Coil component

Abstract

The utility model provides a coil component which ensures insulation between a coil and a metal piece and insulation between wire turns of the coil. A coil component (10) is provided with: a coil (2) formed by connecting a plurality of U-shaped members (21, 22) and I-shaped members (23, 24, 25) having a thickness of 5 mm or more; a mounting metal member (4) that includes a metal member and fixes the coil component (10) to a mounting target surface; and an insulating member (6) disposed between the coil (2) and the installation fitting (4). The peripheries of the U-shaped members (21, 22) and the I-shaped members (23, 24, 25) are not covered by an insulating film. A fitting hole (45) is formed in the setting fitting (4). The insulating member (6) has: a coil support section (61) into which each turn of the coil (2) is inserted and into which each turn is fitted; and a projection (63) that fits into the fitting hole (45) and fixes the insulating member (6) to the mounting fitting (4).

Description

Technical Field

[0001] This utility model relates to a coil component. Background Technology

[0002] Coil components, such as reactors or transformers, are used in the power circuits of various electronic devices, including office automation (OA) equipment, solar power systems, automobiles, and chargers. A reactor is an electromagnetic component that converts electrical energy into magnetic energy and then stores and releases it. A transformer is an electronic component that uses electromagnetic induction to change the voltage level of alternating current.

[0003] The coil components include a core and a coil. When electricity is supplied to the coil, the coil generates magnetic flux. The core contains a magnetic material through which the magnetic flux generated by the coil passes. The coil components include a metal fitting to secure the coil components to an object. The metal fitting is a metal component positioned below the coil.

[0004] [Patent Document 1] Japanese Patent No. 5813160. Utility Model Content

[0005] [The problem that the utility model aims to solve]

[0006] In coil components, large currents exceeding 500 A sometimes flow. Therefore, even when large currents flow, insulation between the coil and the metal components is necessary. Furthermore, because flat wires with a thickness of approximately 1 mm cannot be used to allow large currents to flow in the coil, the coil is formed by connecting thick conductive components. Since the conductive components are not surrounded by an insulating film, insulation between each turn is required.

[0007] This utility model is made to solve the aforementioned problem, and its purpose is to provide a coil component that ensures insulation between the coil and the metal component and insulation between the turns of the coil.

[0008] [Technical means to solve the problem]

[0009] The coil component of this utility model includes: a coil formed by connecting multiple conductive members with a thickness of 5 mm or more; a mounting metal member comprising the metal members and fixing the coil component to a mounting surface; and an insulating member disposed between the coil and the mounting metal member, wherein the plurality of conductive members are not surrounded by an insulating film. A fitting hole is formed in the mounting metal member. The insulating member has: a coil support portion for inserting and fitting each turn of the coil; and a protrusion that fits into the fitting hole and fixes the insulating member to the mounting metal member.

[0010] In one embodiment of this utility model, the coil component further includes: a core for mounting the coil; and a core housing for insulating the core from the coil. The core housing has a plurality of ribs extending in a manner that clamps the turns of the coil.

[0011] In one embodiment of the present invention, the rib has a reinforcing portion that extends in a direction orthogonal to the extending direction of the rib.

[0012] In one embodiment of this utility model, the conductive member has a fastening portion connected to an adjacent conductive member. The coil component further includes a resin cover surrounding the fastening portion. The resin cover has a fastening portion receiving space, which utilizes a top plate and a plurality of wall portions to successively surround the connection portion of the conductive member adjacent to the fastening portion.

[0013] In one embodiment of this invention, the resin cover has at least one of its wall portions a coil insertion port for the conductive member to pass through. The coil insertion port is fitted into the conductive member.

[0014] In one embodiment of this utility model, the coil component further includes: a core for mounting the coil; a core housing for insulating the core from the coil; and a fixing metal member fitted into the core housing and fixed to the mounting metal member, wherein the fixing metal member has a protrusion protruding toward the resin cover. The protrusion abuts against the resin cover.

[0015] In one embodiment of this invention, the conductive component comprises a U-shaped component and an I-shaped component. The coil is formed by alternately connecting the U-shaped component and the I-shaped component.

