Coil device

Abstract

The invention provides a small coil device with excellent withstand voltage reliability. A coil device (1) is provided with: a first bobbin (40) having a first cylinder section (41) and a terminal block (42) on which a terminal (30b) is provided; a first winding wire (10) having a first winding portion (11) provided in the first cylinder portion (41), and a first lead-out portion (12b) led out from the first winding portion (11) and connected to the terminal (30b); a second frame (50) having a second cylinder section (51) for accommodating the first cylinder section (41), and an intermediate section (56) positioned between the second cylinder section (51) and the terminal block (42); and a second winding wire (20) having a second winding portion (21) provided in the second cylinder portion (51), and a second lead-out portion (22b) led out from the second winding portion (21) to a side opposite to the first lead-out portion (12b). Concave and convex parts (57) are formed on the outer surface of the intermediate part (56).

Description

Technical Field

[0001] The invention relates to a coil device. Background Art

[0002] As a coil device for use in a transformer, for example, there is a known coil device as shown in Patent Document 1. The coil device of Patent Document 1 has a skeleton, a core mounted on the skeleton, and a first winding and a second winding wound on the skeleton. The skeleton has a barrel portion provided with a first winding portion of the first winding and a second winding portion of the second winding, a first terminal block formed at one axial end of the barrel portion and provided with a first terminal, and a second terminal block formed at the other axial end of the barrel portion and provided with a second terminal. A first lead portion of the first winding is connected to the first terminal, and a second lead portion of the second winding is connected to the second terminal. An I-type core is inserted into the interior of the barrel portion, and a U-type core arranged on the outside of the barrel portion is connected to both axial ends of the I-type core.

[0003] In the coil device of Patent Document 1, the first winding portion and the second winding portion are arranged along the axial direction of the skeleton. Therefore, in order to ensure the installation space of the first winding portion and the second winding portion, the axial length of the skeleton will inevitably become longer, making it difficult to achieve miniaturization of the coil device. In addition, the coil device of Patent Document 1 has multiple current-carrying components such as a core, a first winding, and a second winding. Therefore, in order to achieve miniaturization of the coil device, the distance between any current-carrying components will become shorter, and the withstand voltage may be reduced.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Laid-Open No. 9-186024 Summary of the invention

[0007] The present invention has been made in view of such actual circumstances, and an object of the present invention is to provide a small coil device having excellent withstand voltage reliability.

[0008] In order to achieve the above object, the coil device involved in the present invention has:

[0009] A first frame having a first cylindrical portion and a terminal block provided with a terminal;

[0010] a first winding having a first winding portion provided on the first barrel portion and a first lead portion led out from the first winding portion and connected to the terminal;

[0011] a second frame having a second cylindrical portion for accommodating the first cylindrical portion, and an intervening portion located between the second cylindrical portion and the terminal block;

[0012] a second winding having a second winding portion provided on the second barrel portion and a second lead-out portion led out from the second winding portion to a side opposite to the first lead-out portion,

[0013] Concavities and convexities are formed on the outer surface of the intervening portion.

[0014] The coil device of the present invention has a first skeleton and a second skeleton, and the first barrel is housed inside the second barrel. That is, the first barrel and the second barrel are arranged in an overlapping manner, so that the length of the coil device is shortened in the axial direction of the first barrel (second barrel) compared with the prior art, and the miniaturization of the coil device can be achieved. In addition, in the coil device of the present invention, the intermediate portion is located between the second barrel and the terminal block of the first skeleton, and a concave-convex portion is formed on the outer surface of the intermediate portion. Therefore, according to the degree of the concave-convex, the surface distance between the second winding portion provided in the second barrel and the terminal (the first lead-out portion connected to the terminal) provided in the terminal block is extended, and the insulation between the second winding portion and the terminal can be ensured. Therefore, according to the present invention, the miniaturization of the coil device can be achieved without reducing the withstand voltage between the second winding portion and the terminal, and a small coil device with excellent withstand voltage reliability can be achieved.

[0015] Alternatively, the concave and convex portions constituting the concave-convex portions extend in a direction orthogonal to the axial direction of the second barrel portion. In this case, the creepage distance between the second winding portion provided on the second barrel portion and the terminal provided on the terminal block can be extended according to the number of repetitions of the concave and convex portions.

[0016] Alternatively, the intermediate portion has a bottom and a side portion rising from the bottom, and the projections and depressions are formed at least on the side portion. In this case, the creepage distance between the second winding portion provided on the second barrel portion and the terminal provided on the terminal block is extended on the side portion, thereby preventing a current path from being formed between them through the side portion.

[0017] Alternatively, the interposed portion has a bottom portion and a side portion rising from the bottom portion, and the concavo-convex portion is formed at least at the bottom portion. In this case, at the bottom portion, the creepage distance between the second winding portion provided on the second barrel portion and the terminal provided on the terminal block is extended, thereby preventing a current path from being formed between them and passing through the bottom portion.

[0018] Alternatively, the interposed portion may have a bottom portion and a side portion rising from the bottom portion, and the projections and depressions are formed continuously from the bottom portion to the side portion. In this case, the creepage distance between the second winding portion provided on the second barrel portion and the terminal provided on the terminal block is extended at the bottom portion and the side portion, thereby preventing a current path from being formed between them through the bottom portion and the side portion.

[0019] Alternatively, there is further a cover, the cover being mounted on the bottom of the second frame and being arranged between the second winding portion and the second lead portion, and the cover having a cover concave-convex shape, the cover concave-convex shape being located at a position corresponding to the concave-convex shape. In this case, the creepage distance between the second lead portion extending on the cover and the terminal provided on the terminal block is extended according to the degree of the cover concave-convex shape. Therefore, it is possible to prevent a current path passing through the cover from being formed between the second lead portion and the terminal, and to ensure insulation between them.

[0020] Alternatively, the cover concavoconvex and concavoconvex may be engaged with each other. In this case, the space distance between the second winding portion provided on the second barrel and the terminal provided on the terminal block is extended according to the degree of the concavoconvex and concavoconvex of the cover. Therefore, it is possible to prevent a current path from being formed between the second winding portion and the terminal through the space between the second frame and the cover, and the insulation between them can be ensured.

[0021] Alternatively, the cover concavo-convex part may be formed on the outer surface and the inner surface of the cover. In this case, the cover concavo-convex part formed on the outer surface of the cover can extend the creepage distance between the second lead portion extending on the cover and the terminal provided on the terminal block. Furthermore, the cover concavo-convex part formed on the inner surface of the cover can extend the spatial distance between the second winding portion provided on the second barrel and the terminal provided on the terminal block. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1A It is a perspective view of a coil device according to one embodiment of the present invention.

[0023] Figure 1B From another perspective Figure 1A A perspective view of the coil device shown.

[0024] Figure 2 yes Figure 1A An exploded perspective view of the coil device shown.

[0025] Figure 3 yes Figure 1A The coil device shown is a cross-sectional view along line III-III.

[0026] Figure 4 yes Figure 2 A stereoscopic view of the first skeleton is shown.

[0027] Figure 5A yes Figure 2 A stereoscopic view of the second skeleton is shown.

[0028] Figure 5B From another perspective Figure 5A A stereoscopic view of the second skeleton is shown.

[0029] Figure 5Cyes Figure 5A A bottom view of the second skeleton is shown.

