Coil device

Abstract

The invention provides a coil device which has excellent heat dissipation performance and can be miniaturized. A coil device includes a core (2) including a magnetic body, windings (4, 5) wound around at least a portion of the core (2), and a terminal block (7) holding a terminal (6) to which lead portions (41a, 41b, 51a, 51b) of the windings (4, 5) are connected. At least a portion of the terminal block (7) is fixed to a portion of the core (2).

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] Patent document 1 discloses a coil device having a cylindrical frame, a winding portion for winding wires arranged on the outer peripheral surface of the frame, and a core having a middle leg portion mounted on the frame. The middle leg portion is inserted into a through hole of the frame and is arranged radially inward of the winding portion. The frame is provided with a terminal block on which a terminal is mounted.

[0003] In conventional coil devices, a terminal block to which terminals are mounted is generally provided on a frame as shown in Patent Document 1. Recently, there is a demand for coil devices that are excellent in heat dissipation and can be reduced in size.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: Japanese Patent Application Publication No. 2014-93404 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 is excellent in heat dissipation and can be reduced in size.

[0008] In order to achieve the above object, a coil device according to one embodiment of the present invention includes:

[0009] a core comprising a magnetic body;

[0010] a winding wire wound around at least a portion of the core;

[0011] a terminal block that holds a terminal to which a lead portion of the winding is connected,

[0012] At least a portion of the terminal block is fixed to a portion of the core.

[0013] In the coil device of one aspect of the present invention, the terminal block is fixed to the core, so there is no need to use a frame. In addition, since there is no need to use a frame, the distance between the winding part of the winding and the core can be shortened, and the coil device can be miniaturized and lightweight.

[0014] Furthermore, the winding portion and the core of the winding can be directly cooled by heat dissipation resin without passing through the frame, which can also improve the heat dissipation and cope with the large current of the coil device. In addition, even if the coil device uses a shell filled with heat dissipation resin, the shell can be miniaturized and the heat dissipation can be particularly improved.

[0015] Furthermore, when a frame is used as in the prior art, a gap must be provided between the core and the frame for ease of assembly, and the overall size of the coil device must be increased. In addition, the frame has been used to limit the direct contact between the heat dissipating resin and the coil and the core.

[0016] Preferably, the terminal block is arranged at a position covering at least a portion of the upper surface of the core. By fixing the terminal block to the core at such a position, it contributes to miniaturization of the coil device and also contributes to improvement of heat dissipation.

[0017] The winding may include at least a first winding and a second winding, the lead portion may include a plurality of lead portions, and the terminal may include a plurality of terminals.

[0018] Preferably, the terminal block is provided with terminals connected to the lead portions of the first windings and terminals connected to the lead portions of the second windings. By configuring in this way, even if the number of terminals is large, the coil device can be easily miniaturized and heat dissipation can be improved.

[0019] The terminal block may be provided at one end of the core along a first axis substantially perpendicular to the winding axis of the winding wire. With such a configuration, it is easy to realize miniaturization of the coil device and also improve heat dissipation.

[0020] The terminal block may also include a terminal mounting portion having mounting grooves for the four or more terminals to be respectively engaged in. By configuring in this way, even if the number of terminals is large, it is easy to mount the terminals, and it is easy to miniaturize the coil device and improve heat dissipation.

[0021] The terminal block may also include a core cover portion, which is continuously provided with the terminal mounting portion and covers the upper surface of the core at a position different from a portion of the upper surface of the core covered by the terminal mounting portion. With such a configuration, it is easy to mount the terminal block on the upper surface of the core.

[0022] The core cover may also have a through groove through which a heat sink disposed in contact with the upper surface of the core passes. With such a configuration, the heat sink is easily in contact with the upper surface of the core, and the heat on the upper surface of the core is easily released to the heat dissipating resin or external air through the heat sink.

[0023] The terminal block may also include: a first terminal mounting portion having mounting grooves into which terminals connected to the pair of lead portions of the first winding are respectively fitted; and a second terminal mounting portion having mounting grooves into which terminals connected to the pair of lead portions of the second winding are respectively fitted. Preferably, the first terminal mounting portion and the second terminal mounting portion are respectively arranged at both ends of the core along a first axis substantially perpendicular to the winding axis of the winding.

[0024] By configuring in this way, even when the number of terminals is large, the number of terminals mounted on each terminal block mounting portion can be reduced, for example, the position of the terminals mounted on each terminal block mounting portion can be easily made consistent with the position of the recess formed on the core, etc. As a result, the miniaturization of the coil device is further improved.

[0025] The first terminal mounting portion and the second terminal mounting portion may also be separately provided, but may also be integrally connected using an intermediate core cover portion. Preferably, the intermediate core cover portion covers the central portion of the upper surface of the core between the first terminal mounting portion and the second terminal mounting portion. By configuring in this way, it is easy to simultaneously position and mount the two terminal mounting portions on the upper surface of the core. In addition, it also contributes to the miniaturization of the coil device.

[0026] The intermediate core cover may also have a through groove, through which a heat sink disposed in contact with the upper surface of the core passes. With such a configuration, the heat sink is easily in contact with the upper surface of the core, and the heat on the upper surface of the core is easily released to the heat dissipating resin or external air through the heat sink.

[0027] The intermediate core cover portion may also have at least one of a through hole extending from the inner surface of the intermediate core cover portion to the outer surface, and a concave-convex portion formed on the outer surface. Forming the through hole and / or the concave-convex portion in the intermediate core cover portion helps prevent the terminal block including the core cover portion from warping, and also helps to reduce the weight of the coil device and improve the cooling efficiency.

[0028] The terminal block may also include a bent piece that enters a recess formed on a side of the core. With this configuration, positioning and fixing of the terminal block to the core becomes easy, and miniaturization and heat dissipation of the coil device are improved.

[0029] Preferably, the bent piece is integrated with the terminal block so that the connection portion of the terminal enters the recessed portion of the core. With this configuration, the coil device can be miniaturized and heat dissipation can be improved.

