Coil device

Abstract

The invention provides a coil device which is high in positioning precision and easy to manufacture. A transformer (10) is provided with: a bobbin (20) around which electric wires (37, 38) are wound; terminals (60a-60d) to which the lead portions (37a, 37b, 38a, 38b) of the electric wires (37, 38) are connected; and a terminal block (80) on which the terminals (60a-60d) are mounted. The terminal block (80) has positioning groove portions (84a-84d) into which the terminals (60a-60d) to which the lead portions (37a, 37b, 38a, 38b) are connected are inserted, and is directly or indirectly connected to the bobbin (20) so as to be detachable.

Description

[0001] This application was filed on [date]. November 4, 2020 Application number is 202011214913.5 The invention is named coil Device A divisional application of the patent application. Technical Field

[0002] The present invention relates to coil devices, for example, suitable for use as transformers. Background Technology

[0003] As a coil device with terminals mounted on a resin substrate (terminal block), the coil device described in Patent Document 1 is known, for example. In the coil device described in Patent Document 1, when multiple terminals are mounted on the resin substrate, as the terminals become thinner or the coil device becomes smaller, a sufficient working area for connecting the leads of the coil to the terminals cannot be ensured, leading to manufacturing difficulties. Furthermore, the coil device described in Patent Document 1 suffers from the problem of difficulty in accurately positioning the front end of the terminals.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2016-92141 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] This invention was developed in view of this actual situation, and its purpose is to provide a coil device with high positioning accuracy and easy manufacturing.

[0009] Solution for solving the problem

[0010] To achieve the above objectives, the present invention provides a coil device comprising:

[0011] A spool on which an electric wire is wound;

[0012] Terminal, on which the lead portion of the wire is connected;

[0013] Terminal block, on which the terminals are mounted.

[0014] The terminal block has a positioning groove for inserting the terminal to which the lead wire is connected, and is directly or indirectly connected to the spool so that it can be easily assembled and disassembled.

[0015] In the coil device of the present invention, the terminal block has a positioning groove for inserting a terminal to which a lead portion is connected, and is directly or indirectly connected to the spool for easy assembly and disassembly. Therefore, with the terminal block removed from the spool, a terminal can be connected to the lead portion, ensuring sufficient working area even when multiple terminals are present. Furthermore, after directly or indirectly connecting the terminal block to the spool, inserting only the terminal to which the lead portion is connected into the positioning groove allows for high-precision positioning of the terminal relative to the terminal block, preventing misalignment of the terminal's front end. Therefore, the coil device according to the present invention provides a coil device with high positioning accuracy and ease of manufacture.

[0016] Preferably, the terminal block has a base forming the positioning groove, the positioning groove opening in a direction orthogonal to the plane of the base. With this structure, the terminal connecting the lead portion can slide and be inserted from a direction orthogonal to the plane of the base (e.g., above the positioning groove), making terminal positioning easy.

[0017] Preferably, an insertion port for inserting the terminal is formed at one end of the positioning groove located on the side near the spool. With this structure, the terminal connected to the lead portion can be inserted into the insertion port and into the positioning groove from the side near the spool, making terminal positioning easy.

[0018] Preferably, the other end of the positioning groove located on the side away from the spool is blocked by the base. With this structure, the front end of the terminal inserted into the positioning groove can be fixed to the other end of the positioning groove, effectively preventing misalignment of the terminal's front end.

[0019] Preferably, the device also includes a lead guide portion for guiding the wire, and the terminal block is detachably connected to the lead guide portion. In this case, the terminal block and the lead guide portion are separate components, so if the direction of wire withdrawal changes, only the structure of the lead guide portion needs to be modified, and the terminal block does not need to be remanufactured from scratch. Therefore, it can flexibly handle changes in the specifications of the lead guide portion, providing a coil device with a high degree of design freedom.

[0020] Preferably, the lead guide is detachably connected to the spool. In this case, the lead guide and the spool are separate components, so if the spool specifications change, only the spool structure needs to be modified, and the lead guide does not need to be remanufactured from scratch. Therefore, it can flexibly respond to changes in spool specifications, providing a coil device with a high degree of design freedom.

[0021] Preferably, the terminal has an external connecting portion that inserts into the positioning groove and an electrical wire connecting portion that clamps and connects to the lead portion. With this structure, the external connecting portion can be precisely positioned in the positioning groove, and the lead portion can be connected to the terminal simply by clamping it in the electrical wire connecting portion, simplifying manufacturing.

[0022] Preferably, the wire connection portion has a clamping piece for holding the wire, the clamping piece being arranged substantially parallel to the base. With this structure, after the lead portion is clamped by the clamping piece, heat pressing can be performed on the wire connection portion while the clamping piece is arranged substantially parallel to the base, and the orientation of the terminal can be changed. The external connection portion can be directly inserted into the positioning groove portion, and the terminal can be easily positioned. Attached Figure Description

[0023] Figure 1A This is a perspective view of the coil device according to the first embodiment of the present invention.

[0024] Figure 1B This is a perspective view of the coil device according to the second embodiment of the present invention.

[0025] Figure 1C This is a perspective view of the coil device according to the third embodiment of the present invention.

[0026] Figure 2 yes Figure 1A An exploded perspective view of the coil device shown.

[0027] Figure 3A From Figure 1A A three-dimensional view of the coil assembly with the core removed.

[0028] Figure 3B yes Figure 3A A top view of the coil assembly shown.

[0029] Figure 3C From Figure 1B A three-dimensional view of the coil assembly with the core removed.

[0030] Figure 3D yes Figure 3C A top view of the coil assembly shown.

[0031] Figure 3E From Figure 1C A three-dimensional view of the coil assembly with the core removed.

[0032] Figure 3F yes Figure 3E A top view of the coil assembly shown.

[0033] Figure 4A From Figure 3AThe diagram shows a partial exploded perspective view of the coil assembly after separating the lead guide and terminal block.

[0034] Figure 4B From Figure 3C The diagram shows a partial exploded perspective view of the coil assembly after separating the lead guide and terminal block.

[0035] Figure 4C From Figure 3E The diagram shows a partial exploded perspective view of the coil assembly after separating the lead guide and terminal block.

[0036] Figure 5A yes Figure 1A The diagram shows a perspective view of the terminals of the coil device.

[0037] Figure 5B yes Figure 1B The diagram shows a perspective view of the terminals of the coil device.

[0038] Figure 6A yes Figure 1A The diagram shows a three-dimensional view of the coil assembly with its spool.

[0039] Figure 6B It means to Figure 6A A three-dimensional view of the lead section being pulled out when the spool is wound with the wire.

[0040] Figure 6C yes Figure 1B The diagram shows a perspective view of the coil assembly, including the spool and the insulating cover mounted on it.

[0041] Figure 6D It means to Figure 6C A three-dimensional view of the lead section being pulled out when the spool is wound with the wire.

[0042] Figure 6E yes Figure 1C The diagram shows a perspective view of the coil assembly, including the spool and the insulating cover mounted on it.

[0043] Figure 6F It means to Figure 6E A three-dimensional view of the lead section being pulled out when the spool is wound with the wire.

[0044] Figure 7A yes Figure 1A The diagram shows a perspective view of the terminal block and lead guide portion of the coil device.

[0045] Figure 7B yes Figure 1B The diagram shows a perspective view of the terminal block and lead guide portion of the coil device.

[0046] Figure 7C yes Figure 1C The diagram shows a perspective view of the terminal block and lead guide portion of the coil device.

[0047] Figure 7D It is a different perspective. Figure 7C The diagram shows a three-dimensional view of the terminal block.

[0048] Figure 8 yes Figure 1A The diagram shows a three-dimensional view of the wires in the coil device. Detailed Implementation

[0049] The present invention will now be described based on the embodiments shown in the accompanying drawings.