[0030] Figure 6 It is a bottom view of a first bobbin around which a first winding is wound and a second bobbin around which a second winding is wound.

[0031] Figure 7 yes Figure 2 A perspective view of the first cover is shown.

[0032] Figure 8 yes Figure 1A Side view of the coil arrangement shown.

[0033] Fig. 9 It is a bottom view when the first cover is installed on the second frame.

[0034] Fig.10 yes Figure 2 A perspective view of the second cover is shown.

[0035] Explanation of symbols

[0036] 1…Coil device

[0037] 10…First winding

[0038] 11…First winding section

[0039] 12a, 12b... first lead-out portion

[0040] 20…Second winding

[0041] 21…Second winding section

[0042] 22a, 22b... second lead-out portion

[0043] 30a~30d…terminal

[0044] 31a~31d…Connection section

[0045] 32a to 32d: External connection part

[0046] 40…First Skeleton

[0047] 41…First barrel

[0048] 410…Through hole

[0049] 411…Core setting surface

[0050] 42…First terminal block

[0051] 420…Main body

[0052] 421…Insulation convex part

[0053] 422a, 422b ... incision

[0054] 423a, 423b ... protrusion

[0055] 424…Block

[0056] 43a, 43b ... side wall portion

[0057] 44a, 44b ... flange portion

[0058] 45a~45c…Separator

[0059] 46…Guide protrusion

[0060] 47a, 47b…lead-out passage

[0061] 50…Second skeleton

[0062] 51…Second barrel

[0063] 510…Through hole

[0064] 52…Second terminal block

[0065] 520…Main body

[0066] 521…Insulation convex part

[0067] 522a, 522b ... incision

[0068] 523a, 523b…lower protrusion

[0069] 524a, 524b…stopper

[0070] 53a, 53b ... side wall portion

[0071] 54a, 54b ... flange portion

[0072] 540a, 540b ... engagement groove

[0073] 541a…flange side wall portion

[0074] 542a, 542b, 543a, 543b, 543c ... engaging convex parts

[0075] 55a~55f…Separator

[0076] 56…Introduction Department

[0077] 560…Bottom

[0078] 561…side

[0079] 57…Concave and convex

[0080] 570…concave

[0081] 571…convex part

[0082] 58a, 58b...Guide protrusions

[0083] 59a, 59b…lead-out passage

[0084] 60…Side protrusion

[0085] 70…First Core

[0086] 80…Second core

[0087] 81…Main body

[0088] 82…Feet

[0089] 90…First Cover

[0090] 91…Hood body

[0091] 91a…External surface

[0092] 91b…Inner surface

[0093] 92…Open slot

[0094] 92a…Part 1

[0095] 92b…Part 2

[0096] 93…Guide

[0097] 93a ... first extension portion

[0098] 93b…Second extension

[0099] 94a~94c…Engagement portion

[0100] 940a~940c…Engagement hole

[0101] 95…Hood bumps

[0102] 950…concave

[0103] 951…convex part

[0104] 96…Protrusion

[0105] 100…Second cover

[0106] 101…Hood body

[0107] 101a…External surface

[0108] 101b…Inner surface

[0109] 102a, 102b ... engagement convex parts

[0110] 103a, 103b...core limiting part

[0111] 104a, 104b ... side convex part

[0112] 105a, 105b ... engaging portion

[0113] 106a, 106b ... engagement holes

[0114] 110…Resin

[0115] 120…Joint

[0116] 130…with. DETAILED DESCRIPTION

[0117] The following is a description of the embodiments of the present invention with reference to the accompanying drawings. In addition, the contents of the drawings are only schematically and exemplarily shown for the purpose of understanding the present invention, and the appearance or dimensional ratio may be different from the actual object. In addition, the present invention is not limited to the following embodiments.

[0118] Figure 1A and Figure 1B The coil device 1 according to one embodiment of the present invention shown in FIG. 1 functions as a transformer (step-up transformer, etc.). Figure 2 As shown, the coil device 1 has a first winding 10, a second winding 20, a first frame 40, and a second frame 50. The coil device 1 also has terminals 30a to 30d ( Figure 1A and Figure 1B ), the first core 70 , the second core 80 , the first cover 90 , the second cover 100 , and the belt 130 , but at least one of these components may be omitted from the coil device 1 .

[0119] exist Figure 2 In the above, the X-axis is an axis corresponding to the long side direction of the first core 70. The Y-axis is an axis corresponding to the short side direction of the first core 70. The Z-axis is an axis perpendicular to the X-axis and the Y-axis. Hereinafter, the positive direction side of the Z-axis is referred to as "upper side", and the negative direction side of the Z-axis is referred to as "lower side". In addition, 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 "inner side", and the direction away from the center of the coil device 1 is referred to as "outer side".

[0120] The length of the coil device 1 along the X axis is 30 to 50 mm, the length along the Y axis is 10 to 20 mm, and the length along the Z axis is 10 to 25 mm. However, the dimensions of the coil device 1 are not limited thereto.

[0121] The first winding 10 includes a first winding portion 11 wound in a coil shape, and first lead portions 12a and 12b ( Figure 1BThe second winding 20 includes a second winding portion 21 wound in a coil shape, and second lead portions 22a and 22b led out from the second winding portion 21 to the side opposite to the first lead portions 12a and 12b. Figure 3 As shown, at least a portion of the first winding portion 11 and the second winding portion 21 are opposite to each other along their radial direction. The first winding 10 constitutes a primary winding, and the second winding 20 constitutes a secondary winding, but their relationship may also be reversed.

[0122] The first winding 10 and the second winding 20 are each composed of a single wire, but may also be a twisted pair or a Litz wire. The first winding 10 and the second winding 20 are, for example, insulating coated windings in which a core wire composed of a metal such as copper is coated with an insulating film. The diameter of each of the first winding 10 and the second winding 20 is not particularly limited, and is 0.1 to 1.0 mm. The diameter of the first winding 10 is different from the diameter of the second winding 20, but their diameters may be equal.

[0123] The first winding portion 11 is not particularly limited, but is formed in one layer along the radial direction. The first winding portion 11 may have multiple layers. The second winding portion 21 is not particularly limited, but is formed in five layers along the radial direction.

[0124] like Figure 1A and Figure 1B As shown, the terminals 30a to 30d have an L shape and have wiring portions 31a to 31d and external connection portions 32a to 32d. The terminals 30a to 30d are formed of a conductor such as metal. The first lead portion 12a is connected to the wiring portion 31a, and the first lead portion 12b is connected to the wiring portion 31b. In addition, the second lead portion 22a is connected to the wiring portion 31c, and the second lead portion 22b is connected to the wiring portion 31d. The external connection portions 32a to 32d are portions connected to an external substrate (not shown). The coil device 1 is mounted on the external substrate in a manner such that the bottom of the second skeleton 50 is parallel to the external substrate, for example.

[0125] like Figure 2 As shown, the first core 70 is an I-shaped core having a rectangular parallelepiped shape. The second core 80 is a U-shaped core. The second core 80 has a main body 81 and leg portions 82 protruding from both ends of the main body 81 in the X-axis direction in a manner orthogonal to the main body 81. The first core 70 and the second core 80 are magnetic bodies, and are composed of a ferrite composition, a metal composition, or a composite composition of them and a resin. The first core 70 and the second core 80 can also be a sintered body of a metal magnetic body.

