 21b extending from both ends of the base portion 22a along the Y-axis toward the lower side along the Z-axis.

[0127] These cores 21, 22 are respectively made of ferrite, metal magnetic body, or resin containing magnetic powder. Figure 5 As shown, the front end of the middle leg 21b is butted against the front end of the middle leg 22b, and the front end 21c1 of the side leg 21c is butted against the front end 22c1 of the side leg 22c. However, in another embodiment, the front end of the middle leg 21b and the front end of the middle leg 22b may not be in direct contact, but a gap may be formed between them. In the gap, Figure 1 The heat dissipating resin 82 shown may enter or may be interposed with other components.

[0128] like Figure 2B As shown, in the present embodiment, the coil core assembly 3 has a core 2 including a first core 21 and a second core 22, a coil body 30, and a terminal block 7 having a terminal 6. The coil body 30 has a first winding winding portion 40 in which a first winding 4 is wound in a coil shape, a second winding winding portion 50 in which a second winding 5 is wound in a coil shape, and a spacer 10 arranged between these winding portions. In the present embodiment, the second winding winding portion 50 is arranged on the upper side along the Z axis of the first winding winding portion 40, but the opposite may be true. In the present embodiment, for example, the first winding winding portion 40 becomes a primary side coil of a transformer, and the second winding winding portion 50 becomes a secondary side coil of a transformer, but the opposite may be true.

[0129] In the present embodiment, the first winding 4 and the second winding 5 are respectively composed of self-welding conductive wires having a welding layer and an insulating layer. The type of the conductive wire is not particularly limited, and it can be a conductive core wire such as a round wire, a flat wire, a stranded wire, a twisted wire, a braided wire, etc. The material of the welding layer or the insulating layer covering the core wire is not particularly limited, and examples thereof include polyurethane, polyamide-imide, polyimide, polyester, etc. In the present embodiment, it is preferred that the first winding portion 40 wound with the first winding 4 and the second winding portion 50 wound with the second winding 5 are respectively pre-formed into a coil shape, and preferably provided in the form of an air-core coil before being integrated with the spacer 10.

[0130] In addition, in the present embodiment, the first winding 4 and the second winding 5 are both composed of self-welding type windings, but only one of them may be a self-welding type winding, or both may be composed of other windings. In addition, at least one of the first winding winding portion 40 and the second winding winding portion 50 may also be a flat coil. The wire diameters of the first winding 4 and the second winding 5 may be the same or different, and there is no particular limitation on both, and are preferably within the range of 1.0 to 3.0 mm, for example.

[0131] Lead portions 41a and 41b are formed at both ends of the first winding 4 constituting the first winding winding portion 40, and each lead portion 41a and 41b is led out from the first winding portion 40 upward along the Z axis and connected to the terminals 6 and 6, respectively. In addition, lead portions 51a and 51b are formed at both ends of the second winding 5 constituting the second winding winding portion 50, and each lead portion 51a and 51b is led out from the second winding portion 50 upward along the Z axis and connected to the terminals 6 and 6, respectively.

[0132] The plurality of terminals 6 to which these plurality of lead portions 41a, 41b, 51a, and 51b are respectively connected are mounted on the terminal block 7. The terminal block 7 has a cover 70, and by mounting the cover 70 on the terminal block 7, the plurality of terminals 6 are fixed along the Y-axis at predetermined intervals along the long side direction of the terminal block 7. The terminal block 7 and the cover 70 are preferably made of an insulating member such as a synthetic resin, and may be made of the same insulating material, but may also be made of different insulating materials. In the present embodiment, the terminal block 7 is directly fixed to the core 2 using an adhesive or the like, but it may not necessarily be fixed to the core 2. For example, the terminal block 7 may be fixed to Figure 1 The housing 8 shown, or in another embodiment, may be mounted on a frame not shown, or may be formed as a part of the frame.