[0050] The transformer 10 shown in Figure 1, which is the coil device of this embodiment, can be used, for example, as an on-board charger for EVs (Electric Vehicles), PHVs (Plug-in Hybrid Vehicles), or commuter vehicles, or as a power circuit for household or industrial electrical equipment, or as a power circuit for computer equipment, etc. Figure 2 As shown, the transformer 10 has: a bobbin 20, magnetic cores (segmented cores) 40a and 40b, a terminal block 80, and a lead guide 110.

[0051] Furthermore, in the attached diagram, the X, Y, and Z axes are perpendicular to each other. The X-axis corresponds to the direction of the long side of the linear shaft 20, and the Y-axis is roughly in the same direction as the dividing line that separates a pair of dividing cores 42a, 42a or a pair of dividing cores 42b, 42b. The direction of the dividing line can also be along the X-axis. The Z-axis corresponds to the height (thickness) direction of the transformer 10.

[0052] The spool 20 has a spool body 24 and a connecting portion 22 formed at one upper end of the spool body 24 in the X-axis direction. Furthermore, the spool 20 is made of plastics such as PPS, PET, PBT, and LCP, but it can also be made of other insulating components. Preferably, the spool 20 is made of a heat-resistant material. To improve strength and thermal conductivity, fillers such as glass can be filled into these insulating components.

[0053] like Figure 8 As shown, the spindle body 24 is wound with a first wire 37 constituting the first coil section 35 and a second wire 38 constituting the second coil section 36.

[0054] like Figure 6AAs shown, in the transformer 10 of this embodiment, at both ends of the winding drum portion 28 of the bobbin 20 in the Z-axis direction, the end partition flanges 31 and 32 extend outward in the radial direction and are integrally formed with the XY plane and are substantially parallel. In the winding drum portion 28 located between the end partition flanges 31 and 32 in the Z-axis direction, Figure 8 The first coil portion 35 and the second coil portion 36 shown are positioned at different locations in the Z-axis direction (the direction of the winding axis). The first coil portion 35 is wound with a first wire 37 that constitutes either a primary coil or a secondary coil, and the second coil portion 36 is wound with a second wire 38 that constitutes either a primary coil or a secondary coil.

[0055] In this embodiment, an insulating partition flange 30, which is substantially parallel to the XY plane, is formed on the outer periphery of the winding cylinder portion 28 located between the first coil portion 35 and the second coil portion 36. A winding partition flange 33 is formed on the first coil portion 35 to separate the wire winding portions that are adjacent to each other along the winding axis (Z-axis) of the first wire 37 according to each region.

[0056] In addition, in this embodiment, the second coil section 36, like the first coil section 35, is formed with a winding partition flange 34 that separates the wire winding portions that are adjacent to each other along the winding axis (Z-axis) of the second wire 38 into each region. At least one connecting groove is formed on each winding partition flange 33 and 34 to connect the adjacent regions S1, S2 to each other or S1a, S2a to each other.

[0057] Although detailed illustrations are omitted, connecting grooves are formed on opposite sides of the connecting portions 22 arranged along the X-axis and X-axis directions in the winding partition flanges 33 and 34. These connecting grooves are formed in a portion of the circumference of each partition flange 33 and 34 to a depth reaching the outer peripheral wall of the winding cylinder portion 28.

[0058] Wound in regions S1 and S2 separated along the Z-axis by partition flanges 30, 33, and 31 Figure 8 The first wire 37 shown has separable wire coiled portions that can be wound around each other according to each region S1, S2. In this embodiment, the width of the region along the Z-axis in each region S1, S2 is set to a width that allows only one wire 37 to enter. However, in this embodiment, the width of the region may also be set to a width that allows two or more wires 37 to enter. In addition, in this embodiment, it is preferable that all the region widths are the same, but they may also be slightly different.

[0059] Figure 8 The second coil section 36 shown is also similar to the first coil section 35, in utilizing... Figure 6A The regions S1a and S2a separated by the partition flanges 30, 34, and 32 along the Z-axis shown are wound with Figure 8 The second wire 38 shown is separated from each other by the separable wire winding portions in each region S1a and S2a. In this embodiment, the width of the region along the Z-axis in each region S1a and S2a is set to a width that allows only one wire 38 to enter. Alternatively, the width of the region can be the same as the wire diameter of the wire 38.

[0060] in addition, Figure 6A The radial width of the partition flanges 30-34 shown is set to a height that allows one or more wires 37 or 38 (one or more layers) to enter. In this embodiment, it is preferably set to a radial width that allows 2 to 10 layers of wire to be wound around. Preferably, all partition flanges 30-34 have the same radial width, but they may also be different.

[0061] like Figure 2 As shown, a lead wire guide 110, which is separate from the spool 20, is installed at the connecting part 22. The lead wire guide 110 is detachably connected to the spool 20 and functions to guide the lead wire parts 37a, 37b, 38a, and 38b. The lead wire guide 110 is pulled out and fixed. Figure 8 The first lead portions 37a and 37b of the first wire 37 and the second lead portions 38a and 38b of the second wire 38 are shown. The width of the connecting portion 22 in the Y-axis direction and the width in the X-axis direction are determined based on the width of the bottom surface of the lead guide portion 110 in the Y-axis direction and the width in the X-axis direction.

[0062] like Figure 2 As shown, a connecting portion 22 is provided on the front side of the spool 20 in the X-axis direction, and a protruding piece 29 is formed on the spool body 24 on the opposite side of the connecting portion 22 in the X-axis direction. The protruding piece 29 has a surface that is substantially parallel to the YZ plane and protrudes from the upper surface of the spool body 24 toward the Z-axis. The protruding piece restricts the movement of the magnetic core 40a in the X-axis direction.

[0063] like Figure 4A As shown, the connecting portion 22, integrally formed with the spool 20, has a base 22a extending along the Y-axis and an insulating wall 22b rising approximately perpendicularly to the base 22a in the upward direction along the Z-axis. The insulating wall 22b is formed parallel to the ZY plane to ensure... Figure 3A Terminals 60a to 60d shown are Figure 1A The insulating component of the magnetic core 40a shown. Additionally, the base 22a is formed parallel to the XY plane for mounting. Figure 4A The lead guide 110 shown is used for this purpose.

[0064] Additionally, at the base 22a, in order to... Figure 8 The lead portions 37a, 37b, 38a, and 38b of the wires 37 and 38 shown are directed towards... Figure 3ATerminals 60a to 60d of the terminal block 80 shown are guided as follows: Figure 4A As shown, four spool-side cuts 23a to 23d are intermittently recessed along the Y-axis towards the X-axis. The spool-side cuts 23a, 23b, 23c, and 23d pass through the lead wire portions 37a, 37b, 38b, and 38a, respectively.

[0065] At both ends of the base 22a along the Y-axis, there are engaging tabs 22c with a wall thickness thinner than that in the center along the Z-axis direction (see reference). Figure 6A Each card assembly 22c can be inserted into the... Figure 7A The lead guide portion 110 shown is fitted with the engaging grooves 114c and 116c on the back side and below both ends in the Y-axis direction.

[0066] In the insulating wall 22b, six spool-side engaging portions 26a to 26f are formed, each protruding intermittently along the Y-axis towards the X-axis. Each spool-side engaging portion 26a to 26f is composed of a protruding convex portion protruding along the X-axis. Figure 3A As shown, the spool-side engaging portions 26a-26c and 26f can engage with the guide-side engaging portions 113a-113d, and the spool-side engaging portions 26d and 26e can be inserted into and fitted with the opposing cutouts 112c and 112d.