[0016] In one embodiment of this invention, the mounting surface is a wall extending in a direction parallel to gravity. When the coil component is fixed to the mounting surface, the winding axis of the coil is parallel to gravity.

[0017] [Effects of the utility model]

[0018] This invention provides a coil component that ensures insulation between the coil and the metal component, as well as insulation between the coil's turns. Attached Figure Description

[0019] Figure 1 It is a three-dimensional diagram showing the main structure of the coil component.

[0020] Figure 2 It is an exploded 3D diagram of the coil.

[0021] Figure 3 It is a three-dimensional diagram showing the state in which the core is covered by a core shell.

[0022] Figure 4 This is an exploded 3D view of the core and shell.

[0023] Figure 5 It is a three-dimensional diagram showing the overall structure of the coil components.

[0024] Figure 6 It is a 3D model of the metal parts.

[0025] Figure 7 This is a diagram showing the configuration of fixing the coil components to the object being set.

[0026] Figure 8 It is a 3D view of the fixed metal part.

[0027] Figure 9 It is a three-dimensional diagram of the insulating component.

[0028] Figure 10 This is a three-dimensional view of the insulating components from the bottom.

[0029] Figure 11 This is a three-dimensional view of the resin cover from the bottom.

[0030] Explanation of icon numbers

[0031] 10: Coil components

[0032] 1: core

[0033] 11: Feet

[0034] 12: Magnetic yoke

[0035] 2: Coil

[0036] 21, 22: U-shaped components

[0037] 23, 24, 25: I-shaped components

[0038] 26: Fastening part

[0039] 3: Core and shell

[0040] 31, 32: Foot coverings

[0041] 33, 34: Yoke covering part

[0042] 35: Positioning Department

[0043] 36, 36a, 36b: Ribs

[0044] 361: Enhancement Department

[0045] 4: Install metal parts

[0046] 41: Long side wall

[0047] 42: Short sidewall

[0048] 43: Fixing part

[0049] 44: Fixing part

[0050] 45: Fitting hole

[0051] 5: Fixing metal parts

[0052] 51: Foot Covered Area

[0053] 511: Positioning hole

[0054] 512: Extension Section

[0055] 513: Protrusion

[0056] 52: Yoke covering part

[0057] 521: Extension Section

[0058] 522: Fixing part

[0059] 6: Insulating components

[0060] 61: Coil support section

[0061] 62: Connecting part

[0062] 63: convex part

[0063] 7: Resin Cover

[0064] 71: Fastening Part Reception Space

[0065] 711: Top Plate

[0066] 712: Wall section

[0067] 72: Coil insertion port

[0068] 8: Insulating sheet

[0069] 91: Fasteners

[0070] 92: Fasteners Detailed Implementation

[0071] [Implementation Method]

[0072] The coil component of the embodiment will be described with reference to the accompanying drawings. In the drawings, for ease of understanding, thickness, dimensions, positional relationships, ratios, or shapes are sometimes emphasized; however, the present invention is not limited to these emphasized aspects.

[0073] Figure 1 This is a perspective view showing the main structure of the coil component. Coil component 10 (refer to...) Figure 5 It is used as an electronic device such as a reactor or transformer. In the coil component 10 of this embodiment, a large current of 500 A or more, for example 1000 A, flows. Figure 1 As shown, the coil component 10 includes a core 1 and a coil 2.

[0074] Core 1 contains a magnetic material, such as a pressed powder core, a ferrite core, a laminated steel plate, or a metal composite core. A metal composite core is a magnetic material formed by mixing magnetic powder with resin and then hardening the resin.

[0075] The core 1 has a pair of legs 11 and a pair of yokes 12. The legs 11 extend in a straight line parallel to the winding axis of the coil 2. The pair of legs 11 are arranged laterally side by side with their extension directions parallel. The yokes 12 connect the pair of legs 11, and the core 1 is in the shape of a ring.

