Composite coil device

Abstract

To provide a composite coil device capable of facilitating automation of winding work and having stable quality at a low cost.SOLUTION: A composite coil device includes: a winding shaft part containing at least part of a magnetic substance and formed with a first partition and a second partition in an axial direction; a first conductor part continuously wound around the first partition and the second partition; and a second conductor part wound around the second partition.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to a composite coil device in which two or more coil elements, such as a transformer and a common mode filter, can be incorporated. [Background technology]

[0002] For example, Patent Document 1 proposes a composite coil device in which two or more coil elements, such as a pulse transformer and a choke coil transformer, can be incorporated.

[0003] However, in the conventional technology shown in Patent Document 1, complex winding was done manually around multiple toroidal cores, which made it difficult to automate the winding process, resulting in unstable quality and high manufacturing costs. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 9-162036 Summary of the Invention [Problem to be solved by the invention]

[0005] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a composite coil device which can easily automate the winding process and has low cost and stable quality. [Means for solving the problem]

[0006] In order to achieve the above object, a composite coil device according to the present invention comprises: a winding portion including at least a portion of a magnetic material and having a first section and a second section formed in an axial direction; a first conductor portion wound continuously around the first section and the second section; and a second conductor portion wound around the second section.

[0007] In the composite coil device according to the present invention, the first conductor is continuous with the first section and the second section, making it possible to form separate coil elements in each section, and also making it possible to form a transformer or the like between the first conductor and the second conductor wound around the second section. Also, in the first section, it is possible to form a coil element having a different function from the transformer or the like formed in the second section.

[0008] In this way, in the composite coil device of the present invention, coil elements having different functions can be formed in the first section and the second section without providing an intermediate wire. Since there is no need to provide an intermediate wire in the composite coil device of the present invention, it becomes easier to automate the winding work using an automatic winding machine, reducing costs and making it easier to ensure stable quality. Furthermore, compared to conventional composite coil devices in which multiple coil devices having different functions are connected by wiring, the composite coil device of the present invention can be significantly more compact.

[0009] The coil may further include a third conductor portion that is different from the first conductor portion and that is wound continuously around the first section and the second section. The first conductor portion, the second conductor portion, and the third conductor portion are wound coaxially around the winding shaft portion.

[0010] With this configuration, it is possible to form a circuit having functions such as a common mode filter between the first conductor and the third conductor in the first section, and it is also possible to form an additional transformer between the third conductor and the second conductor in the second section. Furthermore, with this configuration, it is possible to significantly reduce the size of the device compared to a conventional composite coil device in which a common mode filter and a transformer are fabricated in separate coil devices and connected.

[0011] The winding shaft portion may have a turn-back portion, and the first conductor portion may be wound in opposite directions around the winding shaft portion in the first section and the second section. By forming a turn-back portion on the winding shaft portion, the first conductor portion can be wound in opposite directions around the winding shaft portion in the first section and the second section. Similarly, the third conductor portion can be wound in opposite directions around the winding shaft portion in the first section and the second section, but may be wound in the same direction around the winding shaft portion in the first section and the second section without being turned back at the turn-back portion.

[0012] It is preferable that at least in the second section, the first conductor section and the second conductor section are wound in different layers. Also, when the third conductor section is wound around the winding shaft section continuously from the first section to the second section, it is preferable that the first conductor section, the second conductor section, and the third conductor section are wound in different layers in the second section. Also, it is preferable that the first conductor section and the third conductor section are wound in different layers in the first section. By configuring in this way, it is possible to effectively prevent the winding of each conductor around the winding shaft section from becoming irregular, and it is also easy to control the number of turns, which contributes to stabilizing quality.

[0013] Preferably, the winding shaft portion is formed with a partition wall separating the first section and the second section. By forming the partition wall, it becomes easier to form different coil elements in the first section and the second section, and it becomes easier to suppress mutual interference between the coil elements in the first section and the second section. Preferably, the partition wall is also formed in the magnetic body included in the winding shaft portion. With this configuration, it becomes easier to suppress mutual interference between the coil elements in the first section and the second section.

[0014] Preferably, the partition wall has a notch that connects the first section and the second section. The first conductor portion or the third conductor portion can be wound around the same winding shaft in succession to the first section and the second section through the notch. It is preferable that the second conductor portion is wound around the winding shaft only in the second section, but depending on the application, the second conductor portion may be wound around the winding shaft in the first section and the second section through the notch.

[0015] Preferably, the cutout is formed on the mounting surface side. Also, preferably, the winding shaft portion includes an insulating member, a partition wall is formed in the insulating member, the insulating member is located on the mounting surface side, and the cutout is formed in the partition wall of the insulating member. With this configuration, the first conductor portion or the third conductor portion can be passed between the first section and the second section through the cutout formed in the partition wall of the insulating member. Therefore, it is easy to form a coil element that is continuous in the first section and the second section while ensuring insulation from an external circuit board, etc. This also contributes to miniaturization of the device.

[0016] Preferably, the winding shaft portion is configured by attaching at least a part of the core made of the magnetic material to a recess of a bobbin having an opening. By configuring in this way, it is possible to more easily form coil elements having different functions in the first section and the second section without providing an intermediate connection.

[0017] Preferably, the bobbin is disposed on the mounting surface side. This configuration makes it easier to form continuous coil elements in the first and second sections while ensuring insulation from an external circuit board, etc. This also contributes to miniaturization of the device.