[0067] like Figure 4A and Figure 7A As shown, the lead guide 110 has a rod member 112 extending along the Y-axis direction. End blocks 114 and 116 are integrally formed at both ends of the rod member 112 in the Y-axis direction. A pair of engaging hooks 114b and 114b are formed on end block 114, and a pair of engaging hooks 116b and 116b are formed on end block 116. The connecting portion 87a of the terminal block 80 can be clamped and connected (engaged) between the pair of engaging hooks 114b and 114b, and the connecting portion 87b of the terminal block 80 can be clamped and connected (engaged) between the pair of engaging hooks 116b and 116b. This restricts the movement of the terminal block 80 in the Z-axis direction.

[0068] An engaging protrusion 114a is formed on end block 114, which is clamped by a pair of engaging hooks 114b, 114b. An engaging protrusion 116a is formed on end block 116, which is clamped by a pair of engaging hooks 116b, 116b. The engaging protrusion 114a can engage the connecting hole 870a of the terminal block 80, and the engaging protrusion 116a can engage the connecting hole 870b of the terminal block 80.

[0069] On the back side of the rod member 112 in the X-axis direction, opposing cuts 112a, 112b, 112c, and 112d, which correspond to the Y-axis positions of the spool-side cuts 23a, 23b, 23c, and 23d and face these cuts, are formed to extend intermittently from the Y-axis direction to the X-axis direction. The opposing cuts 112c and 112d are formed such that their length along the X-axis direction is longer than that of the opposing cuts 112a and 112b.

[0070] At the opposing incisions 112a, 112b, 112c, and 112d, Figure 4A The lead portions 37a, 37b, 38b, and 38a shown are... Figure 3A The rod is inserted as shown. On the back side of the rod member 112 in the X-axis direction, positioning recesses 118a and 118b are formed on one and the other side in the Y-axis direction, respectively. The positioning recesses 118a and 118b can be inserted into and engaged. Figure 7A The positioning protrusions 88a, 88b of the terminal block 80 are shown.

[0071] Wire insertion passages 117a to 117d are formed on the back side of the rod member 112 in the X-axis direction. Wire insertion passages 117a and 117b extend obliquely upward in the Z-axis direction and communicate with corresponding cutouts 112a and 112b. Wire insertion passages 117c and 117d extend straight upward in the Z-axis direction and communicate with corresponding cutouts 112c and 112d. Lead wire portions 37a and 37b are pulled out in wire insertion passages 117a and 117b, and lead wire portions 38b and 38a are pulled out in wire insertion passages 117c and 117d.

[0072] On the back side of the rod component 112 in the X-axis direction, corresponding to the positions of the spool-side engaging portions 26a, 26b, 26c, and 26f in the Y-axis direction, the guide-side engaging portions 113a, 113b, 113c, and 113d are recessed (in a stepped manner) from the Y-axis direction towards the X-axis direction. In the guide-side engaging portions 113a to 113d, the spool-side engaging portions 26a to 26c and 26f are... Figure 3A The way it is locked is shown.

[0073] like Figure 2 As shown, in this embodiment, magnetic cores 40a and 40b can be separated into two segmented cores 42a, 42a and 42b, 42b, each having the same shape. In this embodiment, all segmented cores 42a, 42a and 42b, 42b have the same shape, with an E-shaped cross-section in the ZY section, forming a so-called E-type core. Another pair of segmented cores 42b, 42b, located at the lower part in the Z-axis direction, also have an E-shaped cross-section in the ZY section, forming a so-called E-type core.

[0074] Each segment core 42a disposed on the upper side in the Z-axis direction has a base 44a extending along the Y-axis direction and a pair of middle legs 46a and side legs 48a protruding from both ends of the base 44a in the Y-axis direction toward the Z-axis direction. Each segment core 42b disposed on the lower side in the Z-axis direction has a base 44b extending along the Y-axis direction and a pair of middle legs 46b and side legs 48b protruding from both ends of the base 44b in the Y-axis direction toward the Z-axis direction.

[0075] The outer surfaces of the bases 44a and 44b abut against the inner side of the terminal block protrusion formed on the inner side of the terminal block 80 connected to one end of the spool body 24 (the center side of the spool 20 in the X-axis direction) and the inner side of the protrusion 29 formed on the other end of the spool body 24, thereby preventing the magnetic cores 40a and 40b from being misaligned in the X-axis or Y-axis direction.

[0076] A pair of middle legs 46a are inserted into the interior of the core leg through hole 26 of the spool 20 from above in the Z-axis direction. Similarly, a pair of middle legs 46b are inserted into the interior of the core leg through hole 26 of the spool 20 from below in the Z-axis direction. Inside the through hole 26, their front ends are configured to contact the front ends of the middle legs 46a or face each other with a predetermined gap.

[0077] On the inner circumferential surface of the winding cylinder portion 28 that forms the through hole 26, at a position opposite each other in the X-axis direction, a separation protrusion 27 is formed along the Z-axis direction (see reference). Figure 2 A separating protrusion 27 is disposed between the middle legs 42a and 42b, which are configured to face each other with a predetermined gap but not in contact within the through hole 26. The predetermined gap can be adjusted according to the thickness of the separating protrusion 27 in the Y-axis direction.

[0078] The middle legs 42a, 42b or 42b have an elongated elliptical cylindrical shape in the X-axis direction, so that they conform to the inner peripheral surface shape of the through hole 26 when they are combined. However, their shape is not particularly limited and can vary depending on the shape of the through hole 26. Additionally, the side legs 48a, 48b have an inner concave curved surface shape that conforms to the outer peripheral surface shape of the cover body 52 of the cover 50, and their outer surface has a plane parallel to the XZ plane. In this embodiment, the material of each segmented core 42a, 42b can be a soft magnetic material such as metal or ferrite, but is not particularly limited.

[0079] The cover body 52 of the cover 50 has a shape that covers the outer periphery of the spool body 24. At both ends of the cover body 52 in the Z-axis direction, there are locking tabs 54 that are bent into a generally perpendicular direction from the cover body 52 toward the spool body 24.

[0080] A pair of locking tabs 54 formed on both sides of the cover body 52 in the Z-axis direction have locking protrusions 540. A hole 540a is formed approximately at the center of the locking protrusions 540.

[0081] The locking protrusion 540 is fixed to the stepped width expansion portion 250 of the stepped portion 25. More specifically, when the locking protrusion 540 is fixed to the stepped width expansion portion 250, the protrusion 250a formed in the stepped width expansion portion 250 engages with the hole 540a of the locking protrusion 540. Thus, a pair of locking pieces 54 are mounted to clamp the upper and lower surfaces of the spool body 24 in the Z-axis direction and are disposed on the stepped portion 25 formed on the upper surface of the spool body 24.

[0082] like Figure 2 As shown, side leg guide pieces 56 extending along the Z-axis are integrally formed on the outer surfaces of both ends of the cover body 52 in the X-axis direction. Figure 1A In the example shown, the side leg guide plate 56 abuts against the outer surface of the base 44a, 44b in the X-axis direction, but it can also abut against the outer surface of the side legs 48a, 48b in the X-axis direction. The inner surface of the side legs 48a, 48b contacts the outer surface of the cover body 52 located between the pair of side leg guide plates 56, and the movement of the side legs 48a, 48b in the X-axis direction is restricted by the pair of side leg guide plates 56.

[0083] The leg guide plate 56 on one side, closer to the terminal block 80 along the X-axis direction, is formed to be larger than the leg guide plate 56 on the other side, such as... Figure 1A As shown, when the cover 50 is installed on the spool 20, it is positioned... Figure 8 The first lead portion 37a of the first wire 37 is shown nearby. Therefore, the side leg guide piece 56 near the terminal block 80 serves to ensure the insulation distance (spatial distance and surface distance) between the first lead portion 37a of the first wire 37 and the cores 40a, 40b, and to guide the first lead portion 37a upward along the Z-axis. Furthermore, the cover 50 is constructed using an insulating component such as plastic, similar to the spool 20.