[0076] There are three coils 2, which are installed in one of the feet 11. Figure 2 This is an exploded perspective view of coil 2. Coil 2 is formed by U-shaped components 21, 22, 23, 24, and 25. U-shaped components 21, 22, 23, 24, and 25 include conductive components such as copper plates. U-shaped components 21, 22, 23, 24, and 25 are plate-shaped components. The area around U-shaped components 21, 22, 23, 24, and 25 is not insulated with enamel or similar materials.

[0077] Because a large current of 500 A or more flows through them, the thickness t of the U-shaped members 21, 22, 23, 24, and 25 is at least 5 mm. In this embodiment, the thickness t of the U-shaped members 21, 22, 23, 24, and 25 is 8 mm. Furthermore, because a large current of 500 A or more flows through them, the width d of the U-shaped members 21, 22, 23, 24, and 25 is at least twice the thickness t of the U-shaped members 21, 22, 23, 24, and 25. In this embodiment, the width d of the U-shaped members 21, 22, 23, 24, and 25 is 42 mm.

[0078] The U-shaped components 21, 22, 23, 24, and 25 are arranged such that the I-shaped components 23, 24, and 25 are sandwiched between the U-shaped components 21 and 22. That is, when viewed from one side along the winding axis, the I-shaped components 23, 21, 24, 22, and 25 are arranged sequentially. Furthermore, the U-shaped components 21 and 22 are identical in shape and size, as are the I-shaped components 23 and 25.

[0079] Fastening portions 26 are formed in U-shaped components 21, U-shaped components 22, I-shaped components 23, I-shaped components 24, and I-shaped components 25. The fastening portion 26 is a hole. For example... Figure 1 As shown, the fastening portions 26 of adjacent U-shaped members 21, U-shaped members 22, and I-shaped members 23, I-shaped members 24, and I-shaped members 25 are overlapped and fastened using bolts or other fasteners 91, thereby connecting and fixing the adjacent U-shaped members 21, U-shaped members 22, and I-shaped members 23, I-shaped members 24, and I-shaped members 25. In this way, the coil 2 is formed into a single coil turn by multiple conductive members.

[0080] As a method for installing coil 2, firstly, core 1 is housed in core housing 3 (described later). An I-shaped member 23 is inserted inside the annular core 1 housed in core housing 3. Then, the foot 11 of core 1 is inserted inside U-shaped member 21, aligning the fastening portion 26 of I-shaped member 23 with the fastening portion 26 of U-shaped member 21, and secured using fastener 91. When the securing is complete, an I-shaped member 24 is inserted into core 1, and U-shaped member 21 and I-shaped member 24 are secured using fastener 91. By repeating the same operation on U-shaped member 22 and I-shaped member 25, coil 2 is formed, and coil 2 is installed on the foot 11 of core 1.

[0081] Figure 3 This is a three-dimensional diagram showing the state in which core 1 is covered by core shell 3. For example... Figure 3 As shown, the coil component 10 includes a core housing 3. The core housing 3 contains a resin, and examples of resins include epoxy resin, unsaturated polyester resin, urethane resin, bulk molding compound (BMC), polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), or composites thereof. Alternatively, thermosetting resins such as phenolic resins may also be used as the resin for the core housing 3. Furthermore, thermally conductive fillers may be mixed into the resin.

[0082] The core housing 3 exists between the core 1 and the coil 2, thus insulating the core 1 from the coil 2. Therefore, it is sufficient for the core housing 3 to simply cover the area around the core 1, which is equipped with the coil 2. In this embodiment, the core housing 3 covers the entire area around the core 1. That is, the core housing 3 has a foot covering portion 31, a foot covering portion 32, a yoke covering portion 33, and a yoke covering portion 34.

[0083] Foot cover 31 covers the foot 11 on which the coil 2 is installed. Foot cover 32 covers the foot 11 without the coil. Magnetic yoke cover 33 and magnetic yoke cover 34 each cover a pair of magnetic yokes 12. The foot cover 31 insulates the core 1 from the coil 2, and the foot cover 32, magnetic yoke cover 33, and magnetic yoke cover 34 insulate the fixing metal part 5 (described later) from the core 1.

