Coil device

Abstract

A coil device is provided with: a bobbin (3); a coil (1) having a winding portion (10) wound around a bobbin (3); a terminal (71) connected to the coil (1); and a cover (5) for protecting the winding part (10). The cover (5) is provided with a cover main body (50) which covers the outer side of the winding part (10) in the direction perpendicular to the winding shaft. The terminal (71) is attached to the cover body. The terminal (71) has a wiring portion (71a) to which the lead portion (11) led out from the winding portion (10) is connected, and an external connection portion (71c) connected to the wiring portion (71a).

Description

Technical Field

[0001] This disclosure relates to coil devices, for example, suitable for use as transformers, etc. Background Technology

[0002] A transformer as described in Patent Document 1 is known in which the winding shaft of the coil is mounted parallel to a wiring board or the like. In such a transformer, terminal blocks are provided at both ends of the winding shaft, and the transformer is mounted by placing the terminal blocks on a wiring board or the like.

[0003] However, in such transformers, in order to ensure insulation between the coil winding section and the terminals, the terminals are placed at a certain distance away from the winding section, which increases the overall size of the device.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent Application Publication No. 2008-171880 Summary of the Invention

[0007] (a) Technical problems to be solved

[0008] This disclosure was made in view of the current situation, and its purpose is to provide a coil device that can improve insulation performance and achieve space saving.

[0009] (II) Technical Solution

[0010] One aspect of the coil device disclosed herein has:

[0011] spool;

[0012] A coil having a winding portion wound around the spool;

[0013] Terminals, which are connected to the coil; and

[0014] A cover that protects the wound section.

[0015] The cover has a cover body that covers the outer side of the winding portion in the height direction perpendicular to the winding axis.

[0016] The terminal is assembled onto the cover body.

[0017] The terminal has: a wiring portion for connecting a lead portion extending from the winding portion; and an external connection portion connected to the wiring portion.

[0018] With this configuration, the coil assembly can protect the winding section with a cover without requiring a large space, ensuring sufficient insulation between the terminals and the winding section. The terminals can be freely designed with different removal positions on the cover body. Therefore, this structure increases the freedom of terminal removal positions. Thus, according to this coil assembly, even when the coil winding shaft is arranged parallel to the mounting surface, the insulation performance between the coil winding section and the terminals can be improved, and space saving is achieved.

[0019] Preferably, when viewed along the height direction, the external connection portion is positioned closer to the winding shaft than the wiring portion. This configuration reduces the mounting area of ​​the coil assembly.

[0020] Preferably, the cover body is configured to bridge one flange of the spool with the other flange. This configuration reliably protects the coil wound on the spool, further improving insulation.

[0021] Preferably, the cover body is configured to bridge the outer leg of one side of the core mounted on the spool with the outer leg of the other side. This configuration allows for more reliable protection of the coil winding portion by the cover, further improving insulation.

[0022] Preferably, the external connection portion is disposed between the two flange portions of the bobbin. This configuration reduces the mounting area required when mounting the coil assembly on a wiring board or similar substrate.

[0023] Preferably, the wiring portion is positioned inside the outer surface of the core mounted on the spool in the width direction. This configuration prevents the wiring portion from protruding from the core during or after the coil assembly is manufactured, effectively protecting it and improving its reliability. Furthermore, it contributes to space saving.

[0024] Preferably, when viewed along the height direction, the wiring portion is disposed outside the spool and the cover body. Before the core is installed, the space above and below the wiring portion is left empty, allowing the coil lead portion to be easily connected to the wiring portion via a joining method such as heat pressing (or other joining methods), thus simplifying manufacturing.

[0025] Preferably, the external connection portion protrudes from the surface of the cover body. This configuration allows for easy installation by inserting the external connection portion protruding from the cover body into a hole formed in the wiring board, and also improves installation strength.

[0026] The terminal can be pressed into the cover body or embedded in the cover body. Attached Figure Description

[0027] Figure 1 This is a perspective view of a coil device according to one implementation method.

[0028] Figure 2 yes Figure 1 An exploded perspective view of the coil device shown.

[0029] Figure 3 It means Figure 1 A partial perspective view of the structure of the coil and spool of the coil device shown.

[0030] Figure 4 It means Figure 1 A partial perspective view of the core structure of the coil device shown.