[0084] like Figure 3B and Figure 7A As shown, in this embodiment, of the pair of first lead portions 37a and 37b of the first wire 37, one first lead portion 37a originates from region S1 (refer to...). Figure 6A The first lead portion 37a is pulled out near the first end in the Y-axis direction on one side of the lead guide portion 110 and stands upright along the wire insertion passage 117a. After the first lead portion 37a stands upright along the wire insertion passage 117a, it is inserted through the interior of the corresponding cut 112a and pulled out in the X-axis direction. One end of the first lead portion 37a is connected to the first end-side terminal 60a.

[0085] Of the pair of first lead portions 37a and 37b, the other first lead portion 37b is drawn out from region S2 near its first end in the Y-axis direction towards the lead guide portion 110 and stands upright along the wire insertion passage 117b. However, the first lead portion 37b stands upright in a direction parallel to the winding axis near the center of the lead guide portion 110, closer to the first lead portion 37a. After standing upright along the wire insertion passage 117b, the first lead portion 37b is inserted through the interior of the corresponding cutout 112b and drawn out in the X-axis direction. One end of the first lead portion 37b is connected to the first inner terminal 60b.

[0086] Of the pair of second lead portions 38a and 38b of the second wire 38, one second lead portion 38a is pulled out from region S1a towards the second end in the Y-axis direction on the other side of the lead guide portion 110 and stands upright along the wire insertion passage 117d. After the first lead portion 38a stands upright along the wire insertion passage 117d, it is inserted through the interior of the corresponding cut 112d and pulled out in the X-axis direction. One end of the second lead portion 38a is connected to the second end-side terminal 60d.

[0087] Of the pair of second lead portions 38a and 38b, the other second lead portion 38b is drawn out from region S2a towards the second end in the Y-axis direction on the other side of the lead guide portion 110 and stands upright along the wire insertion passage 117c. However, the second lead portion 38b stands upright in a direction parallel to the winding axis near the center of the lead guide portion 110, closer to the second lead portion 38a. After standing upright along the wire insertion passage 117c, the second lead portion 38b is inserted into the interior of the corresponding cut 112c and drawn out in the X-axis direction. One end of the second lead portion 38b is connected to the second inner terminal 60c.

[0088] In this embodiment, the material formed in Figure 6A The connecting groove on the other side of the X-axis of the winding partition flange 34 is shown (illustration omitted). Figure 8 The second wire 38 shown is in Figure 6A The winding cylinder 28 shown is used for α-winding. Additionally, utilizing the... Figure 6A The connecting groove on the other side of the X-axis of the winding partition flange 33 is shown (illustration omitted). Figure 8 The first wire 37 shown is α-wound in the winding drum section 28. Furthermore, the winding method for the first wire 37 and the second wire 38 is not limited to α-wound; ordinary winding may also be used.

[0089] exist Figure 6AThe connecting portion 22 and the insulating partition flange 30 are shown, and the insulating adapter 70 is mounted across them. The insulating adapter 70 has: a curved side portion 71, an upper surface portion 72 formed on the upper part of the side portion 71 in the Z-axis direction, and a bottom portion 73 formed on the lower part of the side portion 71 in the Z-axis direction. A guide groove 76 extending along the Z-axis direction is formed on a portion of the curved outer surface of the side portion 71. Figure 8 Another lead portion 37b of the first wire 37 shown passes through the guide groove 76 along the Z-axis direction.

[0090] A sliding insert 74 is formed on the outer side of the guide groove 76. The sliding insert 74 is inserted into the first sliding insert hole 22e of the connecting part 22, and then the upper surface part 72 is inserted into the second sliding insert hole 22f. Thus, the insulating adapter 70 is installed on the connecting part 22. The bottom part 73 of the insulating adapter 70 is mounted to contact the lower surface of the insulating partition flange 30 in the Z-axis direction.

[0091] like Figure 5A As shown, terminal 60a (and terminals 60b to 60d are the same) has a wire connection portion 61, an external connection portion 62, and a connecting portion 63. The connecting portion 63 is a generally flat plate shape parallel to the XY plane, connecting the wire connection portion 61 and the external connection portion 62. The connecting portion 63 is relative to... Figure 4A The base 81 shown is configured in a generally parallel manner.

[0092] The wire connection portion 61 clamps and connects the lead portions 37a, 37b, 38a, and 38b. The wire connection portion 61 has a protruding piece 610 and a clamping piece 611. The protruding piece 610 is formed by a generally flat plate shape parallel to the XY plane. The protruding piece 610 is integrally connected to one end of the connecting portion 63 in the Y-axis direction and protrudes outward in the Y-axis direction.

[0093] The clamping piece 611 is composed of a generally flat plate shape parallel to the XY plane. The clamping piece 611 is connected to the front end of the protruding piece 610 in the Y-axis direction, and is formed by bending the protruding piece 610 inward in the Y-axis direction (opposite to the protruding direction of the protruding piece 610). The clamping piece 611 can clamp the lead wire portions 37a, 37b, 38a, and 38b. In this embodiment, the protruding piece 610 and the clamping piece 611 are relative to... Figure 4A The base 81 shown is configured in a generally parallel manner.

[0094] In terminals 60a to 60d, lead portions 37a, 37b, 38a, and 38b can be clamped using protruding pieces 610 and clamping pieces 611, and fixed by means of heat pressing or the like. Furthermore, the heat pressing of lead portions 37a, 37b, 38a, and 38b relative to the wire connection portion 61 is performed as follows: while lead portions 37a, 37b, 38a, and 38b are clamped using protruding pieces 610 and clamping pieces 611, a predetermined clamp is used to clamp the protruding pieces 610 and clamping pieces 611 vertically in the Z-axis direction.

[0095] The external connection portion 62 is configured as a generally flat plate parallel to the XZ plane. The external connection portion 62 is integrally connected to one end of the connecting portion 63 in the X-axis direction, approximately orthogonal to the connecting portion 63, and protrudes outward in the X-axis direction. The external connection portion 62 is inserted into the positioning slots 84a to 84d of the terminal block 80 and connected to an external substrate, etc.

[0096] like Figure 4A and Figure 7A As shown, the terminal block 80 includes: a base 81, a housing engagement groove 82, terminal placement portions 83a-83d, positioning groove portions 84a-84d, partition portions 85a-85e, connecting portions 87a, 87b, and positioning protrusions 88a, 88b. Terminals 60a-60d are mounted on the terminal block 80. In this embodiment, the terminal block 80 can be detachably mounted on the lead wire guide portion 110.

[0097] Partition wall portions 85a to 85e are formed on the base 81, slightly rearward (on the positive X-axis side) from the center. Partition wall portion 85a is formed on one end of the base 81 in the Y-axis direction, and partition wall portion 85e is formed on the other end of the base 81 in the Y-axis direction. Partition wall portions 85b to 85d are formed between partition wall portions 85a and 85e. Partition wall portion 85c is located approximately at the center of the base 81 in the Y-axis direction. Partition wall portions 85a, 85c, and 85e are thicker than partition wall portions 85b and 85d in the Y-axis direction.

[0098] A terminal arrangement portion 83a is formed in the region surrounded by partition portions 85a and 85b, and a connection portion 63 for a first end-side terminal 60a can be arranged there. A terminal arrangement portion 83b is formed in the region surrounded by partition portions 85b and 85c, and a connection portion 63 for a first inner-side terminal 60b can be arranged there. A terminal arrangement portion 83c is formed in the region surrounded by partition portions 85c and 85d, and a connection portion 63 for a second inner-side terminal 60c can be arranged there. A terminal arrangement portion 83d is formed in the region surrounded by partition portions 85d and 85e, and a connection portion 63 for a second end-side terminal 60d can be arranged there.