[0084] The core housing 3 has a positioning part 35. The positioning part 35 is provided on the outer peripheral surface of the foot cover 32. The outer peripheral surface of the foot cover 32 is the side opposite to the inner peripheral surface of the foot cover 32 that faces the foot cover 31. The positioning part 35 protrudes from the foot cover 32. The positioning part 35 is inserted into the positioning hole 511 of the fixing metal member 5 described later. The positioning part 35 protrudes in a roughly H-shape when viewed from above. Four positioning parts 35 are provided. In addition, the vertical direction refers to the direction orthogonal to the wide surface of the mounting metal member 4 described later. When fixing the mounting metal member 4 to the mounting target surface, the direction facing the mounting target surface is called downward, and the direction away from the mounting target surface is called upward.

[0085] Figure 4 This is an exploded perspective view of the core shell 3. (See image below.) Figure 4 As shown, the core housing 3 is divided into two parts. The core housing 3 houses the core 1 inside. Alternatively, the core housing 3 can also be formed around the core 1 by molding.

[0086] The core housing 3 has a plurality of ribs 36. The ribs 36 are disposed on the annular surface (annular surface of the core housing 3) of the foot cover 31 on which the coil 2 is mounted. The ribs 36 extend downward from the upper end of the foot cover 31. Each rib 36 has a rib 36a with a longer protruding length and a rib 36b with a shorter protruding length than the rib 36a. Ribs 36a and ribs 36b are provided in the same number and are arranged alternately. Ribs 36a and ribs 36b form a group, and the turns of the coil 2, more specifically, U-shaped members 21 or U-shaped members 22, are disposed between ribs 36a and ribs 36b. Furthermore, without distinguishing between ribs 36a and ribs 36b, they are simply referred to as ribs 36.

[0087] The spacing between adjacent ribs 36a and 36b is approximately the same as or slightly greater than the thickness t of coil 2, i.e., the thickness t of U-shaped components 21 and 22. Ribs 36a and 36b can also be bonded to U-shaped components 21 and 22 using adhesives or the like.

[0088] Rib 36 has a reinforcing portion 361. The reinforcing portion 361 extends from the side of rib 36 parallel to the winding axis of coil 2. That is, the reinforcing portion 361 extends in a direction orthogonal to the extending direction of rib 36. Multiple reinforcing portions 361 are provided in each rib 36.

[0089] Figure 5 This is a perspective view showing the overall structure of coil component 10. (Example) Figure 5 As shown, the coil component 10 includes: a metal part 4, a metal part 5, an insulating member 6, and a resin cover 7.

[0090] Metal component 4 is a member used to fix coil component 10 to the surface to which it is to be installed. Metal component 4 is formed of a metal component such as aluminum. Metal component 4 is flat.

[0091] Figure 6 This is a perspective view of the metal component 4. The metal component 4 includes: a long side wall 41, a short side wall 42, a fixing part 43, a fixing part 44, and a fitting hole 45. The long side wall 41 rises upwards from the long side of the metal component 4. The short side wall 42 rises upwards from the short side of the metal component 4. The rising height of the short side wall 42 is greater than that of the long side wall 41. A fixing part 43, serving as a hole, is formed in the short side wall 42. Two fixing parts 43 are provided in the central portion of each short side wall 42. The fixing parts 43 fix the metal component 5.

[0092] The fixing part 44 is a hole for fixing the coil part 10 to the surface to which it is to be installed. By inserting and tightening fasteners such as bolts into the fixing part 44, the coil part 10 is fixed to the surface to which it is to be installed. Four fixing parts 44 are provided. The four fixing parts 44 are respectively provided at the four corners of the metal part 4.

[0093] The fitting hole 45 is a hole formed on the wide surface of the metal part 4. The protrusion 63 of the insulating member 6 is inserted into the fitting hole 45. The size of the fitting hole 45 is the same as the size of the protrusion 63 of the insulating member 6. The number of fitting holes 45 is only required to secure the insulating member 6.

[0094] Figure 7 This diagram shows the arrangement of the coil component 10 fixed to the surface to which it is to be installed. In this embodiment, the surface to which the coil component 10 is to be installed is a wall that extends parallel to gravity. That is, the coil component 10 is arranged such that the winding axis of the coil 2 is parallel to gravity.