[0031] Figure 5 It means Figure 1 A partial perspective view of the structure of the cover of the coil device shown.

[0032] Figure 6 It indicates assembly. Figure 1 An explanatory diagram showing the state of the coil assembly before the cover is installed.

[0033] Figure 7 yes Figure 1 A top view of the coil assembly shown.

[0034] Figure 8 yes Figure 1 A cross-sectional view of the coil assembly shown at line VIII-VIII.

[0035] Figure 9 This is a cross-sectional view of a coil device according to another embodiment.

[0036] Explanation of reference numerals in the attached figures:

[0037] 100, 200: Transformer; 1, 2: Coil; 10, 20: Winding section; 11, 12, 21, 22: Lead section; 10_1: Intermediate section; 3, 3_1: Bollard; 30, 30_1: Core section; 30a, 30_1a: Through hole; 31, 41, 31_1, 41_1: Flange section; 31a, 41a: Outer surface; 31b, 41b: Inner surface; 32, 42: Lead platform; 320, 420: Cut-out section; 3 21, 322, 421, 422: Lead-out passages; 33, 43: Mounting parts; 3a, 3b, 3c, 3d: Engaging holes; 3_2: Auxiliary spool; 30_2: Auxiliary core part; 30_2a: Auxiliary through hole; 41_2: Auxiliary flange part; 5: Cover; 50: Cover body; 50a: Upper surface; 50b: Lower surface; 511, 512, 513, 514: Press-in holes; 521, 522, 523, 524: Press-in holes; 611, 612, 613: Press-in holes; 621, 622, 623: Press-in holes; 5a, 5b, 5c, 5d: Engaging claws; 71, 72, 81, 82: Terminals; 71a, 72a, 81a, 82a: Wiring section; 71b, 72b, 81b, 82b: Intermediate section; 71c, 72c, 81c, 82c: External connection section; 711, 712, 713, 714: Mounting claws; 721, 722, 723 724: Mounting claw; 811, 812, 813: Mounting claw; 821, 822, 823: Mounting claw; 9 (9a, 9b), 9_1: Core; 910, 920: Outer surface; 9a40, 9b40: Outer surface; 911, 921: Upper surface; 9a1, 9b1: First outer leg; 9a2, 9b2: Second outer leg; 9a3, 9b3: Middle leg; 9a4, 9b4: Base; 9c: Plate core; 300: Shell. Detailed Implementation

[0038] The embodiments of this disclosure will now be described with reference to the accompanying drawings. Furthermore, the illustrations are merely schematic and exemplary for the purpose of understanding this disclosure, and the appearance, size ratios, etc., may differ from the actual object. Additionally, this disclosure is not limited to the following embodiments.

[0039] (First Implementation)

[0040] Figure 1 The coil device 100 shown in this embodiment is an example, for instance, it has the function of a transformer and can be used in EV (Electric Vehicle), PHV (Plug-in Hybrid Vehicle), or on-board chargers for commuting (vehicles), or power circuits for household or industrial electrical equipment, or power circuits for computer equipment, etc.

[0041] The size of the coil device 100 is not particularly limited; for example, the length L0 in the X-axis direction (refer to...) Figure 7 The width W0 in the Y-axis direction can be 1cm to 20cm (refer to...). Figure 7 The height can be 1cm to 20cm, and the height in the Z-axis direction can be 1cm to 20cm, etc.

[0042] Furthermore, in the accompanying drawings, the X-axis is along the winding axis C of the coil, and the X, Y, and Z axes are perpendicular to each other. Additionally, in the following description, the Y-axis direction is sometimes referred to as the width direction, and the Z-axis direction as the height direction. Furthermore, the side facing the center of the coil device 100 is sometimes referred to as the inner side or inner direction, and the side away from the center of the coil device 100 is sometimes referred to as the outer side or outer direction. Also, sometimes, based on the orientation of the accompanying drawings, the direction of the tip of the arrow indicating the Z-axis is sometimes referred to as upward.

[0043] like Figure 2 As shown, the coil assembly 100 generally includes: coils 1 and 2; a bobbin 3 for winding coils 1 and 2; a core 9 mounted on the bobbin 3; and a cover 5 for protecting the winding portions 10 and 20 of the coils. Terminals 71, 72, 81, and 82 are mounted on the cover 5. Figure 1 As shown, the coil device 100 can be housed in the housing 300 and used on a wiring board or the like.