[0018] Preferably, the core is configured by combining separable members. For example, the magnetic body included in the winding shaft portion may be configured with a core having an E-shaped cross section, and the core to be combined with the E-shaped cross section core may be a flat core. If the core has an E-shaped cross section, the first and second sections can be easily formed in the magnetic body, and the partition wall formed between these sections can also be easily formed.

[0019] Furthermore, the core with an E-shaped cross section may be divided in the axial direction of the winding shaft portion. For example, by dividing the core in the axial direction into a core constituting the first section and a core constituting the second section, the mutual interference between the coil elements formed in these sections can be further suppressed. For example, the coupling coefficient between the coil elements can be reduced. The flat core may also be divided in the axial direction of the winding shaft portion. By configuring in this way, the coupling between the coil elements formed in the first section and the second section can be further reduced.

[0020] Preferably, the magnetic body has a shape that forms a closed magnetic circuit in the first section and / or the second section. By configuring in this way, it is possible to further reduce the coupling between the coil elements formed in the first section and the second section, respectively.

[0021] Preferably, the magnetic body has a plate-like member in the first section and / or the second section. By having a plate-like member, an adhesive chuck or the like can be easily attached detachably to the outer surface of the plate-like member, facilitating automation of pick-up and transportation of the composite coil device. In addition, by making the plate-like member a magnetic body, it becomes easier to form a closed magnetic circuit in the first section and / or the second section.

[0022] Preferably, the second conductor portion is formed of at least two conductor wires wound in a bifilar manner around the winding shaft portion. By configuring in this manner, two or more transformers can be easily formed in the second section.

[0023] A spacer for preventing winding irregularities of the first conductor portion or the second conductor portion may be disposed on the outer periphery of the winding shaft portion located in the first section or the second section. By disposing a spacer as necessary, winding irregularities can be effectively prevented. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 is a perspective view of a composite coil device according to one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic cross-sectional view taken along line II-II of the composite coil device shown in FIG. [Diagram 3] FIG. 3 is a plan view of the composite coil device shown in FIG. [Figure 4A] FIG. 4A is a bottom view of the composite coil device shown in FIG. [Figure 4B] FIG. 4B is a bottom view showing how the wires constituting the coil elements of the composite coil device shown in FIG. 4A are wound. [Diagram 5] FIG. 5 is an exploded perspective view of the composite coil device (wires not shown) shown in FIG. [Figure 6] 6(A) to 6(C) are bottom views of the bobbin showing in more detail the way the wire is wound as shown in FIG. 4B. [Figure 7] 7(A) to 7(C) are circuit diagrams showing the parts corresponding to the winding methods of the wires shown in FIGS. 6(A) to 6(C). [Figure 8] FIG. 8 corresponds to FIG. 2 and is a cross-sectional view of a composite coil device according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Hereinafter, the present invention will be described based on the embodiments shown in the drawings.

[0026] First embodiment The composite coil device 10 according to this embodiment shown in Fig. 1 is used as a composite coil device in which a transformer and a common mode filter are integrated, for example, in applications such as a battery management system (BMS). However, the composite coil device 10 may also be used for other applications, such as voltage conversion of a battery in a vehicle such as an automobile, or voltage conversion of a battery in an electronic device. The composite coil device 10 has a bobbin 20, a core body 40, a flat plate portion 50, and a coil portion 60.

[0027] As shown in Fig. 5, the bobbin 20 has a pair of terminal blocks 22, 23 spaced apart in the X-axis direction. These terminal blocks 22, 23 are integrated by being connected to a bottom plate 32 extending in the X-axis direction by a pair of connecting side portions 26. Each of the terminal blocks 22, 23 is formed with a flange accommodating recess 24, 25 having an opening at the top in the Z-axis direction. The opening of the flange accommodating recess 24, 25 is preferably formed with a tapered inclined surface so that a flange portion 43 of a core body 40 described later can easily fit therein.

[0028] In the drawings, the X-axis, Y-axis, and Z-axis are approximately perpendicular to each other, and in this embodiment, the X-axis approximately coincides with the direction in which the connecting side portions 26 extend (also approximately coincides with the winding axis direction of the coil portion 60 shown in FIG. 1), the Y-axis approximately coincides with the direction in which the pair of connecting side portions 26 move apart, the Z-axis coincides with the height direction of the composite coil device 10, and the lower side of the Z-axis is the mounting surface side.

[0029] 5, the core body 40 has a flat bottom wall 42 and a pair of flanges 43 located at both ends of the bottom wall 42 in the X-axis direction. Each of the flanges 43 has a flange central portion 45 having substantially the same width in the Y-axis direction as the bottom wall 42. A pair of flange side protrusions 46 are integrally formed on both sides in the Y-axis direction of each flange central portion 45, and the flange side protrusions 46 are configured to protrude outward in the Y-axis direction beyond both ends of the bottom wall 42 in the Y-axis direction. Note that "outer side" refers to a direction away from the center (center of gravity) of the composite coil device 10, and "inner side" refers to a direction approaching the center (center of gravity) of the composite coil device 10.

[0030] In this embodiment, the Z-axis height (hereinafter also simply referred to as "height") of the flange central portion 45 is set higher than the height of the flange lateral protrusions 46, a step is formed on the Z-axis upper surface (hereinafter also simply referred to as "upper surface") of the flange portion 43, and the Z-axis lower surface (hereinafter also simply referred to as "lower surface") of the flange portion 43 is approximately flush.