[0095] The fixing metal part 5 is formed of a metal component such as aluminum. For example... Figure 5 As shown, the fixing metal member 5 covers the periphery of the core housing 3. The fixing metal member 5 has: a foot covering portion 51 and a pair of magnetic yoke covering portions 52. The foot covering portion 51 and the pair of magnetic yoke covering portions 52 are flat. The magnetic yoke covering portions 52 extend from both ends of the foot covering portion 51, and the fixing metal member 5 has a generally U-shaped shape. The foot covering portion 51 covers the foot portion 11 covered by the foot covering portion 32 of the core housing 3. The magnetic yoke covering portions 52 cover the magnetic yoke portions 12 covered by the magnetic yoke covering portions 33 and 34 of the core housing 3, respectively.

[0096] Figure 8 This is a three-dimensional view of the fixed metal part 5. (See diagram below.) Figure 8As shown, a positioning hole 511 is formed in the foot cover portion 51. A positioning portion 35 of the core housing 3 is inserted into the positioning hole 511. Additionally, an extension portion 512 and a protrusion 513 are formed in the foot cover portion 51. The extension portion 512 extends from the foot cover portion 51 toward the foot portion 11 of the core 1. The extension portions 512 extend from the long side of the foot cover portion 51, and the foot portion 11 is disposed between a pair of extension portions 512.

[0097] The protrusion 513 protrudes from the lower end of the extension 512. The protrusion 513 extends from the lower end of the extension 512 orthogonally to the extension 512 and bends downward at a 90-degree angle. Furthermore, the bent tip of the protrusion 513 abuts against the resin cover 7 (see reference). Figure 5 ).

[0098] An extension portion 521 and a fixing portion 522 are formed in the yoke covering portion 52. The extension portion 521 extends from the yoke covering portion 52 toward the yoke portion 12 of the core 1. The extension portions 521 extend from both ends of the yoke covering portion 52, and the yoke portion 12 is disposed between a pair of extension portions 521.

[0099] A fixing part 522 is provided at the lower end of the magnetic yoke covering part 52. Two fixing parts 522 are provided on each magnetic yoke covering part 52. The fixing part 522 is a hole that overlaps with the fixing part 43 on which the metal member 4 is mounted. With the fixing part 522 of the metal member 5 overlapping the fixing part 43 of the metal member 4, the fixing part 92 (see reference) is used. Figure 5 Tighten the metal parts 5 to secure them to the metal parts 4.

[0100] The insulating member 6 comprises a resin, and examples of resins include epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or composites thereof. Alternatively, thermosetting resins such as phenolic resin may also be used as the resin for the insulating member 6.

[0101] like Figure 5 As shown, an insulating member 6 is disposed between the coil 2 and the metal part 4. Three insulating members 6 are disposed below each coil 2. The three insulating members 6 are identical in shape and size. The insulating members 6 insulate the coil 2 from the metal part 4.

[0102] Figure 9 This is a three-dimensional view of insulating component 6. (For example...) Figure 9As shown, the insulating member 6 has a coil support portion 61 and a connecting portion 62. The coil support portion 61 is a slot for fitting the coil 2. Each turn of the coil 2 is inserted into the coil support portion 61. The size of the coil support portion 61 is the size of one side of the coil 2's turn. Two coil support portions 61 are formed in the insulating member 6. The connecting portion 62 is provided between the two coil support portions 61. The connecting portion 62 connects the two coil support portions 61.

[0103] Figure 10 This is a perspective view of the insulating member 6 from the bottom. The bottom surface of the insulating member 6 is the surface of the insulating member 6 that abuts against the metal part 4. (See image below.) Figure 10 As shown, the insulating member 6 has a protrusion 63. The protrusion 63 protrudes from the bottom surface of the insulating member 6. The protrusion 63 is positioned corresponding to the fitting hole 45 of the metal member 4, and the protrusion 63 is inserted into the fitting hole 45. The length of the protrusion 63 is shorter than the depth of the fitting hole 45. Therefore, even when the protrusion 63 is inserted into the fitting hole 45, the protrusion 63 will not protrude from the fitting hole 45.