[0044] like Figure 2 As shown, the spool 3 generally has a core portion 30 extending along the X-axis and flange portions 31 and 41 at both ends of the core portion 30 in the X-axis direction. The core portion 30 has a through hole 30a extending through in the X-axis direction. The middle legs 9a3 and 9b3 of the core 9 are inserted into the through hole 30a.

[0045] The spool 3 is composed of an insulating component that insulates the coils 1 and 2 from the middle legs 9a3 and 9b3 of the core 9. Examples of such insulating components include plastics such as PPS, PET, PBT, and LCP.

[0046] like Figure 3 As shown, in the core portion 30, coil 1 (2) is wound along the winding axis C to form a winding portion 10 (20). In this embodiment, the winding portion 10 is wound on the winding portion 20 of coil 2, and the winding portion 20 of coil 2 is wound on the core portion 30 (see reference). Figure 8 Lead wires 11 and 12 are drawn from winding section 10. Lead wires 21 and 22 are drawn from winding section 20.

[0047] Coils 1 and 2 can each use known conductive wires. They can also be constructed from known insulated wires, such as copper wires, whose surfaces are insulated with a polyimide film. Coils 1 and 2 can each be made of a single wire, or they can be made of stranded wire. The wire diameter of coils 1 and 2 is preferably, for example, 1.0 to 3.0 mm. The wire diameters of coils 1 and 2 can be equal, or they can be different.

[0048] Coil 2 can be wound onto the outer periphery of the core portion 30 using an automatic winding machine, for example. Coil 1 can also be wound onto the winding portion 20 using an automatic winding machine.

[0049] like Figure 3 As shown, a lead frame 32 for winding a coil is formed above the flange portion 31 in the Z-axis direction. A cutout portion 320 is formed on the lead frame 32, which cuts from the outer surface 31a in the X-axis direction to the inner surface 31b in the X-axis direction. The lead portions 11 and 21 are led out from the winding portions 10 and 20 in the X-axis direction through the cutout portion 320.

[0050] like Figure 3 As shown, a lead-out passage 321 is formed on the lead-out platform 32, which winds the lead-out portion 11 to one side in the Y-axis direction. A lead-out passage 322 is formed on the lead-out platform 32, which winds the lead-out portion 21 to the other side in the Y-axis direction. Engaging holes 3a and 3b for mounting a cover are formed on the lead-out platform 32.

[0051] like Figure 3 As shown, a lead frame 42 for winding the lead portion of the coil is formed above the flange portion 41 in the Z-axis direction. A cut portion 420 is formed on the lead frame 42, which cuts from the outer surface 41a in the X-axis direction to the inner surface 41b in the X-axis direction. The lead portions 12 and 22 are led out from the winding portions 10 and 20 in the X-axis direction through the cut portion 420.

[0052] like Figure 3 As shown, a lead-out passage 421 is formed on the lead-out platform 42, through which the lead wire 12 is wound in the Y-axis direction. Additionally, a lead-out passage 422 is formed on the lead-out platform 42, through which the lead wire 22 is wound in the Y-axis direction. Engaging holes 3c and 3d for mounting a cover are formed on the lead-out platform 42.

[0053] like Figure 3 As shown, mounting portions 33 and 43 are formed below the flange portions 31 and 41 in the Z-axis direction, respectively. Figure 8 As shown, the mounting parts 33 and 43 are mounted on the bottom of the housing 300.

[0054] like Figure 2 as well as Figure 4As shown, core 9 can be divided into core 9a and core 9b. Core 9a and core 9b are respectively so-called E-shaped cores, but are not limited to this; for example, they can also be formed by appropriately combining U-shaped cores, plate cores, etc. The material of core 9 can include magnetic materials such as metals and ferrites, but there is no particular limitation. In addition, cores 9a and 9b can be made of the same material, but they do not have to be made of the same material.

[0055] like Figure 4 As shown, the core 9a has outer legs 9a1 and 9a2, a middle leg 9a3, and a base 9a4. The outer leg 9a1 extends from one end of the base 9a4 in the Y-axis direction toward the inside in the X-axis direction. The outer leg 9a2 extends from the other end of the base 9a4 in the Y-axis direction toward the inside in the X-axis direction.