[0030] A partition may be provided between one end of the winding portion of the winding wire in the winding direction and the core. The partition may also be insulating, in which case the insulation between the core and the winding portion of the winding wire is improved. The partition may also be combined with a terminal block, or the base portion of the core may be sandwiched between the terminal block and the partition. Preferably, a through hole is formed in the partition through which the middle leg of the core passes.

[0031] Preferably, the core has a middle leg portion arranged through the winding portion of the winding wire. In addition, the core may further have a side leg portion covering at least a portion of the outer circumference of the first winding portion or the outer circumference of the second winding portion.

[0032] The invention may further include a housing for accommodating at least a part of the winding portion of the winding wire. Preferably, the interior of the housing is filled with a heat dissipating resin to a position where at least a part of the winding portion of the winding wire is immersed. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a schematic perspective view of a coil device according to an embodiment of the present invention.

[0034] Figure 2A It has been removed Figure 1 A schematic perspective view of the coil device in the housing shown.

[0035] Figure 2B yes Figure 2A A schematic exploded perspective view of the coil device shown.

[0036] Figure 2C yes Figure 2B A schematic exploded perspective view of the terminal block shown.

[0037] Figure 2D yes Figure 2B A partially omitted perspective view of the coil body is shown.

[0038] Figure 3 Observe from different angles Figure 2C A perspective view of the terminal block body shown.

[0039] Fig.4A1 yes Figure 1 A schematic cross-sectional view of the coil device shown along line IVA-IVA.

[0040] Figure 4A2 yes Figure 1 The coil device shown is a schematic cross-sectional perspective view taken along line IVA-IVA.

[0041] Figure 4B yes Fig.4A1 A schematic cross-sectional view of the coil device shown along line IVB-IVB.

[0042] Figure 5 Yes means Figure 4A2 A schematic perspective view showing the flow direction of the heat dissipating resin in the spacer shown.

[0043] Figure 6 yes Figure 4A2 A schematic perspective view of the spacer is shown.

[0044] Figure 7 It is a schematic perspective view of a coil device according to another embodiment of the present invention.

[0045] Figure 8 It has been removed Figure 7 A schematic perspective view of a coil device with a terminal cover is shown.

[0046] Fig. 9 yes Figure 7 A schematic exploded perspective view of the coil device shown.

[0047] Fig.10 Yes means Fig. 9 A schematic exploded perspective view showing the relationship between the terminal block and the partition shown.

[0048] Fig.11 This is a schematic perspective view of a coil device according to still another embodiment of the present invention.

[0049] Fig.12 yes Fig.11 A schematic exploded perspective view of the coil device shown.

[0050] Fig.13 is from Fig.11 The coil assembly shown is a perspective view of the coil assembly with the core and heat sink removed.

[0051] Fig.14 is from Fig.13 The coil device shown is an exploded perspective view of the coil device with the terminal cover removed.

[0052] Fig.15 Observe from different angles Fig.14 An exploded perspective view of the coil device shown.

[0053] Fig.16 is from Fig.11 The coil device shown is a perspective view of the coil device with the terminal block removed and the terminal cover omitted from the illustration.

[0054] Fig.17 This is an exploded perspective view of a core and a heat sink used in a coil device according to still another embodiment of the present invention.

[0055] Fig.18 This is an exploded perspective view of a core and a heat sink used in a coil device according to still another embodiment of the present invention.

[0056] Explanation of symbols

[0057] 1. 1A, 1B…Coil device

[0058] 2, 2B, 2C, 2D... core

[0059] 21, 21B…The first core

[0060] 21B1, 21B2…first core segment

[0061] 21a…Base

[0062] 21a2…Step-shaped recess

[0063] 21a3…Middle concave part

[0064] 21a4…base segment

[0065] 21b…Midfoot

[0066] 21b1…Front End

[0067] 21b2…mid-leg split

[0068] 21b3…butt joint

[0069] 21c…lateral foot

[0070] 21c1…Front End

[0071] 22, 22B…Second core

[0072] 22B1, 22B2…Second core segment

[0073] 22a…base part

[0074] 22a1…concave part

[0075] 22a2…step-shaped recess

[0076] 22a3…Middle concave portion

[0077] 22a4…base segment

[0078] 22b…Midfoot

[0079] 22b1…Front End

[0080] 22b2…mid-leg split

[0081] 22b3…butt joint

[0082] 22c…lateral foot

[0083] 22c1…Front End

[0084] 22c2…side end face

[0085] 23…Split side leg

[0086] 3…Coil core assembly

[0087] 30…Coil body

[0088] 4…First winding

[0089] 40 ... first winding section

[0090] 41a, 41b…lead portion

[0091] 42…first opposite end

[0092] 45…spiral recess

[0093] 5…Second winding

[0094] 50...Second winding section

[0095] 51a, 51b...lead portion

[0096] 52…Second opposite end

[0097] 55…Spiral recess

[0098] 6…terminal

[0099] 60…Terminal base

[0100] 61…Connection

[0101] 62…External connection

[0102] 7, 7A, 7B…Terminal block

[0103] 70, 70B…Terminal cover

[0104] 70a…Handle piece

[0105] 70b…claw

[0106] 70c…Through hole

[0107] 70d…First side piece

[0108] 70e...Mounting tabs

[0109] 70f…Second side piece

[0110] 71…Mounting slot

[0111] 72…Terminal mounting part

[0112] 72a…Inner surface

[0113] 72b…Inner concave part

[0114] 72c…Outer surface

[0115] 72d…Installation convex part

[0116] 72e...Mounting slot

[0117] 73… Flat sheet

[0118] 73a…Inner surface

[0119] 73b…Mounting piece

[0120] 74…Bending piece

[0121] 74a…Inner surface

[0122] 74b…Elastic sheet

[0123] 75…Core cover

[0124] 75a…Intermediate core cover

[0125] 76…Through groove

[0126] 77…Separator

[0127] 77a…Stand-up piece

[0128] 77a1…Central recess

[0129] 77a2…Inner surface convex part

[0130] 77b…fitting convex part

[0131] 77c…Through hole

[0132] 8…Housing

[0133] 80…base plate

[0134] 81…Side panels

[0135] 82…Heat dissipation resin

[0136] 9…Heat Radiator

[0137] 9a…Radiator plate splitter

[0138] 90, 90a…top plate

[0139] 91, 91a…side plate

[0140] 92a ... Insertion plate

[0141] 10…Spacer

[0142] 11...Outside concave part

[0143] 12...inside concave part

[0144] 13…Peripheral part

[0145] 14…Inner circumference

[0146] 16…Through hole. DETAILED DESCRIPTION

[0147] 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.