[0133] like Figure 2CAs shown, in this embodiment, the plurality of terminals 6 have the same shape, and include a terminal base portion 60, a connection portion 61 provided at one end of the terminal base portion 60 along the X axis, and an external connection portion 62 provided at the other end of the terminal base portion 60 along the X axis. The connection portion 61 is connected by riveting, hot pressing, laser melting, welding, etc. Figure 2B Any of the lead portions 41a, 41b, 51a, and 51b shown. The external connection portion 62 is a portion connected to an external connection terminal (not shown) or a terminal connection recess of a circuit board.

[0134] The terminal base portion 60 of each terminal 6 is respectively mounted in a plurality of mounting grooves 71 provided on the terminal block 7 at predetermined intervals along the Y-axis direction, and the tiny protrusions formed in the mounting grooves 71 can enter the fitting holes of the terminal base 60 and be hot-pressed. In addition, the base portion 60 of the terminal 6 can also be fixed to the mounting groove 71 by other methods. In addition, the terminal 6 can be formed by, for example, stamping a metal plate.

[0135] The terminal block 7 includes a base plate portion 72 formed with a mounting groove 71, a pair of flat plates 73 extending downward along the Z axis from both ends of the base plate portion 72 along the Y axis, and a bent plate 74 connecting the pair of flat plates in an integrated manner. Figure 3 As shown, the bent piece 74 of the terminal block 7 has a Figure 2B The inner surface convex portion 74a of the second core 22 shown in FIG. 2 is formed to match the surface of the concave portion 22a1 at one end along the X-axis of the base portion 22a. Figure 2B The inner surface 73a of the side leg portion 22c of the second core 22 shown matches the planar shape of the side end surface 22c2 along the X-axis.

[0136] Figure 3 The inner surface 72a of the base portion 72 of the terminal block 7 shown is mounted on Figure 2B The upper surface of the base portion 22a of the second core 22 shown can be fixed by, for example, an adhesive. Figure 3 The inner surface 74a of the bent piece 74 of the terminal block 7 shown in FIG. Figure 2B The recess 22a1 of the base portion 22a of the second core 22 shown is fitted, Figure 3 The inner surface 73a of the flat plate 73 of the terminal block 7 shown can be Figure 2B The side end surface 22c2 of the side leg portion 22c of the second core 22 shown is in close contact. In this embodiment, no frame is used, and the terminal block 7 can be directly fixed to the core 2 (specifically, the second core 22).

[0137] like Figure 2BAs shown, the cover 70 mounted on the terminal block 7 has holding pieces 70a at both ends of the Y-axis direction and claws 70b at the front end. Figure 3 As shown, the claws 70 b are engaged with inner recesses 72 b provided at both ends along the Y axis of a base plate portion 72 of the terminal block, so that the cover 70 can be fixed to the terminal block 7 .

[0138] like Figure 1 As shown, the housing 8 has a substantially rectangular bottom plate 80, and side plates 81 that rise upward along the Z axis from the four sides of the bottom plate 80 and form a bottomed storage space inside, and an upper opening is formed at the upper part along the Z axis. The lower half or more of the coil core assembly 3 is stored inside the housing 8, and the liquid level of the heat dissipation resin 82 filled inside the housing 8 is preferably a position where at least the lower half of the first winding part 40 and the second winding part 50 are filled with the heat dissipation resin 82. It is further preferred that the liquid level of the heat dissipation resin 82 filled inside the housing 8 is a position where at least the first winding part 40 and the second winding part 50 are filled with the heat dissipation resin 82.

[0139] The heat dissipating resin 82 is also called a potting resin, and is composed of a silicone resin, a polyurethane resin, an epoxy resin, etc. that is soft even after injection, and the longitudinal elastic modulus of the potting resin is preferably 0.1 to 100 MPa. In this embodiment, for example, the heat generated in the first winding portion 40, the second winding portion 50, and the core 2 is efficiently dissipated from the bottom of the shell 8 to the outside through the heat dissipating resin 82 and the shell 8, which can improve the cooling efficiency of the coil device 1. In addition, after the heat dissipating resin 82 is pre-filled into the interior of the shell 8, the shell 8 can be stored. Figure 2A The core-coil assembly 3 shown in the figure may also be housed inside the housing 8. Figure 2A After forming the core-coil assembly 3 as shown, the heat-dissipating resin 82 is poured into the interior of the case 8 .