[0056] like Figure 4 As shown, the middle leg portion 9a3 is located between the outer legs 9a1 and 9a2, extending from approximately the center of the base 9a4 in the Y-axis direction toward the inner side in the X-axis direction. The middle leg portion 9a3 is inserted into the through hole 30a of the core portion 30 of the spool 3 (see reference). Figure 3 The outer legs 9a1 and 9a2 are located on the outside of the through hole 30a.

[0057] like Figure 4 As shown, core 9b has outer legs 9b1 and 9b2, middle legs 9b3, and a base 9b4, all of which have a shape approximately symmetrical along the X-axis to core 9a. The middle leg 9b3 is mated to the middle leg 9a3 inside the through hole 30a of the linear shaft 3 (see reference). Figure 8 The outer leg 9b1 is mated to the outer leg 9a1 on one side of the through hole 30a in the Y-axis direction. The outer leg 9b2 is mated to the outer leg 9a2 on the other side of the through hole 30a in the Y-axis direction. Alternatively, the core 9a and core 9b can be configured without mating, with an appropriate gap.

[0058] like Figure 5 As shown, the cover 5 has a plate-shaped cover body 50. Additionally, the cover 5 has terminals 71, 72, 81, and 82 mounted on the cover body 50. The cover body 50 is constructed of insulating components. Examples of such insulating components include plastics such as PPS, PET, PBT, and LCP. The cover body 50 can be made of the same material as the spool 3, but they do not necessarily have to be the same material. The terminals 71, 72, 81, and 82 can be easily formed from conductive plates such as copper plates through stamping or other processes. Furthermore, a plating layer of tin or the like can be formed on the surfaces of the terminals 71, 72, 81, and 82.

[0059] like Figure 5As shown, terminal 71 has a wiring portion 71a for connecting to the lead portion of a coil, an external connection portion 71c, and an intermediate portion 71b connecting the external connection portion 71c to the wiring portion 71a. Terminal 71 can be assembled to cover body 50 by a suitable method. Specifically, press-in holes 511-514 can be formed on cover body 50 at positions corresponding to mounting claws 711-714 of terminal 71, and terminal 71 is assembled to a predetermined position on cover body 50 by pressing mounting claws 711-714 into the press-in holes 511-514 respectively.

[0060] like Figure 6 As shown, the middle portion 71b is configured along the upper surface (surface) 50a of the cover body 50. The wiring portion 71a is formed in a manner that is positioned inside the upper surface (surface) 50a of the cover body 50 in the Z-axis direction. In addition, the external connecting portion 71c protrudes outward from the upper surface (surface) 50a of the cover body 50 in the Z-axis direction.

[0061] like Figure 5 As shown, terminal 72 also has an external connection portion 72c, a wiring portion 72a, and an intermediate portion 72b, just like terminal 71. Terminal 72, like terminal 71, can be assembled at a predetermined position on the cover body 50 by pressing mounting claws 721-724 into the pressing holes 521-524, respectively.

[0062] like Figure 6 As shown, the middle portion 72b is configured along the upper surface 50a of the cover body 50. The wiring portion 72a is formed in a manner that is positioned inside the upper surface 50a of the cover body 50 in the Z-axis direction. In addition, the external connecting portion 72c protrudes outward from the upper surface 50a of the cover body 50 in the Z-axis direction.

[0063] like Figure 5 As shown, terminal 81 also has an external connection portion 81c, a wiring portion 81a, and an intermediate portion 81b, just like terminal 71. Terminal 81, like terminal 71, can be assembled at a predetermined position on the cover body 50 by pressing the mounting claws 811-813 into the pressing holes 611-613, respectively.

[0064] like Figure 6 As shown, the middle portion 81b is configured along the upper surface (surface) 50a of the cover body 50. The wiring portion 81a is formed in a manner that is positioned inside the upper surface (surface) 50a of the cover body 50 in the Z-axis direction. In addition, the external connecting portion 81c protrudes outward from the upper surface (surface) 50a of the cover body 50 in the Z-axis direction.