[0148] (First Embodiment)

[0149] 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.

[0150] 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 .

[0151] 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.

[0152] 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.

[0153] The cores 21 and 22 are not particularly limited as long as they are cores having magnetic bodies, and are made of, for example, ferrite, metal magnetic bodies, 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.

[0154] The two cores 21 and 22 can be integrated by using an adhesive after the coil body 30 is installed between them, or can be integrated by using a fixing tape or the like, or can be integrated by combining them. As the adhesive, a resin material with good thermal conductivity such as heat dissipation lubricating oil can also be used.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] The plurality of terminals 6 to which the 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 terminal cover 70, and by mounting the terminal cover 70 on the terminal block 7, the plurality of terminals 6 are fixed along the long side direction of the terminal block 7 at predetermined intervals along the Y axis. The terminal block 7 and the terminal cover 70 are preferably made of insulating components such as synthetic resin, and may be made of the same insulating material, or may be made of different insulating materials. In the present embodiment, the terminal block 7 is directly fixed to the core 2.

[0160] The means for directly fixing the terminal block 7 to the core 2 is not particularly limited, and examples thereof include means such as fixing by bonding, welding, and tape, and all fixing means other than fixing by a frame are included.

[0161] 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.

[0162] 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.

[0163] The terminal block 7 includes a plate-shaped terminal mounting portion 72 having a mounting groove 71 formed on an outer surface 72c, a pair of flat plates 73 extending downward along the Z axis from both ends of the terminal mounting portion 72 along the Y axis, and a curved plate 74 that integrates and connects the pair of flat plates. 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.

[0164] Figure 3 The inner surface 72a of the terminal mounting 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).

[0165] like Figure 2BAs shown, the terminal cover 70 mounted on the terminal block 7 has holding pieces 70a at both ends in 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 terminal mounting portion 72 of the terminal block, so that the terminal cover 70 can be fixed to the terminal block 7 .

[0166] like Figure 1 As shown, the housing 8 has a substantially rectangular bottom plate 80, 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 portion along the Z axis. The housing 8 is preferably made of a metal such as aluminum having excellent thermal conductivity, but may also be made of resin.

[0167] The lower half or more of the coil core assembly 3 is accommodated in the housing 8, and the liquid level of the heat dissipating resin 82 filled in 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 dissipating resin 82. It is further preferred that the liquid level of the heat dissipating resin 82 filled in 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 dissipating resin 82.

[0168] 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 .

[0169] 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 Figure 6 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.

[0170] 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.

[0171] In this embodiment, if Figure 5 As shown, the spacer 10 is recessed from the outer peripheral position of the spacer 10 toward the inner peripheral position, and has a plurality of outer side recesses 11 along the circumferential direction that 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 is recessed from the inner peripheral position of the spacer 10 toward the outer peripheral position, and has a plurality of inner side recesses 12 along the circumferential direction that 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.

[0172] 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.

[0173] 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 .

[0174] 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).

[0175] 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.

[0176] 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.

[0177] 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.

[0178] In addition, if Fig.4A1 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.

[0179] 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 .

[0180] 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.

[0181] 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.

[0182] like Figure 5 As shown, the heat dissipating resin 82 as a cooling fluid can be introduced from the radially outer side of the winding parts 40 and 50 to the inner side between the first opposite end 42 and the second opposite end 52 through the outer side recess 11. In addition, the inner side recess 12 can introduce the heat dissipating resin 82 from the radially inner side of the winding parts 40 and 50 to the inner side or from the outer side to the inner side between the first opposite end 42 and the second opposite end 52.

[0183] 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.

[0184] 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 along 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.

[0185] 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.

[0186] By providing the flow path forming area where no components constituting the spacer 10 are present at multiple locations along the circumferential direction on the surface of the spacer 10, the heat dissipating resin as a cooling fluid can be introduced between the first opposite end 42 and the second opposite end 52 at multiple locations along the circumferential direction, thereby further improving the heat dissipation of the coil device 1. 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 adjusted.

[0187] 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 .

[0188] Furthermore, in this embodiment, if Figure 2D As shown, the width of the inner recess 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 to 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 to between the first opposite end 42 and the second opposite end 52 along the inner recess 12, and the heat dissipating resin 82 can be stored at the inner circumferential position where the width of the inner recess 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.

[0189] 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.

[0190] 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 wider 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.

[0191] 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.

[0192] In the present embodiment, the spacer 10 may also be formed of an insulating member and / or a metal member. Examples of the insulating member include synthetic resin, ceramic, glass, etc. When the spacer 10 is formed of an insulating member, the insulation between the first winding portion 40 and the second winding portion 50 is also improved. In the case of ceramics in particular, it is difficult to deform even when used at high temperatures, so it is easy to stabilize the coil characteristics regardless of the temperature.

[0193] When the spacer 10 is formed of a metal component, the heat transfer characteristics of the spacer 10 itself are good, and the heat dissipation is further improved. In addition, when the spacer 10 is formed of a metal component, the windings 4 and 5 are preferably windings covered with an insulating film. In addition, the spacer 10 can also be formed of a composite component of a metal component and an insulating component. For example, the spacer 10 can 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 can also be formed using an insulating component in which metal powder is dispersed.