[0104] The resin cover 7 contains a resin, and examples of resins include epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or composites thereof. Additionally, thermosetting resins such as phenolic resin may also be used as the resin in the resin cover 7.

[0105] The resin cover 7 surrounds the fastening portion 26 of the U-shaped component 21, U-shaped component 22 and I-shaped component 23, I-shaped component 24 and I-shaped component 25 that form the coil 2. Figure 11 This is a perspective view of the resin cover 7 from the bottom. The resin cover 7 has a fastening portion receiving space 71 and a coil insertion port 72. The fastening portion receiving space 71 is a space for receiving fastening portions 26. The fastening portion receiving space 71 is a space divided by a top plate 711 and four wall portions 712. In the fastening portion receiving space 71, one fastening portion 26 of each of the U-shaped member 21 and U-shaped member 22 and one fastening portion 26 of each of the I-shaped member 23, I-shaped member 24, and I-shaped member 25 are received. That is, in the fastening portion receiving space 71, one connecting part of each of the U-shaped member 21, U-shaped member 22 and I-shaped member 23, I-shaped member 24, and I-shaped member 25 is received, and the fastening portion receiving space 71 surrounds one connecting part of each.

[0106] A coil insertion port 72 is formed in the wall portion 712 facing the annular surface of the core 1. The coil 2 is inserted into the coil insertion port 72. More specifically, one of the I-shaped members 23, 24, and 25 is inserted into the coil insertion port 72. The size of the coil insertion port 72 is approximately the same as the thickness t of the I-shaped members 23, 24, and 25. Preferably, the I-shaped members 23, 24, and 25 are fitted into the coil insertion port 72.

[0107] In addition, such as Figure 5 As shown, an insulating sheet 8 can also be provided between the insulating member 6 and the metal part 4. By providing the insulating sheet 8, insulation between the coil 2 and the metal part 4 can be achieved even if the insulating member 6 develops cracks or other defects.

[0108] [Effects]

[0109] As described above, the coil component 10 of this embodiment includes: a coil 2, formed by connecting a plurality of U-shaped members 21, U-shaped members 22, and I-shaped members 23, I-shaped members 24, and I-shaped members 25, each with a thickness of 5 mm or more; a metal member 4, which includes the metal member and fixes the coil component 10 to the mounting surface; and an insulating member 6, disposed between the coil 2 and the metal member 4. The U-shaped members 21, U-shaped members 22, and I-shaped members 23, I-shaped members 24, and I-shaped members 25 are not covered by an insulating film, and a fitting hole 45 is formed in the metal member 4. The insulating member 6 has: a coil support portion 61 for inserting and fitting each turn of the coil 2; and a protrusion 63 that fits into the fitting hole 45 and fixes the insulating member 6 to the metal member 4.

[0110] Thus, insulation between the coil 2 and the mounting metal part 4 can be ensured by the insulating member 6. However, the U-shaped members 21, 22, 23, 24, and 25 are not covered by an insulating film. Therefore, it is necessary to ensure the insulation distance between the turns of the coil 2. Therefore, the insulating member 6, which insulates the coil 2 from the mounting metal part 4, is fitted and fixed to the mounting metal part 4, and has a coil support portion 61 that fits into the coil 2. Therefore, each turn of the coil 2 is supported by the coil support portion 61, and even if the coil part 10 vibrates, the position of each turn of the coil 2 is unlikely to shift, ensuring the insulation distance between the turns of the coil 2. Furthermore, since the coil 2 is supported by the coil support portion 61, damage to the insulating member 6 due to movement of the coil 2 is prevented.

[0111] Furthermore, when forming an insulating film on U-shaped members 21, 22, 23, 24, and 25 with a thickness of 5 mm or more, the cost increases due to the need to form the insulating film after forming the U-shaped members 21, 22, 23, 24, and 25. However, by using the insulating member 6 as in this embodiment, compared to forming an insulating film, workability is improved and costs are reduced, and insulation between the coil 2 and the mounting metal part 4 and support for the coil 2 can be achieved.