[0065] like Figure 5As shown, terminal 82 also has an external connection portion 82c, a wiring portion 82a, and an intermediate portion 82b, just like terminal 72. Terminal 82, like terminal 72, can be assembled at a predetermined position on the cover body 50 by pressing mounting claws 821-823 into the pressing holes 621-623, respectively.

[0066] like Figure 6 As shown, the middle portion 82b is configured along the upper surface (surface) 50a of the cover body 50. The wiring portion 82a is formed in a manner that is positioned inside the upper surface (surface) 50a of the cover body 50 in the Z-axis direction. In addition, the external connecting portion 82c protrudes outward from the upper surface (surface) 50a of the cover body 50 in the Z-axis direction.

[0067] Thus, in this embodiment, terminals 71, 72, 81, and 82 are pressed into the cover body 50. Furthermore, the assembly method for assembling terminals into the cover body 50 is not limited to pressing. For example, terminals can be assembled into the cover body 50 by embedding, such as by surrounding the terminals with insulating components to form the cover body 50, or by attaching them to the surface of the cover body with an adhesive.

[0068] like Figure 6 As shown, engaging claws 5a to 5d are formed on the cover body 50. Engaging claw 5a engages with the engaging hole 3a of the spool. Engaging claw 5b engages with the engaging hole 3b of the spool. Engaging claw 5c engages with the engaging hole 3c of the spool. Engaging claw 5d engages with the engaging hole 3d of the spool. By engaging each engaging claw with the engaging hole in this way, it can be easily installed on the spool 3. The cover 5 is configured such that the cover body 50 bridging one flange 31 of the spool 3 with the other flange 41 along the X-axis direction (see reference). Figure 7 Therefore, foreign objects are less likely to get into the winding section during assembly.

[0069] The cover body 50 is configured to connect one of the outer legs 9a1, 9b1 of the core 9 to the other outer legs 9a2, 9b2 (see reference). Figure 7 By assembling the cover 5 onto the spool 3 in this way, in this embodiment, the upper part of the coil winding portion in the Z-axis direction is completely covered by the cover 5, but the coil winding portion may also be partially exposed.

[0070] In addition, Figure 6 The image shows the state of the core 9 assembled on the spool 3 before the cover 5 is assembled on the spool, but the order of assembly is not particularly limited. Alternatively, the cover 5 can be assembled on the spool 3, and then the core 9 can be installed on the spool 3 after the connection work between the terminal and the lead is completed.

[0071] In this embodiment, the lower surface 50b of the cover body 50 may or may not abut against the upper surface 911 on the side of the outer legs 9a1 and 9b1 and the upper surface 921 on the side of the outer legs 9a2 and 9b2. By having the lower surface 50b abut against the upper surface 911 on the side of the outer legs 9a1 and 9b1 and the upper surface 921 on the side of the outer legs 9a2 and 9b2, the cover body 50 can more effectively protect the winding portions 10 and 20.

[0072] Figure 7 This is a top view of the coil device 100 as observed from above along the Z-axis. (Example) Figure 7 As shown, the wiring portion 71a of terminal 71 extends along the X-axis direction and is positioned above the upper surface 911 of the outer leg portion 9a1 of core 9 in the Z-axis direction (see reference). Figure 1 The wiring portion 71a clamps the lead portion 11 extending along the Y-axis direction outside the cover body 50 and the lead frame 32. Furthermore, the wiring portion 71a is positioned inside the outer surface 910 in the width direction (Y-axis direction) of the core 9. Additionally, the wiring portion 71a is positioned inside the outer surface 31a in the X-axis direction of the flange portion 31. The intermediate portion 71b connects the wiring to the outer connecting portion 71c at the end of the wiring portion 71a located inside the X-axis direction.

[0073] like Figure 7 As shown, the wiring portion 72a of terminal 72 extends along the X-axis direction and is positioned above the upper surface 911 of the outer leg portion 9b1 side of core 9 in the Z-axis direction (see reference). Figure 1 The wiring portion 72a clamps the lead portion 12 extending along the Y-axis direction outside the cover body 50 and the lead frame 42. Furthermore, the wiring portion 72a is positioned inside the outer surface 910 in the width direction (Y-axis direction) of the core 9. Additionally, the wiring portion 72a is positioned inside the outer surface 41a in the X-axis direction of the flange portion 41. The intermediate portion 72b connects the wiring to the outer connecting portion 72c at the inner end of the wiring portion 72a along the X-axis direction.