[0194] In particular, in this embodiment, Figure 2A As shown in FIG. 1 , the terminal block 7 is directly fixed to the upper surface of the second core 22, so there is no need to use a frame. In addition, since there is no need to use a frame, it is possible to reduce Figure 2B The distances between the winding parts 40 and 50 of the winding wire and the core 2 shown can reduce the size of the coil device 1 and also reduce its weight.

[0195] Furthermore, the winding portions 40, 50 and the core 2 of the winding can be directly cooled by the heat dissipation resin 82 or the like without passing through the frame, and the heat dissipation is also improved, and it is also possible to cope with the large current of the coil device 1. In addition, even if the coil device 1 uses the shell 8 filled with the heat dissipation resin 82, the shell 8 can be miniaturized, and the heat dissipation is particularly improved.

[0196] Furthermore, when a frame is used as in the prior art, a gap must be provided between the core and the frame for ease of assembly, and the overall size of the coil device must be increased. In addition, the frame has been used to limit the direct contact between the heat dissipating resin and the coil and the core.

[0197] In particular, in this embodiment, Figure 2A As shown, the terminal block 7 is arranged at a position covering at least a portion of the upper surface of the core 2. By fixing the terminal block 7 to the core 2 at such a position, the coil device 1 can be miniaturized and heat dissipation can be improved.

[0198] In addition, if Figure 2B As shown, terminals 6, 6 connected to lead portions 41a, 41b of the first winding 4, and terminals 6, 6 connected to lead portions 51a, 51b of the second winding 5 are mounted on the terminal block 7. With such a configuration, even if the number of terminals 6 is large, it is easy to miniaturize the coil device 1 and also improve the heat dissipation.

[0199] Furthermore, the terminal block 7 is provided at one end of the core 2 along the X-axis substantially perpendicular to the winding axis (Z-axis) of the windings 4 and 5. With this configuration, the coil device 1 can be easily miniaturized and heat dissipation can be improved.

[0200] like Figure 2C As shown, the terminal block 7 has a terminal mounting portion 72, and the terminal mounting portion 72 has mounting grooves 71 for respectively engaging more than four terminals 6. By configuring in this way, even if the number of terminals 6 is large, it is easy to mount the terminals 6, and it is easy to realize the miniaturization of the coil device 1, and the heat dissipation is also improved.

[0201] In addition, if Figure 3 As shown, the terminal block 7 has a bent piece 74, which is formed in Figure 2B The recessed portion 22a1 is shown on the side of the second core 22. With this structure, the positioning and fixing of the terminal block 7 to the core 2 are facilitated, and the miniaturization and heat dissipation of the coil device 1 are improved.

[0202] (Second Embodiment)

[0203] like Figure 7 to Figure 10 As shown, the coil device 1A of this embodiment is different from the coil device 1 of the above-mentioned embodiment only in the following structures and effects, and the description of the common structures and effects is omitted. Figures 7-10 In, with Figure 1 to Figure 6 The common components among the components shown are denoted by the common reference numerals, and the description of the overlapping parts is omitted.

[0204] like Figure 7As shown, the terminal block 7A of this embodiment has a core cover portion 75. Figure 8 As shown, the core cover portion 75 is continuously provided with the terminal mounting portion 72, and covers the upper surface of the core 2 at a position different from the portion of the upper surface of the core 2 along the Z axis covered by the terminal mounting portion 72. A through groove 76 penetrating along the Y axis is formed on the inner surface of the core cover portion 75, and the top plate portion 90 of the heat sink 9 is inserted along the through groove 76. The top plate portion 90 of the heat sink 9 is configured to contact the upper surface of the core 2 between the inner surface of the core cover portion 75 and the upper surface of the core 2 along the through groove 76.

[0205] The heat generated on the upper surface of the core 2 is transferred to the top plate 90 of the heat sink 9, and is transferred from the top plate 90 to the side plate 91 of the heat sink 9. The heat transferred to the side plate 91 is transferred to the heat sink filled with Figure 1 The heat-dissipating resin 82 inside the illustrated case 8 is further transferred from the heat-dissipating resin 82 to the case 8 , and is cooled by a cooling mechanism in contact with a bottom plate 80 of the case 8 .

[0206] like Fig.10 As shown, the terminal block 7A has a terminal mounting portion 72 having four or more terminal grooves 71 arranged at predetermined intervals along the Y axis. The terminal block 7A has a pair of flat pieces 73 extending downward along the Z axis from both ends of the terminal mounting portion 72 along the Y axis, and a bent piece 74 integrated and continuous between the pair of flat pieces 73, 73. The bent piece 74 of the terminal block 7A has an inner surface convex portion 74a that matches the shape of a central concave portion 77a1 of a rising piece 77a provided at one end of an annular partition plate 77 along the X axis.

[0207] The raised piece 77a of the partition plate 77 has the same Fig. 9 The inner surface convex portion 77a2 of the second core 22 shown matches the surface of the concave portion 22a1 formed at one end along the X-axis of the base portion 22a. Fig.10 The flat plate 73 of the terminal block 7A shown has Fig. 9 The planar shape of the side end surface 22c2 of the side leg portion 22c of the second core 22 along the X-axis matches the inner surface of the shape shown.

[0208] The curved piece 74 formed continuously with the flat piece 73 is provided with elastic pieces 74b on both sides along the Y axis. Notches are formed in a part of the curved piece 74 located on both sides of the elastic piece 74b, and the elastic piece 74b can be elastically flexed and deformed. The elastic piece 74b is formed with a fitting hole, and a fitting protrusion 77b formed on the rising piece 77a of the partition 77 is fitted into the fitting hole, so that the curved piece 74 of the terminal block 7A and the rising piece 77a of the partition 77 can be positioned and fixed.