[0112] It also includes: a core 1 for mounting the coil 2; and a core housing 3 for insulating the core 1 from the coil 2. The core housing 3 has a plurality of ribs 36 extending in such a way as to clamp the turns of the coil 2.

[0113] Therefore, the position of each turn of coil 2 is more firmly restricted by the rib 36, thus effectively suppressing positional displacement between the turns of coil 2. Furthermore, since positional displacement of each turn of coil 2 is suppressed, damage to the insulating member 6 due to vibration of coil 2 can be prevented, maintaining insulation for a long period. In particular, in this embodiment, the rib 36 is bonded to each turn of coil 2 using adhesive, thus significantly enhancing the effect of suppressing positional displacement.

[0114] Furthermore, since the rib 36 also has an insulating function, insulation between the turns of the coil 2 can be achieved. Therefore, compared with the case without the rib 36, the distance between the turns of the coil 2 can be shortened, thus enabling the coil component 10 to be miniaturized.

[0115] The U-shaped components 21, 22, 23, 24, and 25 have fastening portions 26 that connect to adjacent U-shaped components 21, 22, 23, 24, and 25. The coil component 10 also includes a resin cover 7 surrounding the fastening portions 26. The resin cover 7 has a fastening portion receiving space 71, which, using a top plate 711 and a plurality of wall portions 712, successively surrounds the connection portions of the U-shaped components 21, 22, 23, 24, and 25 adjacent to each other via the fastening portions 26.

[0116] This allows for insulation of the connection points of the U-shaped components 21, 22, 23, 24, and 25.

[0117] The resin cover 7 has at least one wall portion 712 with a coil insertion port 72 for inserting I-shaped members 23, 24, and 25, the coil insertion port 72 being fitted into the I-shaped members 23, 24, and 25.

[0118] Therefore, the coil 2 can also be supported using the coil insertion port 72. As a result, the support of the coil 2 becomes more secure, the position of each turn of the coil 2 is less likely to shift, the insulation distance of each turn of the coil 2 can be ensured, and damage to the insulation component 6 can be prevented.

[0119] The object to be set is a wall that extends in a direction parallel to gravity. When the coil component 10 is fixed to the object to be set, the winding axis of the coil 2 is parallel to gravity. Thus, when the coil component 10 is placed on the object, each turn of the coil 2 is stretched downwards due to its own weight, causing the turns of the coil 2 to move. This shortens the initially secured insulation distance, potentially making insulation impossible. However, in this embodiment, each turn of the coil 2 is fitted and supported by the coil support portion 61 of the insulating member 6. Therefore, even with this arrangement of the coil component 10, the insulation distance between the turns can be maintained.

[0120] Rib 36 has a reinforcing portion 361 extending orthogonally to the extending direction of rib 36. This increases the strength of rib 36. Therefore, as in this embodiment, even when the coil 2 is formed using components with a thickness of 8 mm (e.g., U-shaped member 21, U-shaped member 22, I-shaped member 23, I-shaped member 24, I-shaped member 25) and the coil 2 is heavy, damage to rib 36 can be prevented. Therefore, the positional displacement suppression function and insulation function provided by rib 36 can be maintained for a long period.

[0121] It also includes a fixing metal member 5 that fits into the core housing 3 and is fixed to the mounting metal member 4. The fixing metal member 5 has a protrusion 513 that protrudes toward the resin cover 7. The protrusion 513 abuts against the resin cover. Thus, even if the coil component 10 vibrates, the position of the resin cover 7 can be limited by the protrusion 513. Therefore, insulation of the connection points caused by the resin cover 7 or suppression of positional displacement of the individual turns of the coil 2 can be maintained.

[0122] The conductive components include U-shaped components 21, U-shaped components 22 and I-shaped components 23, I-shaped components 24 and I-shaped components 25. The coil 2 is formed by alternately connecting U-shaped components 21, U-shaped components 22 and I-shaped components 23, I-shaped components 24 and I-shaped components 25.