[0074] like Figure 7 As shown, the wiring portion 81a of terminal 81 extends along the X-axis direction and is positioned above the upper surface 921 of the outer leg portion 9a2 side of core 9 in the Z-axis direction (see reference). Figure 1 The wiring portion 81a clamps the lead portion 21 extending along the Y-axis direction outside the cover body 50 and the lead frame 32. Furthermore, the wiring portion 81a is positioned inside the outer surface 920 in the width direction (Y-axis direction) of the core 9. Additionally, the wiring portion 81a is positioned inside the outer surface 31a in the X-axis direction of the flange portion 31. The intermediate portion 81b connects the wiring to the outer connecting portion 81c at the end of the wiring portion 81a located inside the X-axis direction.

[0075] like Figure 7As shown, the wiring portion 82a of terminal 82 extends along the X-axis direction and is positioned above the upper surface 921 of the outer leg portion 9b2 of core 9 in the Z-axis direction (see reference). Figure 1 The wiring portion 82a clamps the lead portion 22 extending along the Y-axis direction outside the cover body 50 and the lead frame 42. Furthermore, the wiring portion 82a is positioned inside the outer surface 920 in the width direction (Y-axis direction) of the core 9. Additionally, the wiring portion 82a is positioned inside the outer surface 41a in the X-axis direction of the flange portion 41. The intermediate portion 82b connects the wiring to the outer connecting portion 82c at the inner end of the wiring portion 82a along the X-axis direction.

[0076] like Figure 7 As shown, the external connection portion 71c is positioned closer to the winding shaft C (center side) than the wiring portion 71a. Similarly, the external connection portion 72c is positioned closer to the winding shaft C than the wiring portion 72a. The external connection portion 81c is also positioned closer to the winding shaft C than the wiring portion 81a. The external connection portion 82c is also positioned closer to the winding shaft C (center side) than the wiring portion 82a.

[0077] like Figure 7 As shown, when viewed along the Z-axis, the terminal wiring portions 71a, 72a, 81a, and 82a are located on the outer surfaces 910, 920, 9a40, and 9b40 of the core 9 near the center. Additionally, the terminal external connection portions 71c, 72c, 81c, and 82c are located on the outer surfaces 910, 920, 9a40, and 9b40 of the core 9 near the center.

[0078] like Figure 1 As shown, in the coil assembly 100, the cover 5 functions as a terminal block. The mounting method of the coil assembly 100 is not particularly limited, but the coil assembly 100 can be mounted by, for example, by having the upper surface (surface) 50a of the cover 5 in contact with a wiring board (not shown). When the coil assembly 100 is mounted in this way, as... Figure 7 As shown, no terminals are provided on the outer surfaces of the core 910, 920, 9a40, and 9b40, resulting in a smaller mounting area for the coil assembly 100.

[0079] like Figure 1 As shown, the external connecting portions 71c, 72c, 81c, and 82c protrude upwards in the Z-axis direction from the upper surface (surface) 50a of the cover body 50. With this configuration, it is easy to install by inserting the external connecting portions 71c, 72c, 81c, and 82c into the holes formed in the wiring board, and the installation strength is improved.

[0080] like Figure 8As shown, the cover 5 covers the area above the winding portions 10 and 20 of the coil in the Z-axis direction. Therefore, during installation, foreign objects can be prevented from entering the winding portions 10 and 20 in the coil assembly 100. Furthermore, the cover body 50 can insulate the terminals 71, 72, 81, and 82 disposed on the upper surface 50a from the winding portions 10 and 20, and provides the external connecting portions 71c, 72c, 81c, and 82c on the central side of the cover body 50 (see reference). Figure 1 Therefore, the mounting area when mounting the coil device 100 on the wiring board or the like can be reduced.

[0081] In such a coil device 100, such as Figure 7 As shown, the lead-out positions can be freely designed on the cover 5, increasing the freedom of the removal positions of terminals 71, 72, 81, and 82. In this embodiment, the external connecting portions 71c, 72c, 81c, and 82c are disposed between the outer surfaces 31a and 41a of the two flange portions of the spool. Therefore, the coil assembly 100 can reduce the mounting area while improving insulation performance.