[0209] The flat plate piece 73 and the bent piece 74 having the same structure as the flat plate piece 73 and the bent piece 74 provided at the lower part along the Z axis of the terminal mounting portion 72 of the terminal block 7A are also provided at the end portion opposite to the terminal mounting portion 72 along the X axis of the core cover portion 75. In addition, a rising piece 77a having the above-mentioned fitting protrusion 77b is also provided at the other end portion along the X axis of the partition plate 77. These rising pieces 77a, 77a are fitted with the outer surfaces of a pair of bent pieces 74, 74 formed on the terminal block 7A, and the terminal block 7A and the partition plate 77 are combined.

[0210] In the state where the terminal block 7A and the partition plate 77 are combined, a gap is formed between the plate-like portion composed of the core cover portion 75 and the terminal mounting portion 72 and the partition plate 77, and a Fig. 9 In addition, a gap extending along the Y axis is formed between the upper surface of the base portion 22a of the second core 22 and the through groove 76 of the core cover portion 75, and in this gap, Figure 8 The top plate portion 90 of the heat sink 9 shown in the figure can dissipate the heat from the upper surface of the core 2 to the outside through the top plate portion 90 and the side plate portions 91 .

[0211] like Fig. 9 As shown, the partition 77 is arranged to contact the upper end of the coil body 30 along the Z axis, and the inner diameter of the through hole 77c formed in the partition 77 is substantially the same as or slightly larger than the inner diameter of the second winding winding portion 50, so that the middle leg portion 22b of the second core 22 can pass through. The partition 77 is preferably made of an insulating member such as a synthetic resin, which is the same as the terminal block 7A, but does not necessarily need to be made of the same insulating member as the terminal block 7A.

[0212] In this embodiment, Figure 8 The terminal mounting portion 72 of the terminal block 7A shown is fixed to the upper surface of one end of the second core 22 along the X-axis, and the end of the core cover portion 75 on the opposite side of the terminal mounting portion 72 along the X-axis is fixed to the upper surface of the other end of the second core 22 along the X-axis. As a means for fixing, for example, an adhesive or the like can be used. In this embodiment, a skeleton is also not used, and the terminal block 7A can be directly fixed to the core 2 (specifically, the second core 22).

[0213] In the coil device 1A of the present embodiment, the terminal block 7A has a core cover portion 75, so the terminal block 7A is stably fixed to the upper surface of the core 2, and the fixing strength is also improved. In addition, the core cover portion 75 has a through groove 76 for passing the heat sink 9, so the heat dissipation of the core 2 is also ensured. Furthermore, in the present embodiment, since there is a partition 77 that can be composed of an insulating component, the insulation between the second core 22 and the coil body 30 is improved, and the insulation between the coil body 30 and each terminal 6 is also improved.

[0214] In this embodiment, the partition plate 77 is combined with the terminal block 7A, but they do not necessarily need to be combined. In addition, the partition plate 77 can also be used in the coil device 1 of the first embodiment described above. The other structures and effects of this embodiment are the same as those of the first embodiment described above.

[0215] (Third Embodiment)

[0216] like Figure 11 to Figure 15 As shown, the coil device 1B of this embodiment is different from the coil device 1 or 1A of the above-mentioned embodiment only in the following structure and effect, and the description of the common structure and effect is omitted. Figures 11 to 15 In, with Figures 1 to 10 Common components to the components shown are denoted by common reference numerals, and description of duplicate parts will be omitted.

[0217] like Fig.11 As shown, the terminal block 7B of this embodiment has an intermediate core cover portion 75a. Fig.12 As shown, the intermediate core cover portion 75 is provided between the terminal mounting portions 72, 72 at both ends along the X-axis of the terminal block 7B, and is formed integrally with these terminal mounting portions 72, 72. The intermediate core cover portion 75a covers the central portion of the upper surface of the core 2B located between the two terminal mounting portions 72, 72. The terminal block 7B is the same as the terminal blocks 7, 7A of the above-mentioned embodiment, and is composed of an insulating member such as a synthetic resin.

[0218] The middle core cover portion 75a of the terminal block 7B is formed with at least one of a through hole penetrating from the inner surface of the middle core cover portion 75a to the outer surface, and a concave-convex portion (reinforcement rib) formed on the outer surface. By forming the through hole and / or the concave-convex portion in the middle core cover portion 75a, it helps to prevent the terminal block 7B including the core cover portion 75a from warping, and also helps to reduce the weight of the coil device 1B and improve the cooling efficiency.

[0219] The middle core cover portion 75a has a through groove 76, and the through groove 76 passes through the top plate portion 90 of the heat sink 9 arranged in contact with the upper surface of the core 2B. With this structure, it is easy to make the heat sink 9 contact with the upper surface of the core 2B, and through the heat sink 9, it is easy to release the heat of the upper surface of the core 2B to the heat dissipating resin or the external air.

[0220] like Fig.12 As shown, the core 2B of this embodiment is made of the same material as the core 2 of the above-mentioned embodiment, and is common in that the longitudinal section is an E-shaped core divided into two, but the shape is slightly different. In this embodiment, the recessed portions formed on both sides of the base portion 22a of the second core 22B along the X-axis are a combination of a stepped recessed portion 22a2 and an intermediate recessed portion 22a3.

[0221] The middle recess 22a3 is formed at the center of the stepped recess 22a2 along the Y axis, and is further recessed inward than the stepped recess 22a2. The outer peripheral surface of the middle leg 22b is exposed at the bottom of the middle recess 22a3. The stepped recess 22a2 is a flat surface that is recessed inward than the side end surface 22c2 of the side leg 22c along the X axis. Similar to the recess 22a1 described above, it may also be tapered and inclined relative to the side end surface 22c2, but in this embodiment, it is recessed substantially parallel.

[0222] The stepped recess 22a2 and the intermediate recess 22a3 are formed on both sides of the base 22a of the second core 22B along the X axis. Similarly, the stepped recess 21a2 and the intermediate recess 21a3 are formed on both sides of the base 21a of the first core 21B along the X axis.