[0140] like Figure 2B As shown, a spacer 10 is disposed between the first opposite end 42 of the first winding portion 40 and the second opposite end 52 of the second winding portion 50. Figure 2D , Fig.4A1 , Figure 4A2 , Figure 5 and Fig. 6A As shown, the spacer 10 has a predetermined thickness t1 (see Figure 2D ). The predetermined thickness t1 is not particularly limited, and is, for example, 0.2 to 2.0 mm.

[0141] In this embodiment, the spacer 10 is preferably fixed to the first opposite end 42 of the first wire winding part 40 and / or the second opposite end 52 of the second wire winding part 50 by means of thermocompression bonding or bonding. They are preferably thermocompressed in the axial direction by a thermocompression bonding layer coated on the outer circumference of the windings 4 and 5 constituting the winding parts 40 and 50.

[0142] In this embodiment, if Figure 5 As shown, the spacer 10 has a plurality of outer recesses 11 along the circumferential direction, which are recessed from the outer circumferential position of the spacer 10 toward the inner circumferential position and do not contact the first opposite end 42 of the first winding portion 40 and the second opposite end 52 of the second winding portion 50. In addition, the spacer 10 has a plurality of inner recesses 12 along the circumferential direction, which are recessed from the inner circumferential position of the spacer 10 toward the outer circumferential position and do not contact the first opposite end 42 of the first winding portion 40 and the second opposite end 52 of the second winding portion 50.

[0143] In this embodiment, the outer and inner circumferences of the annular spacer 10 have repeated concave-convex shapes, and the outer concave portions 11 and the inner concave portions 12 are alternately provided along the circumferential direction. The number of repetitions of the outer concave portions 11 or the inner concave portions 12 along the circumferential direction is not particularly limited, but is preferably 3 to 20, and more preferably about 5 to 15.

[0144] The outer recess 11 and the inner recess 12 may be grooves formed on the surface or back of the spacer 10 , but in the present embodiment, they are cutouts alternately formed on the outer and inner circumferences of the annular spacer, and thus penetrate the surface and back of the spacer 10 .

[0145] Therefore, the outer concave portion 11 functions as an outer flow path that allows the fluid to flow from the radially outer side of the first opposite end 42 or the second opposite end 52 toward the inner side (including the reverse flow), and also functions as an axial flow path that allows the fluid to flow from the first opposite end 42 toward the second opposite end 52 (including the reverse flow). In addition, the inner concave portion 12 functions as an inner flow path that allows the fluid to flow from the radially inner side of the first opposite end 42 or the second opposite end 52 toward the outer side (including the reverse flow), and also functions as an axial flow path that allows the fluid to flow from the first opposite end 42 toward the second opposite end 52 (including the reverse flow).

[0146] In this embodiment, if Figure 2D As shown, the width wo of the outer concave portion 11 along the circumferential direction is preferably wider at the outer circumferential position than at the inner circumferential position, and the width wi of the inner concave portion 12 along the circumferential direction is preferably wider at the inner circumferential position than at the outer circumferential position. In addition, under the condition that the radial positions are the same, the width wo of the outer concave portion 11 along the circumferential direction is preferably wider than the width wi of the inner concave portion 12 along the circumferential direction, but they may be the same or opposite.

[0147] In addition, in the present embodiment, the spacer 10 is formed into a continuous ring along the circumferential direction, but it is not necessarily required to be continuous, and it may have a discontinuous portion (cut-off portion) penetrating the outer circumference and the inner circumference at one or more locations in the circumferential direction. For example, in the present embodiment, all the inner recesses 12 and the outer recesses 11 are continuous along the circumferential direction, but it may also have a cut-off portion penetrating the outer circumference and the inner circumference at any one or more of the inner recesses 12 or the outer recesses 11.