[0031] The lower surface of the bottom wall 42 is generally flush with the lower surface of the flange central portion 45, and the thickness in the Z-axis direction of the bottom wall 42 (hereinafter also simply referred to as "thickness") is generally the same as the height of the connecting side portion 26 from the upper surface of the bottom plate 32. The lower surface of the connecting side portion 26 is generally flush with the lower surface of the bottom plate 32.

[0032] When the flange portion 43 is accommodated inside the flange accommodating recesses 24, 25 of the terminal blocks 22, 23, the bottom wall 42 of the core body 40 is located between the pair of connecting side portions 26, 26, the upper surface of the bottom wall 42 and the upper surface of the connecting side portion 26 are substantially aligned, and the lower surface of the bottom wall 42 is in contact with the upper surface of the bottom plate 32. Note that "substantially aligned" means that some misalignment is permissible as long as it does not interfere with the winding operation of the wires (conductors) 62 to 65, which will be described later.

[0033] In this embodiment, a partition wall 44 is formed integrally with the bottom wall 42 on the upper surface of the flat bottom wall 42 located between the pair of flanges 43. The protruding height of the partition wall 44 from the upper surface of the bottom wall 42 in the Z-axis direction is preferably approximately the same as or slightly lower than the protruding height of the flanges 43 in the Z-axis direction. In addition, the thickness of the partition wall 44 in the X-axis direction is preferably approximately the same as the thickness of the flanges 43 in the X-axis direction. Furthermore, the width of the partition wall 44 in the Y-axis direction is preferably approximately the same as the width of the bottom wall 42 in the Y-axis direction.

[0034] By forming the partition wall 44 in the core body 40, the core body 40 is divided into a first section 48 and a second section 49 along the X-axis direction, and the core body 40 has a substantially E-shape when viewed in a cross section parallel to the XZ axes, as shown in Fig. 2. That is, the core body 40 is also called an E-shaped core.

[0035] The flat plate portion 50 is molded as a separate member from the core body 40, and has a length substantially equal to the length in the X-axis direction of the core body 40 (hereinafter also simply referred to as "length") and a width substantially equal to the width in the Y-axis direction of the bottom wall 42 of the core body 40 (hereinafter also simply referred to as "width"). The thickness of the flat plate portion 50 is preferably 70 to 130% of the thickness of the bottom wall 42. The flat plate portion 50 is preferably in contact with the upper surfaces of at least a pair of flange portions 43, and more preferably in contact with the upper surfaces of the partition walls 44 as well, but is not necessarily required to be in contact with the upper surfaces of the partition walls 44.

[0036] The core body 40 is made of a magnetic material such as metal or ferrite, but the type of magnetic material is not particularly limited. The flat plate portion 50 is preferably made of the same magnetic material as the core body 40, but does not necessarily have to be made of the same magnetic material. The flat plate portion 50 may be made of a non-magnetic material such as synthetic resin.

[0037] 5, a notch 27 is formed in the inner wall in the X-axis direction of each of the terminal blocks 22, 23 of the bobbin 20. The width of the notch 27 is preferably equal to or greater than the width of the bottom wall 42, and is approximately the same as the distance between the pair of connecting plate portions 26 in the Y-axis direction. The height of each notch 27 is approximately the same as the depth (height) of each of the flange accommodating recesses 24, 25.

[0038] Through each cutout 27, the boundary between the bottom wall 42 and the flange portion 43 of the core body 40 is inserted, the flange portion 43 is housed inside the flange accommodating recesses 24, 25, the lower surface of the bottom wall 42 is placed on the lower surface of the bottom wall 32, and the bottom wall 42 is disposed between the pair of connecting side portions 26, 26. Between the pair of connecting side portions 26, 26, the upper portion of the bottom wall 42 opens upward in the Z-axis direction.

[0039] 1, both ends of a flat plate portion 50 separate from the core body 40 are inserted into the upper portion of each notch 27, and as shown in FIG. 2, the upper surface of the flat plate portion 50 projects upward in the Z-axis direction from the upper surfaces of the terminal blocks 22, 23 at a predetermined height. The predetermined height is preferably 1 / 2 or less of the thickness of the flat plate portion 50, and more preferably 1 / 4 or less. The upper surface of the flat plate portion 50 may be at the same level as the upper surfaces of the terminal block portions 22, 23, or may be recessed in the Z-axis direction from them.

[0040] 2 and 5, a bobbin-side partition wall 34 is formed integrally with the bobbin 20 on the outer surface of the connecting side portion 26 of the bobbin 20 at a position corresponding to the partition wall 44 of the core body 40. The bobbin-side partition wall 34 serves to divide the lower surface of the bottom wall 32 and the outer surface of the connecting side portion 26 into a first section 38 and a second section 39 in the X-axis direction. However, as shown in FIG. 4A, on the lower surface of the bottom wall 32, a notch 36 is formed in the partition wall 34 that is not continuous in the Y-axis direction, and the lower surface of the bottom wall 32 is continuous between the first section 38 and the second section 39 in the part where the notch 36 is formed.