[0223] like Fig.12 As shown, the terminal block 7B of this embodiment has: a terminal mounting portion 72 having a pair of mounting grooves 71, 71 in which the terminals 6, 6 connected to the pair of lead portions 41a, 41b of the first winding 4 are respectively fitted; and another terminal mounting portion 62 having a pair of mounting grooves 61 in which the terminals 6, 6 connected to the pair of lead portions 51a, 51b of the second winding 5 are respectively fitted. The one terminal mounting portion 72 and the other terminal mounting portion 72 are respectively located at both ends of the terminal block 7B along the X axis.

[0224] A pair of mounting grooves 71, 71 formed in each terminal mounting portion 72 are formed corresponding to the stepped recesses 22a2 located on both sides of the middle recess 22a3 of the second core 22B. The surface of the stepped recess 22a2 of the second core 22B is covered by stepped curved pieces 74 provided at both ends of the terminal block 7B in the X-axis direction. Fig.14 As shown, the connection portion 61 of the terminal 6 is arranged outside the stepped bent piece 74 .

[0225] like Fig.16 As shown, at both ends of the X-axis of the terminal block 7B, at positions separated by a predetermined interval along the Y-axis, flat plates 73 extending downward from the terminal mounting portion 72 along the Z-axis are respectively formed. The step-shaped curved plate 74 is integrally formed in a manner that is more recessed inward than the flat plate 73. In this embodiment, a pair of cutouts parallel to the Z-axis are formed at a predetermined interval in each flat plate 73, and a flexible and elastically deformable mounting plate 73b is formed between these cutouts. The inner side of the mounting plate 73B can contact the side end surface 22c2 of the second core 22B through elastic force, making it easy to mount the terminal block 7B on the upper surface of the core 2B.

[0226] The inner surface of the stepped curved piece 74 provided on the opposite side of the terminal block 7b along the X-axis has a shape matching the outer surface shape of the stepped recess 22a2 and the middle recess 22a3 of the second core 22B, and is fitted with the stepped recess 22a2 and the middle recess 22a32. At a substantially central position along the Y-axis of each terminal mounting portion 72, a mounting protrusion 72d having an upper surface continuous with the upper surface of the mounting portion 72 is formed integrally with the mounting portion 72 in a manner protruding outward from the mounting portion 72 along the X-axis. The protruding front end position of the mounting protrusion 72d may be substantially flush with the outer surface of the flat sheet 73 of the terminal block 7B, or may protrude outward further than it along the X-axis, or may be an introduced position.

[0227] A slit-shaped mounting groove 72e is formed on the upper surface of the mounting protrusion 72d, which is open toward the upper side of the Z axis and the outer side of the X axis. Fig.15 As shown, the mounting convex portion 70e can be engaged with the mounting groove 72e, and the mounting convex portion 70e is formed on the inner surface of the first side piece 70d extending from the outer end along the X axis to the lower side along the Z axis at the approximately central portion of the terminal cover 70B along the Y axis. By engaging the mounting convex portion 70e with the mounting groove 72e2, the terminal cover 70B can be easily positioned and mounted on the terminal mounting portion 72 of the terminal block 7B.

[0228] Each terminal cover 70B is provided with a second side piece 70f on both sides along the Y axis of the first side piece 70d, respectively, through a cutout and integrally with the terminal cover 70B. The second side piece 70f covers the connection portion 61 of each terminal 6 from the outside along the X axis. The second side piece 70f also has the function of preventing and protecting the connection portion 61 from being exposed to the outside. Fig.11 As shown, the outer surface of the second side piece 70f may be substantially flush with the outer surface of the flat plate 73 of the terminal block 70B, but may protrude further outward along the X-axis.

[0229] In the coil device 1B of the present embodiment, even when the number of terminals 6 is large, the number of terminals 6 mounted on each terminal block mounting portion 72 can be reduced, for example, the position of the terminal 6 mounted on each terminal block mounting portion can be easily matched with the position of the stepped recess 22a2 formed in the second core 22B. Fig.16 As shown, in the present embodiment, most of the connection portion 61 of each terminal 6 is accommodated in the stepped recess 22a2 formed in the second core 22B.

[0230] In addition, if Fig.15 As shown, most of the connection portion 61 of each terminal is accommodated in the stepped recess 74 between the flat plate 73 and the mounting protrusion 72d formed on the terminal block 7B. As a result, as shown in FIG. Fig.16As shown, the coil is received in the stepped recess 22a2. In the present embodiment, because of such a structure, the coil device is further miniaturized. In addition, the heat dissipation is also improved.

[0231] In the above-mentioned embodiment, the terminal mounting portion 72 disposed at one end along the X-axis of the terminal block 7B and the terminal mounting portion 72 disposed at the other end can also be separately equipped, but by integrally connecting the intermediate core cover portion 75a, it is easy to simultaneously position and mount the two terminal mounting portions 72, 72 on the upper surface of the core 2B. In addition, it also contributes to the miniaturization of the coil device 1B. The other structures and effects of this embodiment are the same as those of the first embodiment or the second embodiment described above.

[0232] (Fourth Embodiment)

[0233] like Figure 17-18 As shown, the coil device of this embodiment is different from the coil device 1, 1A or 1B of the above-mentioned embodiment only in the following structure and effect, and the description of the common structure and effect is omitted. Figures 17-18 In, with Figure 1 ~

[0234] Fig.16 The common components among the components shown are denoted by the common reference numerals, and the description of the overlapping parts is omitted.

[0235] The coil device of this embodiment uses Fig.17 The core 2C or Fig.18 The core 2D shown in the figure replaces the core 2 or 2B of the above-mentioned embodiment, and uses Fig.17 or Fig.18 The pair of heat sinks 9 a and 9 a shown in the figure replaces the heat sink 9 of the above-mentioned embodiment. Except for this, the above-mentioned embodiment is the same as any one of the above-mentioned first to third embodiments or a combination thereof.