[0148] like Fig.4A1 As shown, the outer peripheral portion 13 having the largest outer diameter along the radial direction of the spacer 10 is designed to be close to the inner peripheral surface of the side leg portion 21C or 22c of the core 2, and preferably protrudes outwardly from the outer peripheral surface of the winding portion 40 or 50, but it may not protrude or may be on the same surface. Since the outer peripheral portion 13 protrudes outwardly from the outer peripheral surface of the winding portion 40 or 50, the contact between the winding portions 40 and 50 can be effectively suppressed.

[0149] In addition, if Figure 4A2 As shown, the inner peripheral portion 14 having the smallest inner diameter along the radial direction of the spacer 10 is designed to be close to the outer peripheral surface of the middle leg portion 21b or 22b of the core 2, and preferably protrudes inwardly from the inner peripheral surface of the winding portion 40 or 50, but it may not protrude, and it may be on the same surface. The inner peripheral portion 14 may also be in contact with the outer peripheral surface of the middle leg portion 21b or 22b of the core 2. In the case of contact, the heat from the middle leg portion 21b or 22b of the core 2 is easily transferred to the spacer, and the heat dissipation is improved.

[0150] like Figure 4B As shown, the inner circumference of the winding portion 40 or 50 may have a gap with the outer circumference of the middle leg portion 21b or 22b of the core 2, or may be in close contact. Figure 1 The heat dissipating resin 82 shown improves the heat dissipation of the outer peripheral surfaces of the middle leg portions 21 b and 22 b and the inner peripheral surfaces of the winding portions 40 and 50 .

[0151] like Figure 2D As shown, in the coil device 1 of the present embodiment, the spacer 10 having a predetermined thickness is disposed between the first winding portion 40 and the second winding portion 50, so that the distance between the first opposite end 42 of the first winding portion 40 and the second opposite end 52 of the second winding portion 50 can be controlled by the thickness t1 of the spacer 10. As a result, the leakage of the coil device 1 can be adjusted.

[0152] In the coil device 1 of the present embodiment, the spacer 10 having the predetermined thickness t1 has the outer recessed portion 11 corresponding to the outer flow path and the axial flow path, and the inner flow path 12 corresponding to the inner flow path and the axial flow path.

[0153] like Figure 5 As shown, the heat dissipating resin 82 as a cooling fluid can be introduced between the first opposite end 42 and the second opposite end 52 from the radially outer side of the winding parts 40 and 50 toward the inner side through the outer side recess 11. In addition, the heat dissipating resin 82 can be introduced between the first opposite end 42 and the second opposite end 52 from the radially inner side of the winding parts 40 and 50 toward the inner side or from the outer side toward the inner side.

[0154] Furthermore, in this embodiment, if Figure 4B As shown, a spiral concave portion 45 or 55 is formed at the first opposite end 42 of the winding portion 40 and the second opposite end 52 of the winding portion 50, which matches the spiral shape of the winding wire 4 or 5 constituting the winding portions 40 and 50 and is continuous in the circumferential direction. Figure 5 As shown, the heat dissipating resin 82 introduced into the inner side of the winding portion 40 or 50 through the outer recess 11 can also flow into the inner recess 12 located next to the circumferential direction through the spiral recess 45 or 55. Alternatively, it can also flow from the inner recess 12 located next to the circumferential direction into the outer recess 11 through the spiral recess 45 or 55.

[0155] Furthermore, the outer recess 11 and the inner recess 12 are also axial through holes that do not contact the first opposite end 42 and the second opposite end 52, and thus allow the heat dissipating resin to flow in the Z-axis direction. Figure 1 The heat dissipating resin 82 shown is introduced between the first opposite end 42 and the second opposite end 52, and heat is transferred from the inner peripheral side of the winding parts 40 and 50 which are most easily filled with heat to the housing 8 via the spacer 10 and the heat dissipating resin 82 located in its recesses 11 and 12, thereby improving the heat dissipation of the coil device 1.