[0099] A housing engagement groove 82 is formed on the back side (bottom surface) in the Z-axis direction of the base 81. The housing engagement groove 82 is formed in a way that engages with the upper edge of the housing (not shown), and the terminal block 80 can be fixed to the housing via the housing engagement groove 82.

[0100] At the base 81, slightly forward of the center in the X-axis direction (on the negative X-axis side), positioning grooves 84a to 84d are formed at predetermined intervals in the Y-axis direction. Terminals 60a to 60d, which are connected to lead wires 37a, 37b, 38b, and 38a, are inserted into the positioning grooves 84a to 84d.

[0101] The positioning grooves 84a to 84d are formed by grooves penetrating the base 81 in the Z-axis direction and extending along the X-axis direction of the base 81. The positioning grooves 84a to 84d open in directions orthogonal to the plane of the base 81 (above and below the Z-axis), and are not closed. Therefore, as... Figure 3B As shown, inside the positioning grooves 84a to 84d, the external connecting parts 62 of the terminals 60a to 60d connected to the lead wire parts 37a, 37b, 38b, and 38a can be slid and inserted from the top in the Z-axis direction (vertical direction) downwards.

[0102] An insertion port 840a-840d for inserting terminals 60a-60d is formed at one end of the positioning groove portion 84a-84d located near the spool 20. The insertion port 840a-840d opens toward the side where the terminal arrangement portion 83a-83d is arranged, and the positioning groove portion 84a-84d and the terminal arrangement portion 83a-83d are connected via the insertion port 840a-840d. Furthermore, in the illustrated example, a groove that is continuous with the positioning groove portion 84a-84d is also formed in the terminal arrangement portion 83a-83d.

[0103] The other end of the positioning groove 84a-84d located on the side away from the spool 20 is blocked by the end of the base 81 in the X-axis direction. That is, the positioning groove 84a-84d extends to the front side of the base 81 in the X-axis direction.

[0104] like Figure 4A and Figure 7A As shown, a connecting portion 87a is formed at one end of the base 81 in the Y-axis direction, and a connecting portion 87b is formed at the other end of the base 81 in the Y-axis direction. Connecting holes 870a and 870b are formed in the connecting portions 87a and 87b. The connecting holes 870a and 870b engage with the engaging protrusions 114a and 116a, allowing the terminal block 80 and the lead guide portion 110 to be freely connected and detached via the connecting portions 87a and 87b.

[0105] Positioning protrusions 88a and 88b are formed on the back side of the base 81 facing the lead guide portion 110 in the X-axis direction. Positioning protrusion 88a is located on one side in the Y-axis direction, and positioning protrusion 88b is located on the other side in the Y-axis direction. Positioning protrusions 88a and 88b engage with positioning recesses 118a and 118b, thereby positioning the terminal block 80 on the lead guide portion 110.

[0106] In the manufacture of transformer 10, the following components are prepared first: spool 20, first wire 37, second wire 38, cover 50, magnetic core (segmented core) 40a, 40b, lead guide 110 which is separately formed from spool 20, and terminal block 80 which is separately formed from spool 20 and lead guide 110.

[0107] Next, in Figure 6A The outer periphery of the spool 20 shown is formed Figure 8 The first coil section 35 and the second coil section 36 are shown. Furthermore... Figure 8 The formation of the first coil portion 35 and the second coil portion 36 shown can also be performed using an automatic winding machine. Furthermore, the wires 37 and 38 can be made of single wires or stranded wires, preferably insulated wires. The second wire 38 can be the same as the first wire 37, but it can also be different. In this embodiment, the outer diameter of the first wire 37 is larger than the outer diameter of the second wire 38, preferably φ1.0 to φ3.0 mm.

[0108] Next, slide and insert the sliding insert piece 74. Figure 6A The upper surface portion 72 is slid into the sliding insertion hole 22e shown, and the lower surface portion 73 is further fixed to the lower surface of the insulating partition flange 30, thereby installing the insulating adapter 70 onto the connecting portion 22.

[0109] Next, as Figure 4A As shown, lead wires 37a, 37b, 38b, and 38a are inserted into the spool-side cuts 23a to 23d of the connecting part 22, and pulled upwards in the Z-axis direction as indicated by the double-dotted line in the figure. At this time, the second lead wire 37b is inserted. Figure 6B The interior of the guide groove 76 of the insulating adapter 70 shown.

[0110] Next, the lead wire portions 37a, 37b, 38b, and 38a are each clamped using the protruding tabs 610 and clamping tabs 611 of terminals 60a to 60d, and then riveted together using the wire connection portions 61. Alternatively, this process can be performed after the lead wire guide portion 110 is installed on the connection portion 22. Then, in this state, the wire connection portions 61 of the lead wire portions 37a, 37b, 38b, and 38a are riveted together using a clamp via heat pressing.

[0111] Next, engage the spool-side engaging portions 26a-26c and 26f with the terminal block-side engaging portions 113a-113d, and insert and engage the spool-side engaging portions 26d and 26e into the opposing cutouts 112c and 112d. Additionally, insert each engaging tab 22c. Figure 7A The locking grooves 114c and 116c shown are engaged. Thus, the lead guide 110 is installed on the connector 22.

[0112] Next, as Figure 4A and Figure 7A As shown, the engaging protrusions 114a and 116a engage with the connecting holes 870a and 870b, connecting the terminal block 80 and the lead guide 110 via the connecting portions 87a and 87b. Alternatively, the lead guide 110, pre-installed with the terminal block 80, can be mounted on the connecting portion 22.

[0113] Next, the lead wires 37a, 37b, 38b, and 38a are inserted through the opposing cuts 112a to 112d, and the external connecting parts 62 of the terminals 60a to 60d, which are respectively connected to the lead wires 37a, 37b, 38b, and 38a, are inserted from above into the respective positioning grooves 84a to 84d. The front ends of the external connecting parts 62 of the terminals 60a to 60d abut against and are fixed to the ends of the positioning grooves 84a to 84d on the negative X-axis side. Furthermore, as... Figure 3B As shown, each connecting portion 63 of terminals 60a to 60d is disposed (fixed) on terminal mounting portions 83a to 83d. Alternatively, terminals 60a to 60d may be fixed to terminal block 80 using adhesive or the like, as needed.

[0114] Then, Figure 2 The pair of covers 50 shown are installed on the spool 20. Then, the middle leg 46a of the pair of split cores 42a, 42a separated in the X-axis direction and the middle leg 46b of the pair of split cores 42b, 42b separated in the X-axis direction are inserted from both sides of the through hole 26 in the X-axis direction of the core leg.

[0115] Next, utilize as needed Figure 1A The terminal cover 100 shown covers and is installed around the lead guide 110 of the spool 20 and the terminal block 80. Additionally, if necessary, the transformer 10 is housed in a housing (not shown), and casting resin is poured in. The casting resin is made of a soft silicone resin, polyurethane resin, epoxy resin, etc., which is also soft after injection, and the longitudinal elastic modulus of the casting resin is preferably 0.1 to 100 MPa.

[0116] In the transformer 10 of this embodiment, the terminal block 80 has positioning slots 84a-84d into which terminals 60a-60d connected to lead portions 37a, 37b, 38b, 38a are inserted, and is indirectly connected to the spool 20 (via the lead guide portion 110) for easy assembly and disassembly. Therefore, when the terminal block 80 is removed from the spool 20, terminals 60a-60d can be connected to lead portions 37a, 37b, 38b, 38a, and sufficient working area can be ensured when connecting lead portions 37a, 37b, 38b, 38a to terminals 60a-60d.