[0123] Therefore, by inserting I-shaped components 23, 24, and 25 into the core 1, and inserting feet 11 into the U-shaped components 21 and 22, the U-shaped components 21, 22, and I-shaped components 23, 24, and 25 can be fastened together. Thus, the coil 2 can be easily formed, and the coil 2 can be mounted on the feet 11, improving productivity.

[0124] Furthermore, the insulating member 6 has a connecting portion 62 that connects the coil support portion 61. That is, one insulating member 6 has two coil support portions 61. Therefore, compared with the case where the protrusions 63 of the insulating member 6 are fitted into the fitting holes 45 of the metal part 4 one by one, the assemblability is improved and the production efficiency is good.

[0125] [Other Implementation Methods]

[0126] This specification describes embodiments of the present invention, but these embodiments are provided as examples and are not intended to limit the scope of the invention. Such embodiments can be implemented in various other forms, and various omissions, substitutions, and modifications can be made without departing from the scope of the invention. Embodiments or variations thereof are included, in the same way, within the scope or spirit of the invention as those contained in the claims and their equivalents.

[0127] In the described embodiment, the size of the coil insertion port 72 is the same as the thickness t of the I-shaped members 23, 24, and 25, but it can also be slightly larger than the thickness t of the I-shaped members 23, 24, and 25. Even if it is slightly larger, even if the I-shaped members 23, 24, and 25 forming the coil 2 need to move, they can still achieve a certain positional displacement suppression effect by abutting against the coil insertion port 72.

Claims

1. A coil part, characterized by, Comprising: a coil formed by linking a plurality of electrically conductive members having a thickness of 5 mm or more; a setting metal member including a metal member and fixing the coil member to a setting target surface; and an insulating member disposed between the coil and the setting metal member, wherein surroundings of the plurality of electrically conductive members are not covered by an insulating film, in the setting metal member, an insertion hole is formed, the insulating member has: a coil support portion into which each turn of the coil is inserted and with which each turn is fitted; and a protruding portion fitted into the insertion hole and fixing the insulating member to the setting metal member.

2. The coil part according to claim 1, characterized in that Further comprising: a core on which the coil is mounted; and a core housing insulating the core from the coil, the core housing has a plurality of ribs extending in a manner of sandwiching each turn of the coil.

3. The coil member according to claim 2, wherein the ribs have a reinforcing portion extending in a direction orthogonal to the extending direction of the ribs.

4. The coil member according to claim 1, wherein the electrically conductive members have a fastening portion linking with an adjacent electrically conductive member, the coil member further comprises a resin cover surrounding the fastening portion, the resin cover has a fastening portion accommodation space surrounding the linking portion of the electrically conductive members adjacent through the fastening portion by a top plate and a plurality of wall portions.

5. The coil member according to claim 4, wherein the resin cover has, at least in one of the wall portions, a coil insertion opening through which the electrically conductive member is inserted, the coil insertion opening is fitted with the electrically conductive member. Further comprising:

6. The coil part of claim 4, wherein a core on which the coil is mounted; and a core housing insulating the core from the coil, and a fixing metal member fitted into the core housing and fixed to the setting metal member, wherein the fixing metal member has a protruding portion protruding toward the resin cover, the protruding portion abuts against the resin cover.

7. The coil member according to claim 1, wherein the electrically conductive members include U-shaped members and I-shaped members, the coil is formed by alternately linking the U-shaped members and the I-shaped members.

8. The coil member according to any one of claims 1 to 7, wherein the setting target surface is a wall extending in a direction parallel to gravity, when the coil member is fixed to the setting target surface, the winding axis direction of the coil is parallel to gravity. Further comprising:

9. The coil part of claim 5, wherein a core on which the coil is mounted; and a core housing insulating the core from the coil, and a fixing metal member fitted into the core housing and fixed to the setting metal member, wherein the fixing metal member has a protruding portion protruding toward the resin cover, the protruding portion abuts against the resin cover.

10. The coil member according to claim 9, wherein the setting target surface is a wall extending in a direction parallel to gravity, when the coil member is fixed to the setting target surface, the winding axis direction of the coil is parallel to gravity. ​

Images