[0126] The first core 70 is mounted on the first frame 40, and the second core 80 is mounted on the second frame 50. Figure 3As shown, the second core 80 is combined with the first core 70. Two joints 120 are formed between the first core 70 and the second core 80. One joint 120 is a joint between one leg 82 and the first core 70. The other joint 120 is a joint between the other leg 82 and the first core 70. By connecting the first core 70 and the second core 80 to form a ring core, the magnetic properties of the coil device 1 can be improved.

[0127] The length L1 of the first core 70 along the X-axis is not particularly limited, but is longer than the length L2 of the second core 80 along the X-axis. Therefore, the two ends of the first core 70 in the X-axis direction protrude outward along the X-axis than the two ends of the second core 80 in the X-axis direction. The protruding width of the first core 70 is, for example, greater than 1 mm. In the case of L1>L2, even if the joint 120 is shifted in the X-axis direction due to the positional shift of the first core 70 and / or the second core 80 in the X-axis direction, the area of ​​the joint 120 (the cross-sectional area of ​​the magnetic path of the annular core in the joint 120) is not easily changed.

[0128] like Figure 4 As shown, the first frame 40 has a first barrel 41 and is provided with terminals 30a and 30b ( Figure 1B ) of the first terminal block 42. The first frame 40 further includes side wall portions 43a and 43b, flange portions 44a and 44b, partition portions 45a to 45c, and a guide protrusion 46 ( Figure 6 ), and lead-out passages 47a and 47b, but at least one of these components may be omitted from the first frame 40. The first frame 40 is made of plastics such as PPS, PET, PBT, LCP, and other insulating components (preferably heat-resistant materials).

[0129] The first cylinder 41 is composed of a cylinder and has a through hole 410 and a core setting surface 411. The axial direction of the first cylinder 41 corresponds to the X-axis direction. The cross-sectional shape of the first cylinder 41 is not particularly limited, but is rectangular. Figure 2 As shown, the first winding 10 is wound around the outer peripheral surface of the first cylindrical portion 41 to form a first winding portion 11 .

[0130] like Figure 4 As shown, the through hole 410 extends along the axial direction of the first cylindrical portion 41. A first core 70 ( Figure 2 ) at least a portion (see Figure 6 The core installation surface 411 is a flat surface parallel to the XY plane and constitutes the bottom of the inner wall surface of the through hole 410. The first core 70 ( Figure 2 ).

[0131] The flange 44a is formed at one end of the first tube 41 in the X-axis direction, and the flange 44b is formed at the other end of the first tube 41 in the X-axis direction. The flanges 44a and 44b protrude radially outward from the outer circumferential surface of the first tube 41 and extend along the circumferential direction of the first tube 41.

[0132] The partitions 45a to 45c are formed between the flange 44a and the flange 44b. The partitions 45a to 45c protrude from the outer peripheral surface of the first cylinder 41 toward the radially outer side thereof. The partition 45a is formed continuously along the circumference of the first cylinder 41. Figure 6 As shown, the partitions 45 b and 45 c extend intermittently along the circumferential direction of the first cylindrical portion 41 .

[0133] The partitions 45a to 45c divide the outer circumferential surface of the first barrel 41 into a plurality of sections along the X-axis. The first winding section 11 is formed in the section between the partition 45a and the partition 45b. On the other hand, the first winding section 11 is not formed in the section between the partition 45b and the partition 45c, and further in the section between the flange 44a and the partition 45a. Therefore, it is possible to ensure that the first core 70 ( Figure 3 ) and the insulation distance between the first winding portion 11. As needed, the first winding portion 11 can also be formed in other divisions.

[0134] like Figure 4 As shown, the first terminal block 42 is formed at the end of the first tube 41 in the X-axis direction. The first terminal block 42 has a main body 420, an insulating protrusion 421, cutouts 422a and 422b, lower protrusions 423a and 423b, and a stopper 424, for example.

[0135] The main body 420 is formed flush with the core setting surface 411. The length of the main body 420 along the Y axis is longer than the length of the first cylinder 41 along the Y axis. The insulating protrusion 421 is formed at the outer end of the main body 420 in the X axis direction and protrudes upward from the upper surface of the main body 420 along the Z axis. Figure 1B As shown, the insulating protrusion 421 is located between the connecting portions 31a and 31b and the first core 70 with respect to the X-axis direction. The insulating protrusion 421 extends the insulating distance (creepage distance and spatial distance) between the first core 70 and the connecting portions 31a and 31b by separating them.

[0136] The insulating protrusion 421 is formed above the connection parts 31a and 31b. The height of the insulating protrusion 421 may be the same as or greater than the thickness of the first core 70 in the Z-axis direction. In addition, the length of the insulating protrusion 421 along the Y-axis may be the same as or greater than the length of the first core 70 along the Y-axis. Thus, the insulation distance between the first core 70 and the connection parts 31a and 31b can be effectively extended.

[0137] like Figure 4 As shown, cutouts 422a and 422b are formed on the upper portion of the insulating protrusion 421. The cutouts 422a and 422b are formed at one end and the other end of the insulating protrusion 421 in the Y-axis direction, respectively. The stopper 424 is formed at the center of the main body 420 in the Y-axis direction and protrudes upward from the upper surface of the main body 420. The stopper 424 protrudes from the inner surface of the insulating protrusion 421 in the X-axis direction.

[0138] like Figure 1B As shown, the stopper 424 is located between the insulating protrusion 421 and the end of the first core 70 in the X-axis direction. The stopper 424 abuts against the end of the first core 70 in the X-axis direction and positions the first core 70 in the X-axis direction. In addition, the number of the stopper 424 can also be multiple.

[0139] like Figure 1B and Figure 4 As shown, the lower protrusions 423a and 423b protrude downward from the bottom surface of the main body 420. The lower protrusions 423a and 423b are arranged separately along the Y axis. The external connection part 32a is provided on the lower protrusion 423a, and the external connection part 32b is provided on the lower protrusion 423b.

[0140] The terminals 30a and 30b are separately arranged along the Y axis. The terminals 30a and 30b are integrally formed (insert-molded) with the lower protrusions 423a and 423b, respectively. However, the terminals 30a and 30b may be inserted into the lower protrusions 423a and 423b, respectively. The wiring portion 31a protrudes outwardly from the lower protrusion 423a along the X axis. The external connection portion 32a protrudes downward from the lower protrusion 423a. The wiring portion 31b protrudes outwardly from the lower protrusion 423b along the X axis. The external connection portion 32b protrudes downward from the lower protrusion 423b.

[0141] like Figure 4 As shown, the side wall portions 43a and 43b are arranged apart from each other along the Y axis. The side wall portion 43a protrudes upward from the core installation surface 411 or the upper surface of the main body portion 420. The side wall portion 43b protrudes upward from the core installation surface 411 or the upper surface of the main body portion 420.

[0142] like Figure 1BAs shown, the end of the first core 70 in the X-axis direction is arranged between the side wall portion 43a and the side wall portion 43b. The side wall portions 43a and 43b sandwich the end of the first core 70 in the X-axis direction from both sides of the first core 70 in the Y-axis direction. The side wall portions 43a and 43b can prevent the first core 70 from being displaced in the Y-axis direction.