[0117] Furthermore, by indirectly connecting the spool 20 to the terminal block 80, simply inserting the terminals 60a-60d connected to the lead portions 37a, 37b, 38b, and 38a into the positioning slots 84a-84d allows for high-precision positioning of the terminals 60a-60d relative to the terminal block 80, preventing misalignment of the front ends of the terminals 60a-60d. Therefore, the transformer 10 according to this embodiment provides a transformer with high positioning accuracy and ease of manufacture.

[0118] Furthermore, in this embodiment, the terminal block 80 has a base 81, and the positioning grooves 84a to 84d open in a direction orthogonal to the plane of the base 81. Therefore, terminals 60a to 60d connected to lead portions 37a, 37b, 38b, and 38a can be slid and inserted from a direction orthogonal to the plane of the base 81 (above the positioning grooves 84a to 84d), making it easy to position terminals 60a to 60d.

[0119] Furthermore, in this embodiment, the other end of the positioning groove 84a-84d located on the side away from the spool 20 is blocked by the base 81. Therefore, the front end of the terminals 60a-60d inserted into the positioning groove 84a-84d can be fixed to the other end of the positioning groove 84a-84d, effectively preventing misalignment of the front end of the terminals 60a-60d.

[0120] Furthermore, the transformer 10 of this embodiment has a lead guide portion 110, and the terminal block 80 is detachably connected to the lead guide portion 110. In this case, the terminal block 80 and the lead guide portion 110 are separately constructed. Therefore, if the extraction direction of the leads 37a, 37b, 38b, and 38a changes, the situation can be addressed by only modifying the structure of the lead guide portion 110, and the terminal block 80 does not need to be remanufactured from scratch. Therefore, it is possible to flexibly accommodate changes in the specifications of the lead guide portion 110, providing a transformer 10 with a high degree of design freedom.

[0121] Furthermore, in this embodiment, the lead guide 110 is detachably connected to the spool 20. In this case, the lead guide 110 and the spool 20 are separately constructed; therefore, if the specifications of the spool 20 change, this can be addressed by simply modifying the structure of the spool 20, without needing to remanufacture the lead guide 110 from scratch. Thus, changes in the specifications of the spool 20 can be flexibly addressed, providing a transformer 10 with a high degree of design freedom.

[0122] Furthermore, in this embodiment, terminals 60a to 60d have an external connection portion 62 and a wire connection portion 61. Therefore, the external connection portion 62 can be precisely positioned in the positioning groove portions 84a to 84d, and the lead portions 37a, 37b, 38b, and 38a can be connected to terminals 60a to 60d simply by clamping the lead portions 37a, 37b, 38b, and 38a in the wire connection portion 61, making manufacturing easy.

[0123] Furthermore, in this embodiment, the wire connection portion 61 has a clamping piece 611, which is arranged approximately parallel to the base 81. Therefore, after clamping the lead portions 37a, 37b, 38b, and 38a with the clamping piece 611, heat-pressing is performed on the wire connection portion 61 with the clamping piece 611 arranged approximately parallel to the base 81, and without changing the orientation of the terminals 60a to 60d. The external connection portion 62 can be directly inserted into the positioning slots 84a to 84d, and the terminals 60a to 60d can be easily positioned.

[0124] Second Implementation Method

[0125] Figure 1B The transformer 10A of the second embodiment shown below has the same structure as the transformer 10 of the first embodiment, except for the points shown below, and achieves the same effect. Figure 1B In the above, components that are the same as those in the transformer 10 of the first embodiment are marked with the same symbols, and their descriptions are partially omitted.

[0126] like Figure 4B As shown, transformer 10A has a bobbin 20A, a terminal block 80A, and a lead guide 110A. (As shown...) Figure 6C As shown, a connecting portion 22A is formed on the online spindle 20A. On the connecting portion 22A, online spindle-side engaging portions 26g, 26h, and 26i are formed at predetermined intervals along the Y-axis direction, which can respectively engage with... Figure 7B The terminal block side engaging portions 113e, 113f, and 113g of the lead guide portion 110A shown engage.

[0127] like Figure 6CAs shown, an insulating adapter 70A is mounted on one end of the spool 20A in the X-axis direction, where the connecting part 22A is located. The insulating adapter 70A has: a side part 71A, a bottom part 73A, guide grooves 76aA and 76bA, and adapter-side fixing parts 77a and 77b. The bottom part 73A is composed of a surface parallel to the XY plane and has a shape that is curved to the outer periphery of one end of the spool 20A in the X-axis direction. The bottom part 73A abuts against and is fixed to the bottom surface of the insulating partition flange 30.

[0128] A pair of adapter-side fixing portions 77a and 77b are respectively formed on one end side and the other end side of the bottom portion 73A in the Y-axis direction, and protrude upwards. For example... Figure 6D As shown, a pair of adapter-side fixing portions 77a and 77b abut against and are fixed to the spool-side fixing portions 22g and 22h of the connecting portion 22A, respectively. Furthermore, the peripheral shapes of the spool-side fixing portions 22g and 22h are not limited to the shapes shown in the figure; for example, they can be appropriately modified. Figure 6E The shapes shown, etc.

[0129] like Figure 6C As shown, a pair of guide grooves 76aA and 76bA are formed inside the pair of adapter-side fixing portions 77a and 77b in the Y-axis direction, and extend along the Z-axis direction. In the pair of guide grooves 76aA and 76bA, as... Figure 6D As shown, lead wires 37a and 37b are inserted upwards respectively.

[0130] Side portion 71A is formed between a pair of guide grooves 76aA and 76bA, and has a shape that is curved to the outer periphery of one end of the spool 20A in the X-axis direction. Side portion 71A is fixed to cover one end of the spool 20A in the X-axis direction.

[0131] like Figure 4B and Figure 7B As shown, a wire insertion passage 117aA is formed in the lead wire guide portion 110A. The wire insertion passage 117aA and the wire insertion passages 117b to 117d are formed on opposite sides in the X-axis direction and communicate with the corresponding cutout 112a. The wire insertion passage 117aA extends obliquely upward and in the Y-axis direction.

[0132] Positioning protrusions 118c and 118d are formed on the back side of the rod member 112A in the X-axis direction. Positioning protrusion 118c is located on one side of the rod member 112A in the Y-axis direction, and positioning protrusion 118d is located on the other side of the rod member 112A in the Y-axis direction. Positioning protrusions 118c and 118d engage with positioning recesses 88c and 88d of the terminal block 80A, respectively, so that the terminal block 80A can be positioned on the lead guide portion 110A.

[0133] like Figure 5BAs shown, terminal 60aA (and terminals 60bA to 60dA are the same) has a wire connection portion 61A and a connecting portion 63A. The connecting portion 63A has a generally flat shape and a surface parallel to the XZ plane. The connecting portion 63A is an integrally formed portion extending the external connection portion 62 along the X-axis direction. The connecting portion 63A extends parallel to the external connection portion 62 and is located on the extension line of the external connection portion 62.

[0134] The wire connection portion 61A has a protruding piece 610A and a clamping piece 611A. The protruding piece 610A is formed by a generally flat plate shape parallel to the XZ plane. The protruding piece 610A is integrally connected to the lower end of the connecting portion 63A in the Z-axis direction and protrudes downward in the Z-axis direction (in a direction orthogonal to the long side direction of the external connecting portion 62).

[0135] The clamping piece 611A is composed of a generally flat plate shape parallel to the XZ plane. The clamping piece 611A is connected to the lower end of the protruding piece 610A in the Z-axis direction, and is formed by bending the protruding piece 610A inward in the Z-axis direction (opposite to the protruding direction of the protruding piece 610A). In this embodiment, the protruding piece 610A and the clamping piece 611A are relative to... Figure 4B The base 81 shown is configured in a generally parallel manner.