[0041] As shown in Fig. 5, the partition wall 34 formed integrally with the outer surfaces of the connecting side portions 26 protrudes upward in the Z-axis direction beyond the connecting side portions 26. The protruding height of the partition wall 34 in the Z-axis direction is preferably equal to or less than the protruding height of the terminal blocks 22, 23 in the Z-axis direction. Even above the partition wall 34 in the Z-axis direction, the partition wall 34 is cut out with a width equal to or wider than the distance between the pair of connecting side portions 26. In other words, the partition wall 34 can be said to be composed of a pair of partition plate pieces formed integrally with the outer surfaces of the pair of connecting side portions 26, respectively.

[0042] As shown in FIG. 2, the partition wall 34 can be combined with the partition wall 44 on the core side to separate the coil section 60 wound around the winding shaft section 102 formed by the bottom wall 32 and the bottom wall 42 into a first section 60a and a second section 60b. That is, the first section 60a of the coil section 60 is formed by combining the first section 48 of the core body 40 and the first section 38 of the bobbin 20. The second section 60b of the coil section 60 is formed by combining the second section 49 of the core body 40 and the second section 39 of the bobbin 20. Also, as shown in FIG. 4A, the wires (conductors) 62, 65 located in the first section 60a and the wires 62, 65 located in the second section 60b can be connected to each other through the notch 36 formed in the partition wall 34.

[0043] Terminals 70, 90, and 80 are attached in this order to one terminal block 22 of the bobbin 20 shown in Fig. 5 at a predetermined interval along the Y axis. Terminals 70 and 80 have shapes that are linearly symmetrical to each other and have similar components, but are not completely identical members. Furthermore, terminal 90, which is disposed between terminals 70 and 80 along the Y axis direction, differs from terminals 70 and 80 in that it has two connection portions 92a and 92b.

[0044] Terminal 70 has a wire connection portion 72, an embedded portion 74, and a mounting portion 76, which are integrally formed by pressing a conductive plate material such as a metal piece, etc. Terminal 80 has a wire connection portion 82, an embedded portion 84, and a mounting portion 86, which are integrally formed by pressing a conductive plate material such as a metal piece, etc.

[0045] The terminal 90 has two connecting portions 92a, 92b, an embedded portion 94 that is integrally molded to connect the two connecting portions 92a, 92b, and a single mounting portion 96 that is continuous with the lower end portion of the embedded portion 94. Like the terminals 70, 80, the terminal 90 is also integrally molded by pressing or the like from a conductive plate material such as a metal piece.

[0046] 2, the embedded portions 74, 84, 94 of the terminals 70, 80, 90 are embedded in the insulating material constituting the bobbin 20 at the outer side in the X-axis direction and the lower part in the Z-axis direction of the terminal block 22. It is preferable that the embedded portions 74, 84, 94 are embedded in the insulating material constituting the bobbin 20 without being exposed to the inner wall surface of the flange accommodating recess 24 of the terminal block 22.

[0047] Terminals 170, 190, and 180 are attached in this order to the other terminal block 23 of the bobbin 20 shown in FIG. 5 at a predetermined interval along the Y-axis. The terminals 170 and 180 have shapes that are symmetrical to each other and have similar components, but are not completely the same members. The terminals 170 and 180 correspond to the terminals 70 and 80, respectively, and these may be the same members. Furthermore, the terminal 190 disposed between the terminals 170 and 180 along the Y-axis direction has two connection parts 192a and 192b, unlike the terminals 170 and 180. The terminal 190 corresponds to the terminal 90, and these may be the same members.

[0048] Terminal 170 has a connecting portion 172, an embedded portion 174, and a mounting portion 176, which are integrally formed by pressing a conductive plate material such as a metal piece. Terminal 180 has a connecting portion 182, an embedded portion 184, and a mounting portion 186, which are integrally formed by pressing a conductive plate material such as a metal piece.

[0049] Terminal 190 has two connecting portions 192a, 192b, an embedded portion 194 integrally formed to connect these, and a single mounting portion 196 that is continuous with the lower end of embedded portion 194. Like terminals 170, 180, this terminal 190 is also integrally formed by pressing or the like from a conductive plate material such as a metal piece.

[0050] 2, embedded portions 174, 184, 194 of the terminals 170, 180, 190 are embedded in the insulating material constituting the bobbin 20 at the outer side in the X-axis direction and the lower part in the Z-axis direction of the terminal block 23. It is preferable that the embedded portions 174, 184, 194 are embedded in the insulating material constituting the bobbin 20 without being exposed to the inner wall surface of the flange accommodating recess 25 of the terminal block 23.

[0051] The conductive material constituting the terminals 70, 80, 90, 170, 180, 190 is not particularly limited, but examples thereof include metals such as phosphor bronze, tough pitch steel, oxygen-free steel, stainless steel, brass, and copper-nickel alloy.

[0052] The insulating material constituting the bobbin 20 is not particularly limited, but examples include synthetic resins such as LCP, nylon, phenol, DAP, PBT, PET, etc. When the bobbin 20 is molded, the terminals 70, 80 are integrated with the bobbin 20 by insert molding.

[0053] 2, the mounting portions 76, 86, 96 (176, 186, 196) of the terminals 70, 80, 90 (170, 180, 190) are attached to the bobbin 20 so as to protrude outward in the X-axis direction from the end faces of the terminal blocks 22, 23 on the lower surface (bottom surface) of the bobbin 20. Also, the connecting portions 72, 82, 92a, 92b (172, 182, 192a, 192b) are attached to the bobbin 20 at positions higher in the Z-axis direction than the mounting portions 76, 86, 96 (176, 186, 196) so as to protrude outward in the X-axis direction from the end faces of the terminal blocks 22, 23.