[0156] In addition, in the present embodiment, the outer concave portion 11 and the inner concave portion 12 formed in the spacer 10 are also a plurality of flow path forming regions where the components constituting the spacer 10 are removed and do not contact the first opposite end 42 of the winding portion 40 and the second opposite end 52 of the winding portion 50. These plurality of flow path forming regions exist at a plurality of positions along the circumferential direction of the spacer 10.

[0157] By providing the flow path forming area without the components constituting the spacer 10 at multiple locations along the circumferential direction on the surface of the spacer 10, the heat dissipating resin as the cooling fluid can be introduced between the first opposite end 42 and the second opposite end 52 at multiple locations along the circumferential direction, and the heat dissipation of the coil device 1 is further improved. In addition, even if the flow path forming area is formed at multiple locations along the circumferential direction, the spacer 10 has a predetermined thickness t1, and therefore, the leakage of the coil device 1 is well maintained.

[0158] In addition, in this embodiment, if Figure 2D As shown, the circumferential width of the outer recess 11 is wider at the outer circumference than at the inner circumference, thereby making it easier to introduce the heat-dissipating resin 82 from the radially outer side of the winding portion 40 or 50 to the inner side between the first opposing end 42 and the second opposing end 52 .

[0159] Furthermore, in this embodiment, if Figure 2D As shown, the width of the inner recessed portion 12 along the circumferential direction is wider at the inner circumferential position than at the outer circumferential position, thereby making it easy to introduce the heat dissipating resin 82 from the radial inner side of the winding portion 40 or 50 toward the outer side between the first opposite end 42 and the second opposite end 52. Alternatively, the heat dissipating resin 82 can be introduced from the radial outer side of the winding portion 40 or 50 toward the inner side between the first opposite end 42 and the second opposite end 52 along the inner recessed portion 12, and the heat dissipating resin 82 can be stored at the inner circumferential position where the width of the inner recessed portion 12 is wide, thereby improving the heat dissipation from the inner side of the winding portion 40 or 50 and the outer circumferential surface of the middle leg portion 21b or 22b of the core 2.

[0160] In this embodiment, since the inner recess 12 and the outer recess 11 are arranged adjacent to each other in the circumferential direction, the heat dissipating resin can be introduced between the first opposite end 42 and the second opposite end 52 from the radial inside to the outside and from the outside to the inside of the winding portion 40 or 50, and the heat dissipation is further improved. In addition, the heat dissipating resin 82 can also flow between the adjacent inner recess 12 and the outer recess 11 through, for example, the spiral recess 45 or 55 formed at the first opposite end 42 or the second opposite end 52.

[0161] Furthermore, in this embodiment, if Figure 2D As shown in FIG. 1 , the width wo of the outer recess 11 along the circumferential direction is wider than the width wi of the inner recess 11 along the circumferential direction. Figure 4B As shown in FIG. 1 , the middle legs 21 b and 22 b of the core 2 are closely arranged in the inner peripheral portion 14 that serves as the central opening of the spacer 10, so that the heat dissipating resin 82 flows from the radially outer side to the inner side of the spacer 10 more easily than the heat dissipating resin 82 flows from the radially inner side to the outer side of the spacer 10. Therefore, by making the circumferential width wo of the outer recess 11 larger than the circumferential width wi of the inner recess 12, it is easy to introduce the heat dissipating resin 82 between the first opposite end 42 and the second opposite end 52.

[0162] Furthermore, in the present embodiment, at least one of the first winding 4 constituting the first winding winding part 40 and the second winding 5 constituting the second winding winding part 50 is composed of a conductor, and the conductor is covered with an insulating layer having at least a heat-welding layer. By configuring in this way, it is easy to join the parts of the winding 4 or 5 that are in contact with each other by heat-welding, and it is easy to form an air-core coil in which the winding 4 or 5 is wound into a coil shape. In addition, in a state where the first winding winding part 40, the spacer 10, and the second winding winding part 50 are combined, by heat-pressing them along the winding axis direction, it is easy to manufacture the coil body 30 in which the first winding winding part 40, the spacer 10, and the second winding winding part 50 are integrated.