[0143] The ends of the first core 70 in the X-axis direction are connected to the side wall portions 43a and 43b by the resin 110. In addition, the ends of the first core 70 in the X-axis direction are connected to the side wall portions 43a and 43b by the resin 110. Figure 3 ) is connected to the upper surface of the main body 420 on the outer side in the X-axis direction. In order to improve the bonding strength (bonding area) with the resin 110, a notch is formed in the upper part of the side wall parts 43a and 43b.

[0144] like Figure 6 As shown, the guide protrusion 46 protrudes downward from the bottom of the second frame 50. The guide protrusion 46 extends along the X-axis in a long-side shape. The lead-out passages 47a and 47b are formed along the guide protrusion 46 and extend along the X-axis. The first lead-out portion 12a is led from the first winding portion 11 to the wiring portion 31a along the lead-out passage 47a. In addition, the first lead-out portion 12b is led from the first winding portion 11 to the wiring portion 31b along the lead-out passage 47b.

[0145] A portion of the lead-out passage 47a is formed between the guide protrusion 46 and the lower protrusion 423a. By leading the first lead-out portion 12a along the lead-out passage 47a, the first lead-out portion 12a can be protected from external loads by the guide protrusion 46 and the lower protrusion 423a. A portion of the lead-out passage 47b is formed between the guide protrusion 46 and the lower protrusion 423b. By leading the first lead-out portion 12b along the lead-out passage 47b, the first lead-out portion 12b can be protected from external loads by the guide protrusion 46 and the lower protrusion 423b.

[0146] like Figure 5A to Figure 5C As shown, the second frame 50 has a second tube 51, an interposed portion 56, and a concave-convex portion 57. The second frame 50 also has a second terminal block 52, side wall portions 53a and 53b, flange portions 54a and 54b, partitions 55a to 55f, guide protrusions 58a and 58b, lead passages 59a and 59b, and a lateral protrusion 60, but at least one of these components may be omitted from the second frame 50. The second frame 50 is made of the same material as the first frame 40, but may also be made of a different material from the first frame 40.

[0147] like Figure 5AAs shown, the second cylinder 51 is composed of a cylinder and has a through hole 510. The through hole 510 extends along the axial direction of the second cylinder 51. The axial direction of the second cylinder 51 corresponds to the X-axis direction. The cross-sectional shape of the second cylinder 51 is not particularly limited, but is rectangular. Figure 2 As shown in FIG. 5 , the second winding 20 is wound around the outer circumferential surface of the second barrel 51, and a second winding portion 21 is formed. Figure 3 As shown, the first cylindrical portion 41 into which the first core 70 is inserted is accommodated in the through hole 510 .

[0148] like Figure 5A As shown in FIG. 1 , the flange portion 54a is formed at one end of the second cylinder portion 51 in the X-axis direction, and the flange portion 54b is formed at the other end of the second cylinder portion 51 in the X-axis direction. The flange portions 54a and 54b protrude radially outward from the outer peripheral surface of the second cylinder portion 51. The flange portion 54a includes, for example, an engagement groove portion 540a, a pair of flange side wall portions 541a, an engagement convex portion 542a, and engagement convex portions 543a and 543b ( Figure 5C ).

[0149] The engaging groove 540a is formed at the upper end of the flange 54a and extends from one end of the flange 54a in the Y-axis direction to the other end. The engaging protrusion 542a is formed on the outer end surface of the flange 54a and protrudes outward along the X-axis. One flange side wall 541a is formed on one side of the flange 54a in the Y-axis direction, and the other flange side wall 541a is formed on the other side of the flange 54a in the Y-axis direction. The pair of flange side wall 541a protrudes outward along the X-axis.

[0150] like Figure 5C As shown, the engaging protrusions 543a and 543b are formed at the lower end of the flange 54a. The engaging protrusion 543a protrudes outward along the X axis on one side of the flange 54a in the Y axis direction. The engaging protrusion 543b protrudes outward along the X axis on the other side of the flange 54a in the Y axis direction.

[0151] like Figure 5B As shown, the flange portion 54b has, for example, an engagement groove portion 540b and an engagement convex portion 542b. The engagement groove portion 540b is formed at the upper end of the flange portion 54b and extends from one end of the flange portion 54b in the Y-axis direction to the other end. The engagement convex portion 542b is formed on the outer end surface of the flange portion 54b and protrudes outward along the X-axis.

[0152] exist Figure 5A and Figure 5B The engaging grooves 540a and 540b shown in the figure are engaged with Fig.10 The second cover 100 shown in FIG. Figure 5A and Figure 5BThe engaging protrusions 542a and 542b shown are engaged with Figure 1B and Fig.10 The engaging holes 106a and 106b of the second cover 100 are shown.

[0153] like Figure 5B As shown in FIG. 1 , the partitions 55a to 55f are formed between the flange 54a and the flange 54b. The partitions 55a to 55f protrude from the outer peripheral surface of the second cylinder 51 toward the radially outer side thereof. Figure 6 As shown, the partitions 55 a to 55 c extend intermittently along the circumferential direction of the second cylindrical portion 51 .

[0154] The partitions 55a to 55f divide the outer peripheral surface of the second cylinder 51 into a plurality of sections along the X axis. By forming the partitions 55a to 55f in the second cylinder 51, it is possible to prevent the second winding portion 21 ( Figure 2 )'s winding is disordered.

[0155] like Figure 5A As shown, the second terminal block 52 is formed at the end of the second tube 51 in the X-axis direction. The second terminal block 52 has, for example, a body 520, an insulating protrusion 521, cutouts 522a and 522b, lower protrusions 523a and 523b, and stoppers 524a and 524b.

[0156] The main body 520 and the core installation surface 411 of the first cylinder portion accommodated in the second cylinder portion 51 (see Figure 3 The length of the main body 520 along the Y axis is longer than the length of the second cylinder 51 along the Y axis.

[0157] The insulating protrusion 521 is formed at the outer end of the main body 520 in the X-axis direction and protrudes upward from the upper surface of the main body 520. Figure 1A As shown, the insulating protrusion 521 is located between the connecting portions 31c and 31d and the first core 70 in the X-axis direction. The insulating protrusion 521 extends the insulating distance (creepage distance and spatial distance) between the first core 70 and the connecting portions 31c and 31d by separating them.

[0158] The insulating protrusion 521 is formed above the connection parts 31c and 31d. The height of the insulating protrusion 521 may be the same as or greater than the thickness of the first core 70 in the Z-axis direction. In addition, the length of the insulating protrusion 521 along the Y-axis may be the same as or greater than the length of the first core 70 along the Y-axis. Thus, the insulation distance between the first core 70 and the connection parts 31c and 31d can be effectively extended.

[0159] like Figure 5AAs shown, the cutouts 522a and 522b are formed on the upper part of the insulating protrusion 521. The cutouts 522a and 522b are formed at one end and the other end of the insulating protrusion 521 in the Y-axis direction, respectively. The stoppers 524a and 524b are formed at the central part of the main body 520 in the Y-axis direction and protrude upward from the upper surface of the main body 520. The stoppers 524a and 524b are separated along the Y-axis and protrude from the inner surface of the insulating protrusion 521 in the X-axis direction.

[0160] like Figure 1A As shown, the stoppers 524a and 524b are located between the insulating protrusion 521 and the end of the first core 70 in the X-axis direction. The stoppers 524a and 524b abut against the end of the first core 70 in the X-axis direction and position the first core 70 in the X-axis direction. In addition, the number of the stoppers 524a and 524b may be singular.