[0054] 3 and 4A, the connection parts 72, 82, 92a, 92b (172, 182, 192a, 192b) and the mounting parts 76, 86, 96 (176, 186, 196) of the terminals 70, 80, 90 (170, 180, 190) are arranged with a positional deviation in the Y-axis direction when viewed from the Z-axis direction. In this embodiment, the embedded parts 74, 84, 94 (174, 184, 194) shown in FIG. 5 are embedded inside the insulating material constituting the bobbin 20 so that the mounting parts 76, 86, 96 (176, 186, 196) are located between the connection parts 72, 82, 92a, 92b (172, 182, 192a, 192) in the Y-axis direction.

[0055] As shown in FIG. 3, in terminal block 22, terminals 80, 90, and 70 are arranged side by side in this order along the Y-axis direction, whereas in terminal block 23, terminals 170, 190, and 180 are arranged side by side in this order.

[0056] 2, the lower surfaces of the mounting portions 76, 86, 96 (176, 186, 196) are configured to protrude a predetermined height downward from the lower surface of the bobbin 20. The predetermined height is preferably greater than 0, and is preferably about 0.5 to 2 times the thickness of the plate material constituting the mounting portions 76, 86, 96 (176, 186, 196).

[0057] 4A, in this embodiment, a total of ten mounting-side protrusions 28 are formed on the underside of the bobbin 20, and the undersides of the protrusions 28 form the underside of the bobbin 20. Five mounting-side protrusions 28 are formed on the underside of each of the terminal blocks 22, 23, spaced apart at predetermined intervals in the Y-axis direction, and lead connection grooves (conductive paths) 29 are formed between adjacent mounting-side protrusions 28 in the Y-axis direction.

[0058] It is preferable that the outer end surface of the mounting side protrusion 28 in the X-axis direction is recessed at a predetermined interval in the X-axis direction from the outer end surface of the bobbin 20. In this embodiment, as shown in Fig. 2, the mounting parts 76, 86, 96 (176, 186, 196) extend outward in the X-axis direction from the outer end surface of the mounting side protrusion 28 so as to protrude outward beyond the outer end surface of the bobbin 20. With this configuration, the outer end surface of the mounting side protrusion 28 reinforces the boundary between the mounting parts 76, 86, 96 (176, 186, 196) and the embedded parts 74, 84, 94 (174, 184, 194), making it easier to mount the mounting parts 76, 86, 96 (176, 186, 196) on a mounting surface such as an external circuit board (not shown).

[0059] The protruding height of mounting-side convex portion 28 is preferably determined so as to ensure a sufficient depth for flange accommodating recesses 24, 25 shown in FIG. 1 and also to ensure lead connection groove 29 shown in FIG. 4A.

[0060] In this embodiment, the bottom wall 32 located between the pair of connecting side portions 26 shown in Fig. 5 and the bottom wall 42 of the core body 40 are combined to form the winding shaft portion 102 as shown in Fig. 2. That is, the first wire 62, the second wires 63 and 64, and the third wire 65 are wound around the winding shaft portion 102 including the bottom wall 42 of the core body 40 made of a magnetic material to form the coil portion 60. The coil portion 60 is also divided by partition walls 34 and 44 into a first section 60a and a second section 60b.

[0061] Each of the four wires 62 to 65 is a conductive wire (insulated conductor) having an insulating coating formed on the outer circumferential surface thereof. In this embodiment, the insulating coating of the wires 62 to 65 may be made of, for example, polyurethane, ETFE, PFA, PET, polyamide, or PPS.

[0062] The coil portion 60 is formed by winding the wires 62 to 65 from above the winding shaft portion 102 formed by a combination of the bottom wall 42, the bottom wall 32, and the connecting side portion 26. In this embodiment, the winding operation can be performed automatically, but may also be performed manually.

[0063] Next, an example of a procedure for winding the wires 62 to 65 will be described mainly with reference to FIG. 4B and FIG.

[0064] As shown in Figures 4B and 6(A), the lead portion 62a, which is one end of the first wire 62, is entangled (or crimped) with the connecting portion 72 of the terminal 70 (the same applies below). Then, the first wire 62 is passed through the lead connection groove 29 located near the terminal 70, and wound around the winding shaft portion 102 in the first section 60a with a plurality of turns. Note that, for ease of illustration, Figures 4B and 6 show the wire 62 wound with one or less than two turns, rather than multiple turns. The same applies below.

[0065] After the first wire 62 is wound around the winding shaft portion 102 in the first section 60a by multiple turns, it is moved to the second section 60b through the notch 36 of the partition wall 34, and the first wire 62 is hooked on the edge of the notch 36 of the partition wall 34. Then, in the second section 60b, the first wire 62 is wound around the winding shaft portion 102 by multiple turns in the direction opposite to the winding direction in the first section 60a. Then, it is passed through the notch 36 of the partition wall 34 and entangled with the connection portion 92b of the terminal 90 located at the center in the Y-axis direction.