[0163] In the present embodiment, the spacer 10 may also be composed of an insulating component and / or a metal component. Examples of the insulating component include synthetic resins, ceramics, glass, and the like. In the case where the spacer 10 is formed using an insulating component, the insulation between the first winding winding portion 40 and the second winding winding portion 50 is also improved. In particular, in the case of ceramics, it is difficult to deform even when used at high temperatures, so it is easy to stabilize the coil characteristics regardless of the temperature. In the case where the spacer 10 is formed by a metal component, the heat transfer characteristics of the spacer 10 itself are good, and the heat dissipation is further improved. In addition, in the case where the spacer 10 is formed by a metal component, the windings 4 and 5 are preferably windings covered with an insulating film. In addition, the spacer 10 may also be composed of a composite component of a metal component and an insulating component. For example, the spacer 10 may also be a component in which the surface of a metal plate is covered with an insulating component such as a resin. Alternatively, the spacer 10 may also be formed using an insulating component in which metal powder is dispersed.

[0164] (Second Embodiment)

[0165] In this embodiment, in addition to using FIG. 6B to FIG. 6I The spacers 10b to 10i shown in the figure replace the spacers 10b to 10i used in the first embodiment. Fig. 6A The coil device is assembled in the same manner as in the above-described embodiment except for the spacer 10 shown.

[0166] exist Figure 6B In the spacer 10b shown, Fig. 6A Compared with the spacer 10 shown in FIG. 1 , the number of repetitions along the circumferential direction and along the circumferential direction of the outer recess 11 and the inner recess 12 is different. Fig. 6A In the spacer 10 shown in the figure, the shape connecting the inner peripheral part 14 along the circumferential direction is an ellipse, but Figure 6B In the spacer 10 shown in FIG. 1 , the shape connecting the inner peripheral portion 14 along the circumferential direction is a circle. Fig. 6A In the spacer 10 shown in the figure, the shape connecting the outer peripheral part 12 along the circumferential direction is an ellipse, but Figure 6BIn the spacer 10 shown, the shape connecting the outer peripheral portion 12 along the circumferential direction is circular. In conjunction with the shapes of the inner peripheral portion 14 and the outer peripheral portion 13 of the spacer 10b, the outer peripheral shape of the middle leg portion 21b or 22b of the core 2 and the inner peripheral shape of the side leg portion 21c or 22c become circular.

[0167] Figure 6C The spacer 10c shown is Figure 6B The modified examples of the spacer 10 b shown are the same except that the ratio of the circumferential width of the outer recess 11 to the circumferential width of the inner recess 12 is different.

[0168] Fig.6D The spacer 10d shown is Fig. 6A The modified example of the spacer 10 shown is not provided Fig. 6A The outer recess 11 and the inner recess 12 of the spacer 10 shown in the figure are formed into an elliptical ring plate shape as a whole, and a plurality of radially elongated through holes 16 are arranged at predetermined intervals along the circumference thereof. Other than this, it is the same as the first embodiment described above.

[0169] exist Fig.6D In the illustrated embodiment, a cooling fluid such as a heat dissipating resin 82 can flow between the first opposite end 42 and the second opposite end 52 through the through hole 16. The through hole 16 is a flow path forming region that does not contact both the first opposite end 42 and the second opposite end 52, and has a structure that does not contact both.

[0170] Fig. 6E The spacer 10e shown is Fig.6D In the modified example of the spacer 10d shown in FIG. 1 , the shape of the through hole 16 is changed from a long hole to a circular shape. Fig. 6F The spacer 10f shown is Fig.6D In the modified example of the spacer 10d shown, each through hole 16 of the spacer 10d communicates with the inner peripheral side of the spacer 10d to form the inner recess 12. That is, the through hole also serves as the inner recess 12.