[0161] like Figure 5A As shown, the lower protrusions 523a and 523b protrude downward from the bottom surface of the main body 520. The lower protrusions 523a and 523b are arranged separately along the Y axis. The external connection part 32c is provided on the lower protrusion 523a, and the external connection part 32d is provided on the lower protrusion 523b.

[0162] The terminals 30c and 30d are separately arranged along the Y axis. The terminals 30c and 30d are integrally formed with the lower protrusions 523a and 523b, respectively (insert molding). However, the terminals 30c and 30d may be inserted into the lower protrusions 523a and 523b, respectively. The wiring portion 31c protrudes outwardly along the X axis from the lower protrusion 523a. The external connection portion 32c protrudes downward from the lower protrusion 523a. The wiring portion 31d protrudes outwardly along the X axis from the lower protrusion 523b. The external connection portion 32d protrudes downward from the lower protrusion 523b.

[0163] The side wall portions 53a and 53b are arranged separately along the Y axis. The side wall portions 53a and 53b protrude upward from the upper surface of the main body portion 520. Figure 1A As shown, the end of the first core 70 in the X-axis direction is arranged between the side wall portion 53a and the side wall portion 53b. The side wall portions 53a and 53b sandwich the end of the first core 70 in the X-axis direction from both sides of the first core 70 in the Y-axis direction. The side wall portions 53a and 53b can prevent the first core 70 from being displaced in the Y-axis direction.

[0164] The ends of the first core 70 in the X-axis direction are connected to the side wall portions 53a and 53b by the resin 110. In addition, the ends of the first core 70 in the X-axis direction are connected to the side wall portions 53a and 53b by the resin 110 at a position closer to the bonding portion 120 ( Figure 3) is connected to the upper surface of the main body 520 on the outer side in the X-axis direction. In order to improve the bonding strength (bonding area) with the resin 110, cutouts are formed in the upper parts of the side walls 53a and 53b.

[0165] like Figure 5C As shown in FIG. 1 , guide protrusions 58a and 58b protrude downward from the bottom of the second frame 50. The guide protrusions 58a and 58b are arranged separately along the Y axis. In addition, the guide protrusions 58a and 58b extend in a long-side shape along the X axis. The lead-out passages 59a and 59b are formed along the guide protrusions 58a and 58b, respectively, and extend along the X axis. Figure 6 As shown, the second lead portion 22a is led out from the second winding portion 21 to the connecting portion 31c along the lead path 59a. In addition, the second lead portion 22b is led out from the second winding portion 21 to the connecting portion 31d along the lead path 59b.

[0166] A portion of the lead-out passage 59a is formed between the guide protrusion 58a and the lower protrusion 523a. By leading the second lead-out portion 22a along the lead-out passage 59a, the second lead-out portion 22a can be protected from external loads by the guide protrusion 58a and the lower protrusion 523a. In addition, a portion of the lead-out passage 59b is formed between the guide protrusion 58b and the lower protrusion 523b. By leading the second lead-out portion 22b along the lead-out passage 59b, the second lead-out portion 22b can be protected from external loads by the guide protrusion 58b and the lower protrusion 523b.

[0167] like Figure 5B As shown, the lateral protrusion 60 protrudes outward along the X-axis from the end of the intervening portion 56 in the X-axis direction. The lateral protrusion 60 is formed at a bottom 560 of the intervening portion 56 described below. An engaging protrusion 543c is formed on the lateral protrusion 60. Figure 5C The engaging protrusions 543a to 543c shown are engaged with Figure 7 The engaging holes 940a to 940c of the first cover 90 are shown.

[0168] The intervening portion 56 is formed integrally with the second cylindrical portion 51 and is located on the side opposite to the second terminal block 52. Figure 1A As shown, in the state where the first frame 40 and the second frame 50 are combined, the intervening portion 56 is located between the second cylinder portion 51 (or the second winding portion 21) and the first terminal block 42. The intervening portion 56 is adjacent to the second winding portion 21 and adjacent to the lower protruding portions 423a and 423b of the first terminal block 42. Figure 5B As shown, the intervening portion 56 has a U-shape, and includes a bottom portion 560 and a pair of side portions 561 .

[0169] The bottom 560 is formed in a continuous manner with the bottom of the second tube 51. The bottom 560 protrudes outward along the X-axis from the end of the second tube 51 in the X-axis direction. A pair of side portions 561 are formed in a continuous manner with the side portions of the second tube 51. The pair of side portions 561 protrude outward along the X-axis from the end of the second tube 51 in the X-axis direction. One side portion 561 stands upward from the bottom 560 at one end of the bottom 560 in the Y-axis direction in a manner orthogonal to the bottom 560. The other side portion 561 stands upward from the bottom 560 at the other end of the bottom 560 in the Y-axis direction in a manner orthogonal to the bottom 560.

[0170] like Figure 5B and Figure 5C As shown, the concavoconvex 57 is formed on the outer surface of the intervening portion 56, that is, the outer surface of the bottom 560 and the outer surface of the side portion 561. The concavoconvex 57 extends in a U shape along the outer surface of the intervening portion 56. The concavoconvex 57 is formed from the outer surface of the second winding portion 21 ( Figure 1A ) is formed to a position adjacent to the lower protrusions 423a and 423b of the first terminal block 42.

[0171] The concavoconvex 57 has a concave portion 570 and a convex portion 571. The concave portion 570 and the convex portion 571 are formed continuously from the bottom portion 560 to one side portion 561. In addition, the concave portion 570 and the convex portion 571 are formed continuously from the bottom portion 560 to the other side portion 561.

[0172] The concavoconvex 57 has a plurality of (two in this embodiment) concave portions 570 and a plurality of (three in this embodiment) convex portions 571. However, the number of the concave portion 570 may be one, or may be three or more. In addition, the number of the convex portions 571 may be two, or four or more.

[0173] The widths of the two concave portions 570 along the X-axis are the same, but may be different. In addition, the widths of the three convex portions 571 along the X-axis are the same, but may be different. The three convex portions 571 are arranged at a certain interval, but may be arranged at different intervals. The width of the concave portion 570 along the X-axis is larger than the width of the convex portion 571 along the X-axis, but may be the same or smaller.

[0174] In the bottom 560, the recessed portion 570 and the convex portion 571 extend in a direction (Y-axis direction) orthogonal to the axial direction of the second cylindrical portion 51. The recessed portion 570 and the convex portion 571 extend continuously along the Y-axis from one end to the other end of the bottom 560 in the Y-axis direction. The recessed portion 570 and the convex portion 571 extend linearly along the Y-axis, but may also be bent or curved. In addition, the recessed portion 570 and the convex portion 571 may also extend obliquely relative to the Y-axis.

[0175] By forming the concavo-convex 57 on the bottom 560, the Figure 1B The shown connection portion 31a (the first lead portion 12a connected to the connection portion 31a) and the second winding portion 21 are provided with a creepage distance, and the further connection portion 31b (the first lead portion 12b connected to the connection portion 31b) and the second winding portion 21 are provided with a creepage distance.

[0176] In the side portion 561, the recessed portion 570 and the convex portion 571 extend in a direction (Z-axis direction) orthogonal to the axial direction of the second cylinder portion 51. The recessed portion 570 and the convex portion 571 extend linearly along the Z-axis from the lower end of the side portion 561, but may be bent or curved. In addition, the recessed portion 570 and the convex portion 571 may extend obliquely relative to the Z-axis.