[0066] As a result, as shown in FIG. 7(A), the first wire 62 constitutes one coil element of the common mode filter circuit in the first section 60a, and at the same time constitutes one coil element NP2 of the transformer in the second section 60b.

[0067] Next, as shown in Fig. 4B and Fig. 6B, the lead portion 63a, which is one end of one second wire 63, is wound around the connection portion 172 of the terminal 170, and the lead portion 64a, which is one end of the other second wire 64, is wound around the connection portion 192b of the terminal 190. Then, these second wires 63, 64 are passed through the lead connection grooves 29 located near the connection portions 172, 192b of the respective terminals 170, 190, and are wound around the winding shaft portion 102 in the second section 60b by bifilar winding in a plurality of turns. The winding directions of these second wires 63, 64 are mutually the same and are opposite to the winding direction of the first wire 62 in the second section 60b.

[0068] The lead portion 63b, which is the other end of one second wire 63, is wound around the connection portion 192a of the terminal 160. In addition, the other end 64b of the other second wire 64 is wound around the connection portion 182 of the terminal 180. Since the connection portion 192a and the connection portion 192b are formed on the same terminal 190, the lead portion 63b and the lead portion 64a are electrically connected by the terminal 190.

[0069] As a result, as shown in FIG. 7B, the second wires 63 and 64 form the coil elements NS1 and NS2 of the transformer in the second section 60b. In this embodiment, the two second wires 63 and 64 are simultaneously bifilar-wound, but the second wires 63 and 64 may be wound separately one by one. Also, for example, a single second wire may be wound from the connection section 172 of the terminal 170 around the winding shaft section 102 in the second section 60b in the same manner as the second wire 63, and then entangled with the connection section 192a, and then returned to the second section 60b, where it may be wound in the same manner as the second wire 64. In that case, the two coil elements NS1 and NS2 shown in FIG. 7B can be formed with a single second wire.

[0070] 4B and 6(C), the lead portion 65a, which is one end of the third wire 65, is wound around the connection portion 82 of the terminal 80. Then, the third wire 65 is passed through the lead connection groove 29 located near the terminal 80, and wound around the winding shaft portion 102 in the first section 60a by multiple turns. The winding direction of the third wire 65 in the first section 60a is the same as the winding direction of the first wire 62 in the first section 60a.

[0071] After the third wire 65 is wound around the winding shaft portion 102 in the first section 60a by multiple turns, it is moved to the second section 60b through the notch 36 of the partition wall 34, and in the second section 60b, the third wire 65 is wound around the winding shaft portion 102 by multiple turns in the same direction as the winding direction in the first section 60a. Then, the third wire 65 is passed through the notch 36 of the partition wall 34 and entangled with the connection portion 92a of the terminal 90 located at the center in the Y-axis direction.

[0072] As a result, as shown in FIG. 7(C), the third wire 65 constitutes another coil element of the common mode filter circuit in the first section 60a, and at the same time constitutes one coil element NP1 of the transformer in the second section 60b.

[0073] The above winding example is one example of the winding order of the wires 62 to 65, and the winding order is not limited to the above. For example, in the above, the winding work starts from the lead parts 62a to 65a and ends at the lead parts 62b to 65b, but the reverse is also possible. Also, it is possible to wind multiple wires in various winding methods and winding orders according to the circuit to be designed.

[0074] When the winding operation is completed, the tip of each of the connecting wire portions 72, 82, 92a, 92b, 172, 182, 192a, and 192b may be irradiated with, for example, a laser to form the connecting portion 100 shown in Fig. 3, and each of the lead portions 62a, 62b, 63a, 63b, 64a, 64b, 65a, and 65b may be electrically connected and fixed to each of the connecting wire portions. Note that the connecting portion 100 may also be formed by a method other than laser irradiation, for example, soldering, bonding with a conductive adhesive, heat fusion, or resistance welding.

[0075] In this embodiment, it is preferable that the flat plate portion 50 is attached to the bobbin 20 after the connection portion 100 shown in FIG. 1 is formed, but the flat plate portion 50 may be attached to the notch 27 of the bobbin 20 after the winding operation of the wires 62 to 65 for forming the coil portion 60 before the connection portion 100 is formed. After the flat plate portion 50 is attached, an adhesive may be applied to the bonding recesses 30 formed on both sides of the flange receiving grooves 24, 25 in the Y-axis direction shown in FIG. 3. By applying this adhesive, the flat plate portion 50, the core body 40, and the bobbin 20 can be bonded and fixed at the same time. The adhesive is not particularly limited, but for example, a silicone resin, an epoxy resin, a UV resin, an anaerobic resin, or the like can be used.

[0076] In the composite coil device 10 according to this embodiment, the coil section is not formed by directly winding the wire around the toroidal core, but rather, with the core body 40 attached to the bobbin 20, the connecting side portion 26 and the bottom wall 32, which are part of the bobbin 20, together with the bottom wall 42 of the core body 40 form the winding shaft portion 102, and the wires 62-65 are wound around the winding shaft portion 102 to form the coil section 60. Therefore, the strength of the winding shaft portion 102 is improved, the winding operation of the wires 62-65 is easy, the productivity is excellent, and there is little variation in characteristics.

[0077] Furthermore, the dielectric strength is improved because the flange portion 43 of the core body 42 is housed inside the flange housing recesses 24, 25 of the terminal block portions 22, 23. In this embodiment, the shortest distance (insulation distance or creepage distance) between the core body 40 and the terminals 70, 80, 90, 170, 180, 190 can be set sufficiently long as shown in Fig. 2, so that the insulating property is excellent.