[0136] A protrusion 620 is formed on one side of the surface of the external connecting portion 62 in the Y-axis direction, and a recess 621 is formed on the other side of the surface of the external connecting portion 62 in the Y-axis direction. The protrusion 620 and the recess 621 formed on the surface of the external connecting portion 62... Figure 7B The recesses (not shown) on the surrounding walls of the positioning grooves 84a-84d are fitted together, and the recesses 621 are fitted together with the protrusions (not shown) formed on the surrounding walls of the positioning grooves 84a-84d. Thus, the terminals 60aA-60dA can be securely fixed to the terminal block 80A via the protrusions 620 and the recesses 621. Furthermore, the terminals 60aA-60dA can also be fixed to the terminal block 80A using adhesive or the like, if necessary.

[0137] like Figure 7B As shown, terminal arrangement portions 83aA to 83dA are formed on the terminal block 80A. Terminal arrangement portion 83aA is formed in the area surrounded by partition portions 85a and 85b, as shown... Figure 3D As shown, a connecting portion 63A can be configured for the first end-side terminal 60aA, and a lead portion 38a connected to the first end-side terminal 60aA is inserted. A terminal fixing portion 830a is formed in the terminal configuration portion 83aA, which can fix the wire connection portion 61A of the first end-side terminal 60aA.

[0138] like Figure 7BAs shown, the terminal configuration portion 83bA is formed in the area surrounded by the partition portion 85b and the partition portion 85c, as... Figure 3D As shown, a connecting portion 63A can be configured for the first inner terminal 60bA, and a lead portion 37a connected to the first inner terminal 60bA is inserted. A terminal fixing portion 830b is formed in the terminal configuration portion 83bA, which can fix the wire connection portion 61A of the first inner terminal 60bA.

[0139] like Figure 7B As shown, the terminal configuration portion 83cA is formed in the area surrounded by the partition portion 85c and the partition portion 85d, as... Figure 3D As shown, a connecting portion 63A for the second inner terminal 60cA can be configured, and a lead portion 37b connected to the second inner terminal 60cA is inserted. A terminal fixing portion 830c is formed in the terminal configuration portion 83cA, which can fix the wire connection portion 61A of the second inner terminal 60cA.

[0140] like Figure 7B As shown, a terminal configuration portion 83dA is formed in the area surrounded by a partition portion 85d and a partition portion (not shown) located on the outer side in the Y-axis direction. A connection portion 63A for a second end-side terminal 60dA can be configured therein, and a lead portion 38b connected to the second end-side terminal 60dA is inserted. A terminal fixing portion 830d is formed in the terminal configuration portion 83dA to fix the wire connection portion 61A of the second end-side terminal 60dA.

[0141] like Figure 7B As shown, a positioning recess 88c is formed in the partition wall portion 85a, and a positioning recess 88d is formed in the partition wall portion 85d. This allows... Figure 4B The positioning protrusion 118c of the lead guide portion 110A shown engages with the positioning recess 88c, so that the positioning protrusion 118d of the lead guide portion 110A engages with the positioning recess 88d.

[0142] Covered mounting protrusions 871a and 871b are formed in the connecting portions 87a and 87b, which can be engaged. Figure 1B The terminal cover 100 shown has a snap-fit ​​protrusion 110.

[0143] like Figure 3C and Figure 4B As shown, lower partition portions 86a to 86c are formed on the back side of the base 81 in the Z-axis direction. The lower partition portions 86a to 86c protrude downward in the Z-axis direction and extend along the X-axis direction. The protrusion width of the lower partition portion 86b in the Z-axis direction is smaller than the protrusion width of the lower partition portions 86a and 86c in the Z-axis direction.

[0144] The lower partition 86a is located between the positioning groove 84a and the positioning groove 84b, the lower partition 86b is located between the positioning groove 84b and the positioning groove 84c, and the lower partition 86c is located between the positioning groove 84c and the positioning groove 84d. Each of the lower partitions 86a to 86c ensures a good insulation distance between the terminals 60aA to 60dA inserted into the positioning grooves 84a to 84d.

[0145] In this embodiment, transformer 10A is also manufactured using the same method as transformer 10. However, in this embodiment, in... Figure 5B After the wire connection portion 61A of each of the terminals 60aA to 60dA shows clamps the lead portion 38a, 37a, 37b, and 38b respectively, the method of heat-pressing the terminals 60aA to 60dA using a predetermined clamp is different from that of the transformer 10 in the first embodiment.

[0146] That is, in this embodiment, terminals 60aA to 60dA, which are connected to lead portions 38a, 37a, 37b, and 38b, are connected to... Figure 5B The direction shown is rotated 90 degrees clockwise or counterclockwise around the X-axis to change the direction, so that the wire connection part 61A is arranged parallel to the XY plane. Then, in this state, heat pressing is performed by clamping the protruding piece 610A and the clamping piece 611A from above and below in the Z-axis direction using a predetermined clamp.

[0147] After heat pressing, the terminals 60aA to 60dA connected to the lead wires 38a, 37a, 37b, and 38b are rotated 90 degrees counterclockwise or clockwise around the X-axis, and the direction is changed again. Figure 5B The state shown. Then, insert each of the external connection portions 62 of terminals 60aA to 60dA from above. Figure 4B The interior of each of the positioning grooves 84a to 84d shown. Figure 3D As shown, each connecting portion 63A of terminals 60aA to 60dA is disposed (fixed) on terminal mounting portions 83aA to 83dA.

[0148] In this embodiment, the same effects as in the first embodiment can be achieved. In addition, in this embodiment, such as... Figure 5B As shown, the structure of terminals 60aA, etc., can be simplified, and the installation space of terminals 60aA, etc. in terminal block 80A can be saved.

[0149] Third Implementation Method

[0150] Figure 1CThe transformer 10B of the third embodiment shown has the same structure as the transformer 1 of the first embodiment, except for the points shown below, and achieves the same effect. Figure 1C In the above, components that are the same as those in the transformer 10 of the first embodiment are marked with the same symbols, and their descriptions are partially omitted.

[0151] Transformer 10B has a bobbin 20B, a terminal block 80B, and a lead guide 110B. For example... Figure 6E As shown, the connecting portion 22B of the linear shaft 20B has sliding engagement portions 22i and 22j. The sliding engagement portions 22i and 22j have a hook shape (bent into an approximately L-shape) and extend along the X-axis direction. The sliding engagement portion 22i is formed on one side of the connecting portion 22B in the Y-axis direction, and the sliding engagement portion 22j is formed on the other side of the connecting portion 22B in the Y-axis direction. The sliding engagement portions 22i and 22j can engage. Figure 4C and Figure 7C The bottom engaging portions 119a and 119b of the lead wire guide portion 110B shown.

[0152] Bottom-side engaging portions 119a and 119b are formed on the back side of the rod member 112B in the Z-axis direction. The bottom-side engaging portions 119a and 119b have a hook shape (bent into an approximately L-shape) and extend along the X-axis direction. Bottom-side engaging portion 119a is formed on one side of the rod member 112B in the Y-axis direction, and bottom-side engaging portion 119b is formed on the other side of the rod member 112B in the Y-axis direction. As described above, the bottom-side engaging portions 119a and 119b engage and fix the sliding engaging portions 22i and 22j of the fixed connecting portion 22B.

[0153] Stepped partition portions 850a to 850d are formed in terminal block 80B. Stepped partition portions 850a to 850d are each formed on one side of the stepped portions 85a to 85d in the X-axis direction (opposite to the side where the bobbin 20 is disposed). The upper surface of the stepped partition portions 850a to 850d is located above the upper surface of the stepped portions 85a to 85d in the Z-axis direction.