[0177] like Figure 1A As shown, the recess 570 and the convex portion 571 extend from the lower end of the side portion 561 along the Z axis to a position above the first terminal block 42 (more specifically, the upper surface of the main body 420). However, the recess 570 and the convex portion 571 may extend from the lower end of the side portion 561 along the Z axis to the same position as the first terminal block 42 (more specifically, the upper surface of the main body 420). Alternatively, the recess 570 and the convex portion 571 may extend from the lower end to the upper end of the side portion 561 along the Z axis.

[0178] By forming the concavo-convex 57 on the side portion 561, the Figure 1B The shown connection portion 31a (the first lead portion 12a connected to the connection portion 31a) and the second winding portion 21 are provided with a creepage distance, and the further connection portion 31b (the first lead portion 12b connected to the connection portion 31b) and the second winding portion 21 are provided with a creepage distance.

[0179] like Figure 6 As shown in FIG. 1 , the first tube portion 41 of the first frame 40 is inserted into the second tube portion 51 of the second frame 50 in the direction indicated by the arrow. Figure 3 As shown, the first barrel 41 that houses the first core 70 in the through hole 410 is housed inside the through hole 510. The end of the second barrel 51 on the positive direction side of the X axis abuts against the lower protrusions 423a and 423b, and is positioned by the lower protrusions 423a and 423b with respect to the X axis direction. The first core 70 is arranged across the upper surface of the main body 420 of the first terminal block 42, the core setting surface 411, and the upper surface of the main body 520 of the second terminal block 52.

[0180] like Figure 1A and Figure 1B As shown, the first cover 90 is mounted on the bottom of the second frame 50. Figure 7 As shown, the first cover 90 has a cover concave-convex 95. The first cover 90 has a cover body 91, an opening groove 92, a guide portion 93 ( Fig. 9), the engaging parts 94a to 94c, and the protrusion 96, but at least one of these components may be omitted from the first cover 90. The first cover 90 is, for example, formed by connecting with the first frame 40 ( Figure 4 ) are made of the same material.

[0181] The cover body 91 is composed of a flat plate. The cover body 91 covers the second winding portion 21 ( Figure 1A The cover body 91 has an outer surface 91a and an inner surface 91b. The outer surface 91a is located adjacent to the second cylindrical portion 51 ( Figure 5A ) is a surface on the opposite side of the second tube portion 51, and the inner surface 91b is a surface located on the same side as the second tube portion 51.

[0182] like Fig. 9 As shown, the cover body 91 is disposed between the second winding portion 21 and the second lead portion 22a. The cover body 91 extends the insulation distance (creeping distance and spatial distance) between the second winding portion 21 and the second lead portion 22a by separating them. Figure 3 As shown, the cover body 91 abuts against the partitions 55 a to 55 f of the second frame 50 .

[0183] like Figure 7 As shown, the opening groove 92 is formed in a manner that passes through the outer surface 91a and the inner surface 91b of the cover body 91. The opening groove 92 is bent in an L shape and has a first portion 92a and a second portion 92b. The first portion 92a extends inward from the end of the cover body 91 in the Y-axis direction along the Y-axis. The second portion 92b extends along the X-axis in a manner orthogonal to the first portion 92a.

[0184] like Fig. 9 As shown, the second lead portion 22a is led out from the second winding portion 21 to the outside of the cover body 91 via the opening groove 92. More specifically, the second lead portion 22a passes through the first portion 92a and is guided inward from the end portion on the Y-axis direction side of the cover body 91. Then, the second lead portion 22a passes through the second portion 92b and is guided to the connecting portion 31c.

[0185] The guide portion 93 is formed on the outer surface 91a and protrudes downward from the outer surface 91a. The height of the guide portion 93 is equal to or greater than the wire diameter of the second lead portion 22a, but may be lower than the wire diameter.

[0186] The guide portion 93 is bent in an L-shape and has a first extension portion 93a and a second extension portion 93b. The first extension portion 93a extends from the end portion of the cover body 91 in the Y-axis direction toward the inside along the first portion 92a of the opening groove 92. The second extension portion 93b extends along the X-axis in a manner orthogonal to the first extension portion 93a. A portion of the second extension portion 93b extends along the second portion 92b of the opening groove 92. The guide portion 93 prevents the position of the second lead portion 22a from being offset and guides the second lead portion 22a to the wiring portion 31c.

[0187] like Figure 7 As shown, the engaging parts 94a and 94b are formed at one end of the cover body 91 in the X-axis direction and protrude upward. The engaging parts 94a and 94b are arranged separately along the Y-axis. The engaging part 94c is formed at the other end of the cover body 91 in the X-axis direction. The engaging part 94c has an L shape and is bent upward.

[0188] Engagement holes 940a to 940c are formed in the engagement portions 94a to 94c, respectively. Fig. 9 As shown, the engaging protrusions 543a to 543c of the second frame 50 are engaged with the engaging holes 940a to 940c.

[0189] The cover concavoconvex 95 is formed integrally with the cover body 91. More specifically, the cover concavoconvex 95 is formed along the Y axis from one end to the other end of the cover body 91 in the Y axis direction. In addition, the cover concavoconvex 95 is formed along the X axis from a position adjacent to the opening groove 92 to an end of the cover body 91 in the X axis direction. The cover concavoconvex 95 is formed in a wave-like (S-shaped or crank-shaped) bending manner.

[0190] The cover protrusions and recesses 95 are formed on the outer surface 91a and the inner surface 91b of the cover body 91. Therefore, the outer surface 91a is curved in a wave shape (S-shaped or crank-shaped) by the cover protrusions and recesses 95. In addition, the inner surface 91b is curved in a wave shape (S-shaped or crank-shaped) by the cover protrusions and recesses 95.

[0191] The cover concavoconvex 95 has a plurality of concave portions 950 and a plurality of convex portions 951. Two concave portions 950 are formed on the outer surface 91a, and three convex portions 951 are formed. However, the number of concave portions 950 formed on the outer surface 91a may be one, or may be three or more. In addition, the number of convex portions 951 formed on the outer surface 91a may be one, two, or four or more.

[0192] The inner surface 91b is formed with three recesses 950 and two protrusions 951. However, the number of recesses 950 formed on the inner surface 91b may be one, two, or four or more. In addition, the number of protrusions 951 formed on the inner surface 91b may be one, three or more.

[0193] On the outer surface 91a, the widths of the two concave portions 950 along the X-axis are the same, but may be different. In addition, the widths of the three convex portions 951 along the X-axis are the same, but may be different. The three convex portions 951 are arranged at a certain interval, but may be arranged at different intervals. The width of the convex portion 951 along the X-axis is larger than the width of the concave portion 950 along the X-axis, but may be the same or smaller.

[0194] On the inner surface 91b, the widths of the three concave portions 950 along the X-axis are the same, but may be different. In addition, the widths of the two convex portions 951 along the X-axis are the same, but may be different. The three concave portions 950 are arranged at a certain interval, but may be arranged at different intervals. The width of the convex portion 951 along the X-axis is larger than the width of the concave portion 950 along the X-axis, but may be the same or smaller.