[0236] Fig.17 The core 2C shown is also Fig.12 A modification of the core 2B shown, Fig.12 The first core 21B and the second core 22B shown are each composed of a collection of core segments separated at the center position along the Y axis. Fig.17 The core 2C shown has a pair of first core divided bodies 21B1 and a pair of second core divided bodies 22B1.

[0237] Each first core segment 21B1 includes a side leg portion 21c, a middle leg segment 21b2, and a base segment 21a4. The first core segment 21B1 is connected to the base segment 21a4 by abutting the abutting surfaces 21b3 formed on the respective segments 21B1. Fig.12 The same structure as the first core 21B shown in FIG. Fig.17 In the state where the first core segments 21B1 are combined with each other, as shown in FIG. Fig.12 As shown, an elliptical column or cylindrical middle foot portion 21b is formed, and a stepped recess 21a2 and an intermediate recess 21a3 are formed.

[0238] In addition, similarly, Fig.17 Each second core segment 22B1 shown in the figure has a side leg portion 22c, a middle leg segment 22b2, and a base segment 22a4. The abutting surfaces 22b3 formed on each segment 22B1 are abutted against each other to form a base segment 22a4. Fig.12 The second core 22B shown in FIG. Fig.17 In the state where the second core segments 22B1 are combined with each other, as shown in FIG. Fig.12 As shown, an elliptical column or cylindrical middle foot portion 22b is formed, and a stepped recess 22a2 and an intermediate recess 22a3 are formed.

[0239] In addition, in this embodiment, instead of Fig.12 The single heat sink 9 shown in FIG. Fig.17 As shown, a pair of heat sink split bodies 9a are used. Each heat sink split body 9a has a top plate portion 90a, a side plate portion 91a extending downward along the Z axis from the outer end along the Y axis of the top plate portion 90a, and an insertion plate portion 92a extending downward along the Z axis from the inner end along the Y axis of the top plate portion 90a.

[0240] Fig.17 The side plate portion 91a shown has Fig.12 The side plate portion 91 shown has the same width and length. Fig.17 The top plate portion 90a shown has Fig.12 The top plate portion 90 shown has the dimensions of a structure separated in the center along the Y axis. In addition, the insertion plate portion 92a is inserted between the butt joint surfaces 22b3, 22b3 (21b3, 21b3) of the core segments 22B1, 22B1 (21B1, 21B1) and has a width of about half the width of the side plate portion 91a along the X axis. In addition, the insertion plate portions 92a formed on the pair of heat sinks 9a, 9a are arranged offset along the X axis so that the butt joint surfaces 22b3, 22b3 (21b3, 21b3) do not overlap along the Y axis.

[0241] The core segments 22B1 and 21B1 of this embodiment can be made of the same material as the cores 2 and 2B of the above-mentioned embodiment. Also, like the above-mentioned heat sink 9, the heat sinks 9a and 9a are preferably made of a metal plate or the like having a better heat dissipation property than the core 2C.

[0242] In this embodiment, the core 2C is composed of four divided bodies 22B1, 21B1, and the divided bodies 22B1, 21B1 are combined in a state where the insertion plate portions 92a, 92a of the heat dissipation plate 9a are inserted between the butt surfaces 22b3, 22b3 (21b3, 21b3) of the divided bodies 22B1, 21B1. Therefore, the heat from the inside of the middle leg portion, which is most likely to be filled with heat, can be transferred to the top plate portion 90a and the side plate portion 91a through the insertion plate portion 92a, and can be effectively dissipated to the outside.

[0243] In addition, in this embodiment, Fig.12 The cores 21B and 22B of the embodiment shown are each divided into two, but it is also possible to Figure 2B or Fig. 9 The cores 21 , 22 shown are each divided into two.

[0244] Furthermore, Fig.18 The core 2D shown is also Fig.12 Another modification of the core 2B shown in FIG. Fig.12 The first core 21B and the second core 22B shown in the figure have different division positions and division numbers, and the core 2D is composed of a collection of divided bodies of the separated and divided cores. That is, Fig.18 The illustrated core 2D includes a pair of first core segments 21B2 , a pair of second core segments 22B2 , and a pair of divided side plate portions 23 .

[0245] Each first core segment 21B2 includes a middle leg segment 21b2 and a base segment 21a4. The first core segment 21B2 is formed by abutting the abutting surfaces 21b3 formed on each segment 21B2 with each other to form a first core segment 21B2 without a middle leg segment 21b2. Fig.12 The first core 21B of the side leg portion 21c shown in FIG. Fig.18 In the state where the first core segments 21B2 are combined with each other, as shown in FIG. Fig.12 As shown, an elliptical column or cylindrical middle foot portion 21b is formed, and a stepped recess 21a2 and an intermediate recess 21a3 are formed.

[0246] In addition, similarly, Fig.18 Each second core segment 22B2 shown in the figure has a middle leg segment 22b2 and a base segment 22a4, and the abutting surfaces 22b3 formed on each segment 22B2 are abutted against each other to form a Fig.12 The second core 22B shown in FIG. Fig.18 The second core segments 22B2 are combined with each other as shown in FIG. Fig.12 As shown, an elliptical column or cylindrical middle foot portion 22b is formed, and a stepped recess 22a2 and an intermediate recess 22a3 are formed.

[0247] Fig.18The split side plate portion 23 shown has the following structure: Fig.12 The side plate portions 21 c and 22 c of the cores 21B and 22B shown in the figure, which are located at one end along the Y axis, are continuous along the Z axis and are separated from the base portions 21 a and 22 a. Fig.18 The end portion of the divided side plate portion 23 shown along the Z axis is fixed to the inner surface close to the outer end of each of the base divided bodies 21 a 4 and 22 a 4 along the Y axis by, for example, an adhesive.

[0248] In addition, in this embodiment, instead of Fig.12 The single heat sink 9 shown in FIG. Fig.18 As shown, a pair of heat sink split bodies 9a are used. Each heat sink split body 9a has Fig.17 The heat dissipation divided body 9a shown in the figure has the same structure, so its detailed description is omitted.