[0171] in addition, Figure 6G The spacer 10g shown is Fig.6D In the modified example of the spacer 10d shown, each through hole 16 of the spacer 10d communicates with the outer peripheral side of the spacer 10d to form the outer recessed portion 11. That is, the through hole is a structure that also serves as the outer recessed portion 11.

[0172] in addition, Figure 6H The spacer 10h shown is Figure 6G In the modified example of the spacer 10g shown, the circumferential width of each outer recessed portion of the spacer 10h is different from the circumferential width of the outer recessed portion 11 of the spacer 10g.

[0173] Furthermore, the spacer 10i shown in FIG. 6i is Figure 6G The outer recess 11 and the outer recess 12 of the spacer 10g are shown Fig. 6F The illustrated spacer 10f has an example in which the inner recessed portions 12 are formed alternately along the circumferential direction.

[0174] In addition, the present invention is not limited to the above-mentioned embodiment, and various changes can be made within the scope of the present invention.

[0175] For example, in the above-described embodiment, the first opposite end 42 of the first wire winding portion 40 or the second opposite end 52 of the second wire winding portion 50 and the surface of the spacer 10 may be bonded by a bonding method other than thermocompression bonding, such as an adhesive.

[0176] In addition, in the above-mentioned embodiment, the first winding 4 constituting the first winding winding portion 40 and the second winding 5 constituting the second winding winding portion 50 are respectively constituted by different windings, but the first winding 4 and the second winding 5 may also be constituted by a continuous single winding. In this case, the first winding winding portion 40 and the second winding winding portion 50 do not constitute a transformer in the circuit, but form a continuous single coil, and can also be used as a part of a transformer or as a coil device other than a transformer. As a coil device other than a transformer, for example, an inductor, a resonance coil, a choke coil, a PFC coil, a reactor coil, etc. can be exemplified.

[0177] The spacers 10, 10b to 10i are annular, but may be partially cut or divided in the circumferential direction. The spacers 10, 10b to 10i are preferably composed of a single layer along the Z axis (winding axis), but may be composed of a stack of multiple spacers.

[0178] The spacers 10 and 10b to 10i may be mesh-shaped in themselves, or radial or mesh-shaped grooves connecting the radially outer side and the radially inner side of the spacer may be formed on one or both sides of the spacer.

[0179] In the above-mentioned embodiment, the flow path forming area provided on the spacers 10, 10b~10i is composed of a cutout or a through hole penetrating the front and back surfaces of the spacers, but the flow path forming area can be a groove formed only on a single side surface of the spacers 10, 10b~10i, or it can be a groove formed on both sides of the spacers.

[0180] For example, the outer recess 11 only needs to be recessed from the outer side to the inner side of the winding portion 40 or 50 in the radial direction, and can be a cutout or a groove as long as it is a structure that does not contact at least one of the first opposite end 42 and the second opposite end 52. In addition, at least a part of the outer recess 11 or the inner recess 12 can pass through from the outer side to the inner side of the spacer 10 in the radial direction.

[0181] In the coil device 1 of this embodiment, Figure 2A The coil core assembly 3 shown is housed in a housing 8 filled with a heat dissipating resin to improve heat dissipation. However, depending on the situation, the housing 8 and the heat dissipating resin 82 may not be necessary. For example, a cooling fluid such as cooling air may also be used with the Figure 2A The coil core assemblies 3 are shown in direct contact.

[0182] Furthermore, the coil device may be assembled by combining any of the above-described embodiments.

Claims

1. A coil device, in, have: a first winding coiling portion; a second wire winding portion disposed adjacent to the first wire winding portion along a winding axis of the first wire winding portion; and a spacer disposed between a first opposite end of the first winding portion along the winding axis and a second opposite end of the second winding portion along the winding axis, The spacer has a predetermined thickness along the winding axis, and The spacer has: an outer flow path allowing fluid to flow from the radial outer side to the inner side of the first relative end or the second relative end, an inner flow path allowing fluid to flow from the radial inner side to the outer side of the first relative end or the second relative end, and at least one of the axial flow paths allowing fluid to flow from the first relative end to the second relative end.