[0195] The concave portion 950 and the convex portion 951 are arranged relative to the second cylindrical portion 51 ( Figure 8 ) in a direction (Y-axis direction) perpendicular to the axial direction of the cover body 91. The recessed portion 950 and the convex portion 951 extend continuously along the Y-axis from one end to the other end of the cover body 91 in the Y-axis direction. The recessed portion 950 and the convex portion 951 extend linearly along the Y-axis, but may also be bent or curved. In addition, the recessed portion 950 and the convex portion 951 may extend obliquely relative to the Y-axis.

[0196] like Figure 8 As shown, the cover protrusions and recesses 95 are formed at positions corresponding to the protrusions and recesses 57 of the second frame 50. The cover protrusions and recesses 95 are opposite to the bottom 560 and engage with the protrusions and recesses 57 formed on the bottom 560. That is, the convex portion 571 of the protrusions and recesses 57 engages with the concave portion 950 in a manner that enters the concave portion 950 of the cover protrusions and recesses 95. In addition, the convex portion 951 of the cover protrusions and recesses 95 engages with the concave portion 570 in a manner that enters the concave portion 570 of the protrusions and recesses 57.

[0197] The convex part 571 and the concave part 950 are in contact, but a gap may be formed between them. In addition, a gap is formed between the convex part 951 and the concave part 570, but they may be in contact.

[0198] By forming the cover protrusions and depressions 95 on the cover body 91, it is possible to extend the Figure 1B The shown connection portion 31a (the first lead portion 12a connected to the connection portion 31a) and the second winding portion 21 have a surface distance, and the further connection portion 31b (the first lead portion 12b connected to the connection portion 31b) and the second winding portion 21 have a surface distance and a spatial distance.

[0199] like Figure 7As shown, the protrusion 96 is formed on the convex portion 951 and protrudes downward from the outer surface 91a. The protrusion 96 extends from one end of the convex portion 951 in the Y-axis direction to the other end along the Y-axis. The width of the protrusion 96 along the X-axis is smaller than the width of the convex portion 951 along the X-axis. Three protrusions 96 are formed on each of the three convex portions 951 formed on the outer surface 91a. At least one of these protrusions 96 may be omitted from the first cover 90.

[0200] like Fig.10 As shown, the second cover 100 includes, for example, a cover body 101, engaging protrusions 102a and 102b, core restricting portions 103a and 103b, side protrusions 104a and 104b, engaging portions 105a and 105b, and engaging holes 106a and 106b. The second cover 100 is not particularly limited, but is made of the same material as the first cover 90.

[0201] The cover body 101 is composed of a flat plate. The cover body 101 has an outer surface 101a and an inner surface 101b. The outer surface 101a is located adjacent to the second cylindrical portion 51 ( Figure 5A ) is a surface on the opposite side of the second tube portion 51, and the inner surface 101b is a surface located on the same side as the second tube portion 51.

[0202] like Figure 1B As shown, the cover body 101 covers the second cylindrical portion 51 from above. The cover body 101 is arranged between the second winding portion 21 and the main body 81 of the second core 80. The cover body 101 extends the insulation distance (creepage distance and spatial distance) between the second winding portion 21 and the main body 81 by separating the second winding portion 21 from the main body 81. Figure 3 As shown, the cover body 101 abuts against the partitions 55 a to 55 f of the second frame 50 .

[0203] like Fig.10 As shown, the engaging protrusions 102a and 102b protrude downward from the inner surface 101b. The engaging protrusion 102a is located on one side of the cover body 101 in the X-axis direction, and the engaging protrusion 102b is located on the other side of the cover body 101 in the X-axis direction. The engaging protrusions 102a and 102b extend from one end of the inner surface 101b in the Y-axis direction to the other end along the Y-axis.

[0204] The core limiting portions 103a and 103b protrude upward from the outer surface 101a. The core limiting portion 103a is located on one side of the cover body 101 in the Y-axis direction, and the core limiting portion 103b is located on the other side of the cover body 101 in the Y-axis direction. The core limiting portions 103a and 103b extend from one end of the outer surface 101a in the X-axis direction to the other end along the X-axis. Figure 1BAs shown in FIG. 1 , the second core 80 is disposed between the core restriction portion 103a and the core restriction portion 103b. Therefore, the core restriction portions 103a and 103b can prevent the second core 80 from being displaced in the Y-axis direction.

[0205] like Fig.10 As shown, a plurality of (three in the present embodiment) lateral protrusions 104a are formed on the outer surface 101a and are separately arranged along the Y-axis. The lateral protrusions 104a protrude outwardly along the Y-axis from the core limiting portion 103a. In addition, a plurality of (three in the present embodiment) lateral protrusions 104b are formed on the outer surface 101a and are separately arranged along the Y-axis. The lateral protrusions 104b protrude outwardly along the Y-axis from the core limiting portion 103b. By forming the lateral protrusions 104a and 104b on the cover body 101, the strength of the cover body 101 can be improved.

[0206] The engaging portion 105a is formed at one end of the cover body 101 in the X-axis direction and protrudes downward. The engaging portion 105b is formed at the other end of the cover body 101 in the X-axis direction and protrudes downward. Engaging holes 106a and 106b are formed in the engaging portions 105a and 105b, respectively. Figure 5A The engaging protrusion 542a shown in the figure is engaged with the engaging hole 106b. Figure 5B The engaging protrusion 542b shown (see Figure 1B ).

[0207] Next, a method for manufacturing the coil device 1 will be described. First, prepare Figure 2 The first terminal block 42 of the first frame 40 is pre-installed with the terminals 30a and 30b ( Figure 1B ) Similarly, the terminals 30c and 30d are pre-installed on the second terminal block 52 of the second frame 50.

[0208] Next, the first winding 10 is wound around the first barrel 41 to form the first winding portion 11. Figure 6 As shown, the first lead portions 12a and 12b are led out from the bottom surface side of the first cylindrical portion 41 toward the connecting portions 31a and 31b, and are connected to the connecting portions 31a and 31b, respectively.

[0209] In addition, the second winding wire 20 is wound around the second barrel 51 to form the second winding portion 21. Fig. 9 As shown, the first cover 90 is mounted on the second frame 50. Fig. 9 As shown, the second lead portion 22a is led out from the bottom surface side of the second cylinder 51 toward the connecting portion 31c by passing through the opening groove 92 (the first portion 92a and the second portion 92b) of the first cover 90, and connected to the connecting portion 31c. Figure 6As shown, the second lead portion 22b is led out from the second winding portion 21 toward the connecting portion 31d and connected to the connecting portion 31d.

[0210] Next, to Figure 2 The through hole 410 of the first cylindrical portion 41 shown in FIG. 4 is inserted into the first core 70. Figure 6 The first cylindrical portion 41 into which the first core 70 is inserted is inserted into the through hole 510 of the second cylindrical portion 51 in the direction indicated by the arrow.

[0211] Then, if Figure 1B As shown, the second cover 100 is mounted on the second frame 50. Next, the second core 80 is mounted from above the second cover 100. Figure 3 As shown, at the joint portion 120 , the leg portion 82 of the second core 80 is brought into contact with the surface of the first core 70 .

[0212] Then, if Figure 1A As shown, the resin 110 is attached to the end of the first core 70 on the positive side of the X axis. Then, the end of the first core 70 on the positive side of the X axis is connected to the leg 82 of the second core 80, the side wall portions 53a and 53b, and the upper surface of the main body 520 ( Figure 5A )connect.