[0249] In this embodiment, the core 2D is composed of six divided bodies 22B2, 21B2, 23, and the divided bodies 22B2, 21B2, 23 are combined in a state where the insertion plate portions 92a, 92a of the heat dissipation plate 9a are inserted between the butt surfaces 22b3, 22b3 (21b3, 21b3) of the divided bodies 22B2, 21B2. Therefore, the heat from the inside of the middle leg portion, which is most likely to be filled with heat, can be transferred to the top plate portion 90a and the side plate portion 91a through the insertion plate portion 92a, and can be effectively dissipated to the outside.

[0250] In addition, in this embodiment, Fig.12 The core 2B of the embodiment shown is divided into six parts, but it is also possible to Figure 2B or Fig. 9 The core 2 shown is divided into 6. The other structures and effects of this embodiment are the same as those of the first embodiment, the second embodiment, or the third embodiment described above.

[0251] 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.

[0252] 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.

[0253] 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.

[0254] The separator 10 is annular, but may be partially cut or divided in the circumferential direction. The separator 10 is preferably composed of a single layer along the Z-axis (winding axis), but may be composed of a laminate of a plurality of separators.

[0255] In addition, the spacer 10 may have any shape or structure as long as it has at least one of the outer recess 11 that allows the fluid to flow from the radial outer side to the inner side of the first opposite end 42 or the second opposite end 52, the inner recess 12 that allows the fluid to flow from the radial inner side to the outer side of the first opposite end 42 or the second opposite end 52, and the through hole that allows the fluid to flow from the first opposite end 42 to the second opposite end 52. For example, the spacer 10 may be a mesh itself, or radial or mesh-shaped grooves that connect the radial outer side and the radial inner side of the spacer 10 may be formed on one or both sides of the spacer 10.

[0256] Furthermore, in the above-mentioned embodiment, the flow path forming area provided on the spacer 10 is composed of a cutout or a through hole penetrating the front and back surfaces of the spacer, but the flow path forming area can be a groove formed only on one side surface of the spacer 10, or it can be a groove formed on both sides of the spacer.

[0257] Furthermore, in the above-described embodiment, the spacer 10 is disposed inside the coil body 30 , but the spacer 10 may not be provided in a coil device according to another embodiment.

[0258] In the coil devices 1, 1A, and 1B of the above-mentioned embodiments, the coil core assembly 3 is housed in the housing 8 filled with 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 be used in combination with the coil core assembly 3. Figure 2A The coil core assemblies 3 are shown in direct contact.

[0259] Furthermore, the coil device may be assembled by combining any of the above-described embodiments.

Claims

1. A coil device, wherein: have: a core comprising a magnetic body; a winding wound around at least a portion of the core; and a terminal block that holds a terminal to which a lead portion of the winding is connected, At least a portion of the terminal block is fixed to a portion of the core.

2. The coil device according to claim 1, wherein: The terminal block is arranged at a position covering at least a portion of the upper surface of the core.

3. The coil device according to claim 1, wherein: The windings at least have a first winding and a second winding, The lead portion has a plurality of lead portions, The terminal has a plurality of terminals, The terminal block is provided with terminals to which the lead portions of the first windings are connected and terminals to which the lead portions of the second windings are connected.

4. The coil device according to claim 3, wherein: The terminal block is provided at one end of the core along a first axis substantially perpendicular to a winding axis of the winding wire.

5. The coil device according to claim 3, wherein: The terminal block has a terminal mounting portion having mounting grooves into which four or more terminals are respectively fitted.

6. The coil device according to claim 5, wherein: The terminal block further includes a core cover portion that is provided continuously with the terminal mounting portion and covers an upper surface of the core at a position different from a portion of the upper surface of the core covered by the terminal mounting portion.

7. The coil device according to claim 6, wherein: The core cover portion has a through groove through which a heat sink plate disposed in contact with an upper surface of the core passes.

8. The coil device according to claim 3, wherein: The terminal block has: A first terminal mounting portion having mounting grooves into which terminals connected to the pair of lead portions of the first winding are respectively engaged; The second terminal mounting portion has mounting grooves into which the terminals connected to the pair of lead portions of the second winding are respectively fitted, The first terminal mounting portion and the second terminal mounting portion are respectively arranged at both ends of the core along a first axis substantially perpendicular to a winding axis of the winding wire.

9. The coil device according to claim 8, wherein: The first terminal mounting portion and the second terminal mounting portion are integrally connected by an intermediate core cover portion. The intermediate core cover portion covers a central portion of an upper surface of the core located between the first terminal mounting portion and the second terminal mounting portion.

10. The coil device according to claim 9, wherein: The intermediate core cover portion has a through groove through which a heat sink plate disposed in contact with an upper surface of the core passes.

11. The coil device according to claim 9, wherein: The intermediate core cover portion includes at least one of a through hole penetrating from an inner surface to an outer surface of the intermediate core cover portion and a concavo-convex portion formed on the outer surface.

12. The coil device according to any one of claims 1 to 11, wherein: The terminal block has a bent piece that enters a recess formed at a side of the core.

13. The coil device according to claim 12, wherein: The bent piece is integrated with the terminal block in such a manner that the connection portion of the terminal enters the interior of the recessed portion of the core.

14. The coil device according to any one of claims 1 to 11, wherein: A partition is interposed between one end of the winding portion of the winding wire in the winding axis direction and the core.

15. The coil device according to any one of claims 1 to 11, wherein: The core has a middle leg portion arranged by a winding portion of the winding wire.

16. The coil device according to claim 15, wherein: The core further includes a side leg portion covering at least a portion of an outer circumference of the first winding portion or an outer circumference of the second winding portion.

17. The coil device according to any one of claims 1 to 11, wherein: It also includes a housing for accommodating at least a portion of the winding portion of the winding, The interior of the housing is filled with a heat-dissipating resin to a position where at least a portion of the winding portion of the winding wire is immersed.

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