[0154] A cover portion 89 is formed on one side of the step partition portion 850a-850d in the X-axis direction. For example... Figure 3E As shown, the cover 89 covers the upper surface of the base 81 on one side in the X-axis direction. Additionally, as... Figure 7D As shown, the cover portion 89 is formed to cover the positioning groove portions 84a to 84d from above in the Z-axis direction. Therefore, the positioning groove portions 84a to 84d are not opened upwards relative to the plane of the base 81, but are closed. The positioning groove portions 84a to 84d only open downwards and to the side (on the side where the terminal mounting portions 83aA to 83dA are disposed) relative to the plane of the base 81.

[0155] Therefore, as Figure 3F As shown, inside the positioning grooves 84a to 84d, the external connecting part 62, which connects to the terminals 60aA to 60dA of the lead parts 38a, 37a, 37b, and 38b, cannot slide downwards and be inserted from the Z-axis direction (vertical direction). Instead, it can be inserted by sliding from one side to the other in the X-axis direction. Figure 7D Insert through the shown insertion ports 840a to 840d.

[0156] In this embodiment, insertion ports 840a-840d for inserting terminals 60aA-60dA are formed at one end of the positioning groove portion 84a-84d located near the spool 20. Therefore, as Figure 7D As shown, even when the upper part of the positioning groove 84a to 84d is blocked, the terminals 60aA to 60dA connected to the lead wires 38a, 37a, 37b, and 38b can be inserted into the insertion ports 840a to 840d from the side close to the spool 20 and inserted into the positioning groove 84a to 84d, so that the terminals 60aA to 60dA can be easily positioned.

[0157] Furthermore, the present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the present invention.

[0158] The above embodiments illustrate application examples of the transformer of the present invention, but the present invention is not only applicable to transformers, but also applicable to other coil devices.

[0159] In the above embodiments, the terminal block 80 is connected to the spool 20 via the lead wire guide 110, but it can also be directly connected to the spool 20.

[0160] In the above embodiments, the lead guide 110 is detachably connected to the spool 20, but it can also be integrally formed with the spool 20.

[0161] In the above embodiments, the lead portions 37a, 37b, 38a, and 38b can also be connected by means other than riveting. Examples of other connection methods include brazing, welding, resistance welding, laser welding, riveting, thermoforming, and thermofusion.

[0162] In the above embodiments, a magnetic core is formed by combining E-cores, which serve as dividing cores. However, a magnetic core can also be assembled by combining E-cores and I-cores.

[0163] Alternatively, the first coil portion 35 and the second coil portion 36 may also be arranged on the winding shaft of the spool 20 in the opposite manner to the above embodiment. In addition, the configuration of the first lead portions 37a, 37b and the second lead portions 38a, 38b may also be reversed.

[0164] Symbol Explanation

[0165] 10, 10A, 10B... Transformers

[0166] 20, 20A, 20B... spools

[0167] 22, 22A, 22B... Connecting parts

[0168] 22a…base

[0169] 22b…Insulating wall

[0170] 22c…card combination

[0171] 22d… Snap-fit ​​slot

[0172] 22e, 22f… Sliding insertion holes

[0173] 22g, 22h… spool side fixing part

[0174] 22i, 22j... Sliding engagement part

[0175] 23a~23d… Side cuts on the spool

[0176] 24…Spool body

[0177] 25… Step section

[0178] 26a~26i…Spool-side engagement part

[0179] 250… Step width enlargement section

[0180] 250a…protrusion

[0181] 26… Through holes for core legs

[0182] 27… Separation protrusion

[0183] 28… Winding section

[0184] 29…prominent film

[0185] 30…Insulating partition flange

[0186] 31, 32… End partition flanges

[0187] 33, 34…wrap around the adjacent flange

[0188] 35…First coil section

[0189] 36…Second coil section

[0190] 37…First Electric Wire

[0191] 37a, 37b... First lead section

[0192] 38…Second wire

[0193] 38a, 38b... Second lead section

[0194] 40a, 40b... magnetic core

[0195] 42a, 42b…split core

[0196] 44a, 44b... base

[0197] 46a, 46b... mid-leg

[0198] 48a, 48b... Side leg

[0199] 50… cover

[0200] 52… Cover body

[0201] 54…stop film

[0202] 540…Sticker Protrusion Piece

[0203] 540a…hole

[0204] 56…Side leg guide plate

[0205] 60a~60d, 60aA~60dA... terminals

[0206] 61, 61A… Wire connection part

[0207] 610, 610A... protruding film

[0208] 611, 611A... clamping plates

[0209] 62…External connection section

[0210] 620…sudden rise

[0211] 621…concave

[0212] 63, 63A... Connecting parts

[0213] 70, 70A… Insulation adapter

[0214] 71, 71A... Side view

[0215] 72…upper surface

[0216] 73, 73A... Bottom surface

[0217] 74… Sliding Insert Piece

[0218] 76, 76aA, 76bA… guide slots

[0219] 77a, 77b... Adapter-side fixing part

[0220] 80…Terminal block

[0221] 81…base

[0222] 82… Housing engagement groove

[0223] Terminal configuration section 83a~83d, 83aA~83dA…

[0224] 830a~830d…Terminal fixing part

[0225] 84a~84d… Positioning groove section

[0226] 840a~840d…Insert Port

[0227] 85a~85e… next door

[0228] 850a~850d…Step partition

[0229] 86a~86c…lower partition

[0230] 87a, 87b... Connecting parts

[0231] 870a, 870b... connecting holes

[0232] 871a, 871b... cover mounting protrusions

[0233] 88a, 88b…positioning convex portion

[0234] 88c, 88d…positioning recess

[0235] 89…Gaibu

[0236] 110, 110A, 110B... Lead guide section

[0237] 112, 112A, 112B... rod components

[0238] 112a, 112b, 112c, 112d… Opposite cuts

[0239] 113a~113g…Terminal block side engagement part

[0240] 114, 116... end blocks

[0241] 114a, 116a... engaging protrusions

[0242] 114b, 116b... Snap hook

[0243] 114c, 116c... Snap-fit ​​slot

[0244] 117a, 117aA, 117b, 117c, 117d… Wire insertion circuit

[0245] 118a, 118b... positioning recess

[0246] 118c, 118d…positioning convex portion

[0247] 119a, 119b... Bottom side engagement part

[0248] 100…Terminal cover

[0249] 110…Kaihe protrusion.

Claims

1. A coil device, comprising: a bobbin on which an electric wire is wound; a terminal to which a lead portion of the electric wire is connected; a terminal base on which the terminal is mounted, the terminal base having a positioning groove portion into which the terminal to which the lead portion is connected is inserted, and being directly or indirectly coupled to the bobbin so as to be detachable, the coil device further comprising a lead guide portion that guides the lead portion of the electric wire, and the terminal base and the lead guide portion being detachably coupled.

2. The coil device according to claim 1, wherein the terminal base has a base portion that forms the positioning groove portion, and the positioning groove portion is open in a direction orthogonal with respect to a plane of the base portion.

3. The coil device according to claim 1 or 2, wherein an insertion opening for inserting the terminal is formed at one end of the positioning groove portion on a side close to the bobbin.

4. The coil device according to claim 2, wherein the other end of the positioning groove portion on a side away from the bobbin is blocked by the base portion.

5. The coil device according to claim 1, wherein the lead guide portion is detachably coupled to the bobbin.

6. The coil device according to claim 1, wherein the terminal has an external connection portion that is inserted into the positioning groove portion, and an electric wire connection portion that holds and connects the lead portion.

7. The coil device according to claim 6, wherein the terminal base has a base portion that forms the positioning groove portion, the electric wire connection portion has a holding piece that holds the electric wire, and the holding piece is disposed substantially in parallel with respect to the base portion. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

Images