[0213] Likewise, if Figure 1B As shown, the resin 110 is attached to the end of the first core 70 on the negative side of the X axis. Then, the end of the first core 70 on the negative side of the X axis is connected to the leg 82 of the second core 80, the side wall portions 43a and 43b, and the upper surface ( Figure 4 ) connection. Then, Figure 1A As shown, the second frame 50, the first cover 90, the second core 80, etc. are fixed with a belt 130. The belt 130 is an insulating belt formed of plastic or rubber, etc., and is a belt for fixing them so as not to remove the assembly structure of the second frame 50, the first cover 90, the second core 80, etc. As described above, the coil device 1 can be manufactured.

[0214] like Figure 2 As shown, the coil device 1 of this embodiment includes a first frame 40 and a second frame 50, and the first cylinder 41 is accommodated in the second cylinder 51. Figure 3 As shown, the first cylindrical portion 41 and the second cylindrical portion 51 are arranged overlapping each other. Therefore, compared with the prior art, the length of the coil device 1 with respect to the axial direction (X-axis direction) of the first cylindrical portion 41 is shortened, and the coil device 1 can be miniaturized.

[0215] In addition, if Figure 1AAs shown, the intermediate portion 56 is located between the second barrel portion 51 and the first terminal block 42, and a concave-convex portion 57 is formed on the outer surface of the intermediate portion 56. Therefore, according to the degree of the concave-convex portion 57, the surface distance between the second winding portion 21 provided in the second barrel portion 51 and the terminals 30a and 30b (the first lead portion 12a connected to the terminal 30a and the first lead portion 12b connected to the terminal 30b) provided in the first terminal block 42 is extended, and the insulation between the second winding portion 21 and the terminals 30a and 30b can be ensured. Therefore, according to this embodiment, the miniaturization of the coil device 1 can be achieved without reducing the withstand voltage between the second winding portion 21 and the terminals 30a and 30b, and a small coil device 1 with excellent withstand voltage reliability can be achieved.

[0216] In addition, if Figure 5B As shown in FIG. 1 , the recess 570 and the convex portion 571 extend in a direction (Y-axis direction or Z-axis direction) orthogonal to the axial direction of the second barrel 51. Therefore, depending on the number of repetitions of the recess 570 and the convex portion 571, the second winding portion 21 ( Figure 1B ) and the terminals 30a and 30b ( Figure 1B ) is the creepage distance between them.

[0217] In addition, the concavoconvex 57 is formed at least on the side portion 561. Therefore, on the side portion 561, the second winding portion 21 ( Figure 1B ) and the terminals 30a and 30b ( Figure 1B ) are extended, which can prevent a current path from being formed between them through the side portion 561.

[0218] In addition, the concavoconvex 57 is formed at least on the bottom 560. Therefore, at the bottom 560, the second winding portion 21 ( Figure 1B ) and the terminals 30a and 30b ( Figure 1B ) are extended along the surface distance between them, which can prevent a current path from being formed between them through the bottom 560.

[0219] In addition, the concavoconvex 57 is continuously formed from the bottom 560 to the side 561. Therefore, the second winding portion 21 ( Figure 1B ) and the terminals 30a and 30b ( Figure 1B ) are extended along the surface distance between them, which can prevent the formation of a current path passing through the bottom 560 and the side 561 between them.

[0220] In addition, if Figure 7 As shown, the first cover 90 is formed with a cover protrusion 95, and the cover protrusion 95 is located at the same position as the protrusion 57 ( Figure 5B ) corresponding to the position. Therefore, Fig. 9 As shown, the creepage distance between the second lead portion 22a extending on the first cover 90 and the terminals 30a and 30b provided on the first terminal block 42 is extended according to the degree of the cover protrusion 95. Thus, it is possible to prevent a current path passing through the second cover 100 from being formed between the second lead portion 22a and the terminals 30a and 30b, and to ensure insulation between them.

[0221] In addition, if Figure 8 As shown, the cover protrusions and depressions 95 are engaged with the protrusions and depressions 57. Therefore, the space distance between the second winding portion 21 provided on the second barrel 51 and the terminals 30a and 30b provided on the first terminal block 42 is extended according to the extent of the protrusions and depressions 57 and the cover protrusions and depressions 95. Therefore, it is possible to prevent the formation of a current path passing through the space between the second frame 50 and the first cover 90 between the second winding portion 21 and the terminals 30a and 30b, and to ensure insulation between them.

[0222] In addition, the cover protrusions and depressions 95 are formed on the outer surface 91a and the inner surface 91b of the first cover 90. Fig. 9 As shown, by forming the cover protrusions and depressions 95 on the outer surface 91a, the creepage distance between the second lead-out portion 22b extending on the first cover 90 and the terminals 30a and 30b provided on the first terminal block 42 can be extended. Moreover, by forming the cover protrusions and depressions 95 on the inner surface 91b of the first cover 90, the spatial distance between the second winding portion 21 provided on the second barrel 51 and the terminals 30a and 30b provided on the first terminal block 42 can be extended.

[0223] 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.

[0224] In the above-mentioned embodiment, the example of applying the present invention to the transformer has been described, but the present invention can also be applied to other coil devices other than the transformer.

[0225] In the above embodiment, the I-type cores may be combined to form the second core 80 ( Figure 2 ).

[0226] In the above embodiment, the concavoconvex 57 has a plurality of concave portions 570, but the number of concave portions 570 may be one. In addition, the concavoconvex 57 has a plurality of convex portions 571, but the number of convex portions 571 may be one. In addition, the cover concavoconvex 95 has a plurality of concave portions 950, but the number of concave portions 950 may be one. In addition, the cover concavoconvex 95 has a plurality of convex portions 951, but the number of convex portions 951 may be one.

Claims

1. A coil device, wherein: have: A first frame having a first cylindrical portion and a terminal block provided with a terminal; a first winding having a first winding portion provided on the first barrel portion and a first lead portion led out from the first winding portion and connected to the terminal; a second frame having a second cylindrical portion for accommodating the first cylindrical portion, and an intervening portion located between the second cylindrical portion and the terminal block; and a second winding having a second winding portion provided on the second barrel portion and a second lead-out portion led out from the second winding portion to a side opposite to the first lead-out portion, Concavities and convexities are formed on the outer surface of the intervening portion.

2. The coil device according to claim 1, wherein: The concave portion and the convex portion constituting the concavo-convex portion extend in a direction orthogonal to the axial direction of the second cylindrical portion.

3. The coil device according to claim 1 or 2, wherein: The intervening portion has a bottom portion and a side portion rising from the bottom portion. The concavoconvexity is formed at least on the side portion.

4. The coil device according to claim 1 or 2, wherein: The intervening portion has a bottom portion and a side portion rising from the bottom portion. The concavoconvex is formed at least on the bottom.

5. The coil device according to claim 1 or 2, wherein: The intervening portion has a bottom portion and a side portion rising from the bottom portion. The concavities and convexities are continuously formed from the bottom to the side.

6. The coil device according to claim 1 or 2, wherein: A cover is also provided, the cover is mounted on the bottom of the second frame and is arranged between the second winding portion and the second lead-out portion, The cover has a cover concavoconvex shape. The cover concavo-convex is located at a position corresponding to the concavo-convex.

7. The coil device according to claim 6, wherein: The cover concavo-convex is engaged with the concavo-convex.

8. The coil device according to claim 6, wherein: The cover concavoconvexities are formed on the outer surface and the inner surface of the cover.

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