[0082] like Figure 7 As shown, the cover body 50 is configured to bridging one flange 31 of the bobbin 3 with the other flange 41. The cover body 50 is also configured to bridging one outer leg 9a1, 9b1 of the core 9 with the other outer leg 9a2, 9b2. Therefore, the cover 5 provides more reliable protection for the coil winding portions 10, 20, further improving insulation. Furthermore, in the coil assembly 100, since the cover 5, which includes terminals 71, 72, 81, 82, is positioned inside the bobbin and core in the X-axis and Y-axis directions, the product can be miniaturized.

[0083] like Figure 7 As shown, the wiring portions 71a, 72a, 81a, and 82a are positioned closer to the inner side of the outer surfaces 910 and 920 in the Y-axis direction of the core 9. This configuration ensures that the wiring portions 71a, 72a, 81a, and 82a do not protrude from the core 9 during or after the manufacturing process of the coil assembly 100, effectively protecting them and improving their reliability. Furthermore, it also contributes to space saving.

[0084] like Figure 7As shown, lead portions 11 and 12 extend towards the outer surface 910 of the core 9 along the Y-axis direction. Additionally, lead portions 21 and 22 extend towards the outer surface 920 of the core 9 along the Y-axis direction. Wiring portions 71a, 72a, 81a, and 82a are disposed outside the spool and the cover body. When the cover 5 is assembled onto the spool 3 and the terminals and lead portions are connected, and then the core 9 is installed onto the spool 3, the spaces above and below the wiring portions 71a, 72a, 81a, and 82a are left empty before the core 9 is installed onto the spool 3. In this case, the lead portions 11, 12, 21, and 22 of the coil can be easily connected to the wiring portions 71a, 72a, 81a, and 82a by means of heat bonding or other joining methods, simplifying manufacturing. Furthermore, as... Figure 7 As shown, since the wiring portions 71a, 72a, 81a, and 82a are arranged inside the outline of the coil device 100, poor connection caused by contact with other devices is less likely to occur during the manufacturing process, and the installation area of ​​the coil device can be reduced.

[0085] The connection between the terminals and the coil leads can be achieved, for example, by removing the insulating coating from the leads and performing heat bonding such as melting. Alternatively, the terminals and leads can be joined using appropriate methods such as soldering or laser welding.

[0086] Although not illustrated, potting resin can be injected into the interior of the housing 300 in a manner that brings it into contact with the coil assembly 100. The potting resin can be injected into the housing 300 after the coil assembly 100 is housed within it, or it can be injected into the housing 300 beforehand. Furthermore, the potting resin does not need to cover the entire coil assembly 100; it can be injected into the housing 300 beforehand to cover only a portion of the coil assembly 100.

[0087] The coil assembly 100 improves insulation performance and saves space. Furthermore, the coil assembly 100 has a simple structure and can be easily assembled.

[0088] (Second Implementation)

[0089] like Figure 9 As shown, the structure of the spool and core of the coil device 200 in this embodiment differs from that of the coil device 100 in the first embodiment, but other structures are common and it performs the same function as the coil device 100 in the first embodiment. In the following description, the parts common to the first embodiment are omitted as much as possible, and the same reference numerals as those in the first embodiment are used where necessary.

[0090] like Figure 9As shown, the coil device 200 of this embodiment includes a bobbin 3_1 and an auxiliary bobbin 3_2. The bobbin 3_1 generally has a core portion 30_1 extending along the X-axis and flange portions 31_1 and 41_1 at both ends of the core portion 30_1 in the X-axis direction.

[0091] The auxiliary spool 3_2 has an auxiliary core portion 30_2 extending along the X-axis. One end of the auxiliary core portion 30_2 in the X-axis direction is connected to the spool 3_1. An auxiliary flange portion 41_2 is formed at the other end of the auxiliary core portion 30_2 in the X-axis direction.

[0092] The through hole 30_1a of the core portion 30_1 communicates with the auxiliary through hole 30_2a of the auxiliary core portion 30_2. An E-shaped core 9a's middle leg 9a3 is inserted into the through hole 30_1a. An I-shaped core 9c is positioned in the through hole 30_1a of the core portion 30_1. The core 9c and the E-shaped core 9a abut against each other inside the through hole 30_1a.