[0078] Moreover, the wires 62 to 65 are made of conductive wire material with an insulating coating formed on the outer circumferential surface. Since some parts of the wires 62 to 65 are in contact with the surface of the core body 40, the insulating coating can be formed to insulate the wires 62 to 65 from the core 40. It is also possible to use a conductive core such as a metal core as the core body 40.

[0079] Furthermore, the terminal block parts 22 and 23 are formed with a notch 27 into which the boundary between the bottom wall 42 and the flange part 43 is inserted, which facilitates the attachment and alignment of the core body 40 to the bobbin 20 and improves workability. Moreover, both ends of the flat plate part 50, which is separate from the core body 40, are inserted into the upper part of the notch 27, which facilitates the alignment and attachment of the flat plate part 50, the core body 40, and the bobbin 20. The flat plate part 50 does not necessarily have to be made of a magnetic material. In that case, the flat plate part 50 can function as, for example, an adsorption part of a suction nozzle for moving a transformer when mounting the transformer.

[0080] In particular, in the composite coil device 10 according to this embodiment, as shown in Fig. 4B, the first wire 62 is continuous with the first section 60a and the second section 60b, and as shown in Fig. 7(A), it is possible to form separate coil elements in each of the sections 60a and 60b. Also, it is possible to form a transformer or the like between the coil element NS2 formed by the second wire 64 wound around the second section 60b shown in Fig. 7(B) and the coil element NP2 formed by the first wire 62. Also, in the first section 60a, it is possible to form a coil element such as a common mode filter circuit having a function different from that of the transformer formed in the second section 60b.

[0081] In this way, in the composite coil device 10 of this embodiment, coil elements having different functions can be formed in the first section 60a and the second section 60b without providing an intermediate wire connection. In the composite coil device 10 of this embodiment, since there is no need to provide an intermediate wire connection, it becomes easier to automate the winding work using an automatic winding machine, reducing costs and making it easier to ensure stable quality. Furthermore, compared to a conventional composite coil device in which multiple coil devices having different functions are connected by wiring, the composite coil device 10 of this embodiment can be significantly more compact.

[0082] Furthermore, in this embodiment, a third wire 65 is further provided that is wound continuously around the first section 60a and the second section 60b in addition to the first wire 62. The first wire 62, the second wires 63 and 64, and the third wire 65 are wound coaxially around the winding shaft portion 102.

[0083] With this configuration, in the first section 60a, it is possible to form a circuit having a function such as a common mode filter with the first wire 62 and the third wire 65, and in the second section 60b, it is also possible to form an additional transformer between the third wire 65 and the second wire 63, and between the first wire 62 and the second wire 64. Furthermore, with this configuration, it is possible to significantly reduce the size of the device compared to a conventional composite coil device in which a common mode filter and a transformer are fabricated in separate coil devices and connected.

[0084] 4B, a folded portion is formed in the winding shaft portion 102 by the edge of the notch 36 in the partition wall 34, and for example, the first wire 62 can be wound in opposite directions around the winding shaft portion 102 in the first section 60a and the second section 60b. By forming a folded portion in the winding shaft portion 102 by the notch 36 in the partition wall 34, it becomes possible for the first wire 62 to be wound in opposite directions around the winding shaft portion 102 in the first section 60a and the second section 60b.

[0085] Similarly, the third wire 65 can be wound in the first section 60a and the second section 60b in opposite directions around the winding shaft portion 102, but in this embodiment, the third wire 65 is wound in the first section 60a and the second section 60b in the same direction around the winding shaft portion 102 without being folded back at the turn-back portion. As a result, the circuit shown in FIG. 7(C) can be formed.

[0086] 2, in the first section 60a, the first wire 62 and the third wire 65 are wound in different layers, and in the second section 60b, the first wire 62, the second wires 63 and 64, and the third wire 65 are wound in different layers. This configuration effectively prevents the wires 62 to 65 from being wound irregularly around the winding shaft portion 102, and also makes it easy to control the number of turns, contributing to stabilizing quality.

[0087] Furthermore, the winding shaft portion 102 is formed with partition walls 34, 44 that separate the first section 60a and the second section 60b. By forming the partition walls 34, 44, it becomes easier to form different coil elements in the first section 60a and the second section 60b, and it becomes easier to suppress mutual interference between the coil elements in the first section 60a and the second section 60b. The partition wall 44 is also formed in the core body made of a magnetic material. With this configuration, it becomes easier to suppress mutual interference between the coil elements in the first section 60a and the second section 60b.

[0088] Moreover, in this embodiment, as shown in Fig. 4B, a notch 36 is formed in the partition wall 34 on the bobbin 20 side, connecting the first section 60a and the second section 60b. The first wire 62 or the third wire 65 can be wound around the winding shaft section 102 of the same axis core, continuing from the first section 60a and the second section 60b, through this notch 36. It is preferable that the second wire 63, 64 is wound around the winding shaft only in the second section 60b, but depending on the application, the second wire 63 or 64 may be wound around the winding shaft section 102 in the first section 60a and the second section 60b through this notch 36.