2. The coil device according to claim 1, in, At least one of the outer flow path, the inner flow path, and the axial flow path is a plurality of flow path forming areas where components constituting the spacer are removed and which do not contact the first opposite end and / or the second opposite end. The plurality of flow path forming regions exist at a plurality of locations along the circumferential direction of the spacer.

3. The coil device according to claim 2, in, At least one of the plurality of flow path forming regions has an outer concave portion that is recessed from an outer peripheral position toward an inner peripheral position of the spacer and does not contact the first opposing end and / or the second opposing end.

4. The coil device according to claim 3, in, The width of the outer recessed portion along the circumferential direction is wider at the outer circumferential position than at the inner circumferential position.

5. The coil device according to claim 2, in, At least one of the plurality of flow path forming regions has an inner recessed portion that is recessed from an inner peripheral position toward an outer peripheral position of the spacer and does not contact the first opposing end and / or the second opposing end.

6. The coil device according to claim 5, in, The width of the inner recessed portion along the circumferential direction is wider at the inner circumferential position than at the outer circumferential position.

7. The coil device according to claim 2, in, At least one of the plurality of flow path forming regions has a through hole communicating from the first opposing end toward the second opposing end.

8. The coil device according to claim 2, in, The plurality of flow path forming regions include: an inner concave portion that is concave from an inner peripheral position toward an outer peripheral position of the spacer and does not contact the first opposite end and / or the second opposite end; The outer recessed portion is disposed beside the inner recessed portion in the circumferential direction, is recessed from the outer circumferential position toward the inner circumferential position of the spacer, and does not contact the first opposing end and / or the second opposing end.

9. The coil device according to claim 8, in, The width of the outer recessed portion along the circumferential direction is wider than the width of the inner recessed portion along the circumferential direction.

10. A coil device, in, have: a first winding coiling portion; a second wire winding portion disposed adjacent to the first wire winding portion along a winding axis of the first wire winding portion; and a spacer disposed between a first opposite end of the first winding portion along the winding axis and a second opposite end of the second winding portion along the winding axis, the spacer having a predetermined thickness along the winding axis, and The spacer has: an outer recess allowing fluid to flow from the radial outer side to the inner side of the first relative end or the second relative end, an inner recess allowing fluid to flow from the radial inner side to the outer side of the first relative end or the second relative end, and at least one through hole allowing fluid to flow from the first relative end to the second relative end.

11. The coil device according to any one of claims 1 to 10, in, At least one of the first winding wire constituting the first winding winding portion and the second winding wire constituting the second winding winding portion is formed of a conductor, and the conductor is covered with an insulating layer having at least a heat-sealing layer.

12. The coil device according to any one of claims 1 to 10, in, The first opposite ends of the first wire winding portion or the second opposite ends of the second wire winding portion are engaged with a surface of the spacer.

13. The coil device according to any one of claims 1 to 10, in, The spacer is composed of an insulating member and / or a metal member.

14. The coil device according to any one of claims 1 to 10, in, It also has a core. The spacer has a central opening extending along the winding axis. The core has a middle leg portion arranged in the central opening through the first winding portion or the second winding portion.

15. The coil device according to claim 14, in, The core further includes a side leg portion covering at least a portion of an outer periphery of the first winding portion or an outer periphery of the second winding portion, and a predetermined gap is provided between an outer peripheral end of the spacer and an inner peripheral surface of the side leg portion.

16. The coil device according to any one of claims 1 to 10, in, The device further comprises a housing for accommodating at least a portion of the first wire winding unit and the second wire winding unit, The interior of the housing is filled with a heat-dissipating resin up to a position where the spacer located between the first winding portion and the second winding portion is at least impregnated.

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