[0093] The middle leg 9b3 of the E-shaped core 9b is inserted into the auxiliary through hole 30_2a. The E-shaped core 9b abuts against the side of the core 9c opposite to the side of the E-shaped core 9a. This forms the core 9_1.

[0094] Similar to the first embodiment, a winding portion 20 of the coil 2 is formed on the outer periphery of the core portion 30_1. The lead portion 22 of the coil 2 is led out from the winding portion 20 through the cut portion 420 formed in the flange portion 41_1 to the auxiliary spool 3_2.

[0095] The core portion 30_1 of the spool 3_1 has a winding portion 10 of the coil 1 formed on the outside of the winding portion 20. In the coil 1, the intermediate portion 10_1 led out from the winding portion 10 is led out to the auxiliary spool 3_2 through the cut portion 420.

[0096] In this embodiment, the lead portion 22 of the coil 2 is connected to the terminal without being wound around the auxiliary spool 3_2. The coil 1 is wound around the auxiliary core portion 30_2 of the auxiliary spool 3_2 to form the winding portion 10.

[0097] Thus, in this embodiment, coil 1 is wound across bobbin 3_1 and auxiliary bobbin 3_2. With this configuration, leakage flux can be adjusted more easily in the coil device 200, and multiple components with different functions can be easily integrated. For example, in the coil device 200, the coil wound on bobbin 3_1 can function as a transformer, and the coil wound on auxiliary bobbin 3_2 can function as an inductor.

[0098] like Figure 9As shown, the cover 5 is mounted on the spool 3_1 such that the cover body 50 bridging one flange 31_1 and the other flange 41_1 of the spool 3_1 along the X-axis direction. By mounting the cover 5 to the spool 3_1 in this way, the portion of the coil wound on the spool 3_1 above the core portion 30_1 in the Z-axis direction is covered by the cover 5. On the other hand, the portion of the coil wound on the auxiliary core portion 30_2 of the auxiliary spool 3_2 is exposed. Thus, even with partial exposure of the coil portion, sufficient insulation performance can be achieved.

[0099] The above embodiments mainly illustrate applications for transformers, but they can also be applied to coil devices other than transformers.

[0100] 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. Additionally, the structures of each embodiment can be appropriately recombined for application.

[0101] In the above embodiments, the wiring portions are arranged separately at the four corners of the core, but it is not limited to this. For example, it can also be arranged on the upper side of the outer leg or the upper side of the base, which is closer to the core.

[0102] In the above embodiments, a horizontally mounted coil device with the coil winding axis parallel to the mounting surface such as the wiring board has been described. However, the present invention can also be applied to a so-called vertically mounted coil device with the winding axis perpendicular to the mounting surface such as the wiring board.

Claims

1. A coil device comprising: spool; A coil having a winding portion wound around the spool; Terminals, which are connected to the coil; and A cover that protects the wound section. The cover has a cover body that covers the outer side of the winding portion in the height direction perpendicular to the winding axis. The terminal is assembled onto the cover body. The terminal has: a wiring portion for connecting a lead portion extending from the winding portion; and an external connection portion connected to the wiring portion.

2. The coil device according to claim 1, characterized in that, When viewed along the height direction, the external connection portion is positioned closer to the winding shaft than the wiring portion.

3. The coil device according to claim 1, characterized in that, The cover body is configured to bridge the flange of one side of the spool with the flange of the other side.

4. The coil device according to claim 3, characterized in that, The external connecting portion is disposed between the two flange portions of the spool.

5. The coil device according to claim 1, characterized in that, The cover body is configured to bridging the outer leg of one side of the core mounted on the spool with the outer leg of the other side.

6. The coil device according to any one of claims 1 to 5, characterized in that, The connector is positioned inside the outer surface of the core assembled on the spool in the width direction.

7. The coil device according to any one of claims 1 to 5, characterized in that, When viewed along the height direction, the wiring portion is located outside the spool and the cover body.

8. The coil device according to any one of claims 1 to 5, characterized in that, The external connecting portion protrudes from the surface of the cover body.

9. The coil device according to any one of claims 1 to 5, characterized in that, The terminals are pressed into or embedded in the cover body.

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