[0089] In this embodiment, the notch 36 is formed on the mounting surface side. The winding shaft portion 102 includes a part of the bobbin 20 which is an insulating member, the partition wall 34 is formed on the bobbin 20 which is an insulating member, the lower surface of the bottom wall 32 of the bobbin 20 is located on the mounting surface side, and the notch 36 is formed in the partition wall 34 of the bottom wall 32.

[0090] With this configuration, the first wire 62 or the third wire 65 can be passed between the first section 60a and the second section 60b along the lower surface of the bottom wall 32 through the notch 36 formed in the partition wall 34. Moreover, the lower surface of the partition wall 34 protrudes sufficiently downward in the Z-axis direction relative to the lower surface of the bottom wall 32. This makes it easier to form continuous coil elements in the first section 60a and the second section 60b while ensuring insulation from an external circuit board (not shown) and the like. This also contributes to miniaturization of the device.

[0091] 2, the winding shaft portion 102 is configured by attaching at least a part of the core body 40 made of a magnetic material to a recess of the bobbin 20 having an opening on the upper side. By configuring it in this way, it is possible to more easily form coil elements having different functions in the first section 60a and the second section 60b without providing an intermediate connection.

[0092] 2, the bottom wall 32 of the bobbin 20 is disposed on the mounting surface side, which makes it easier to form continuous coil elements in the first section 60a and the second section 60b while ensuring insulation from an external circuit board (not shown), etc. This also contributes to miniaturization of the device.

[0093] Furthermore, since the core body 40 is a core having an E-shaped cross section, the first section 48 and the second section 49 can be easily formed in the magnetic material, and the partition wall 44 formed between these sections 48, 49 can also be easily formed.

[0094] Furthermore, as shown in FIG. 8, the core body 40 having an E-shaped cross section may be divided in the X-axis direction of the winding shaft portion 102. For example, by dividing the core body 40 in the axial direction into a core constituting the first section 48 and a core constituting the second section 49, the mutual interference between the coil elements formed in these sections 48, 49 can be further suppressed. For example, the coupling coefficient between the coil elements can be reduced. In addition, the flat section 50 formed of a flat magnetic core may also be divided in the X-axis direction of the winding shaft portion. By configuring in this way, the coupling between the coil elements formed in the first section 60a and the second section 60b can be further reduced.

[0095] 2, in this embodiment, the core body 40 and the flat plate portion 50 made of a magnetic material have a shape that forms a closed magnetic circuit in the first section 48 and the second section 49. By configuring in this manner, it is possible to reduce the coupling between the coil elements formed in the first section 60a and the second section 60b, respectively.

[0096] Furthermore, since the first section 60a and the second section 60b have the flat plate portion 50 made of a magnetic material, a closed magnetic circuit can be easily formed in the first section 48 and the second section 49.

[0097] Furthermore, since the second wire is composed of at least two conductor wires 63, 64 that are bifilarly wound around the winding shaft portion 102, it becomes easier to form two transformers in the second section 60b.

[0098] 2, a spacer 68 for preventing irregular winding of the first wire 62, the second wire 63, 64, or the third wire 65 may be disposed on the outer periphery of the winding shaft portion 102 located in the first section 38, 48 or the second section 39, 49. By disposing the spacer 68 as necessary, irregular winding can be effectively prevented. The spacer 68 can also be formed by winding an insulating tape around the outer periphery of the winding shaft portion 102.

[0099] The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the present invention.

[0100] For example, the shape of the core body 40 is not particularly limited as long as it is a shape that becomes at least a part of the winding shaft portion 102, and it may be a so-called U-shaped core or a drum-shaped core. Furthermore, the number of wires 62 to 65 and the number of terminals are not particularly limited. As shown in Fig. 4B, the bottom of the notch 36 is flush with the lower surface of the bottom wall 32 of the winding shaft portion 102, but is not limited thereto, and there may be a slight difference in level with the lower surface of the bottom wall 32.

[0101] Also, the winding shaft portion 102 may be formed only from the core body 40 and the connecting side portion 26. That is, the bottom plate 32 of the bobbin 20 may be omitted. Alternatively, the winding shaft portion 102 may be formed only from the core body 40. [Explanation of symbols]

[0102] 10... Composite coil device 20… Bobbin 22,23…Terminal block 24,25… Tsuba receiving recess 26… Connecting side 27…Notch 28… Mounting side protrusion 29… Lead connection groove 30…Adhesive recess 32… Bottom wall 34… Partition wall 36…Notch 38… Section 1 39…Second Section 40… Core body 42… Bottom wall 43… flange 44… Partition wall 45… Center of tsuba 46… Side protrusion of tsuba 48… Section 1 49…Second Section 50… Flat plate part 60... Coil section 60a... Section 1 60b…Second section 62... First wire (first conductor) 63, 64… Second wire (second conductor) 65... Third wire (third conductor) 62a, 62b, 63a, 63B, 64a, 64b, 65a, 65B... Lead section 68…Spacer 70,80,90… Terminal 72,82,92a,92b… Connection section 74,84,94… Embedded part 76,86,96… Mounting section 100…Joint part 102... Winding shaft part 170,180,190… Terminal 172,182,192a,192b… Connection section 174,184,194… Embedded part 176,186,196… Mounting section

Claims

1. a winding portion including at least a portion of a magnetic material, the winding portion having a first section and a second section formed in an axial direction; a first conductor portion wound continuously around the first section and the second section; a second conductor portion wound around the second section; the winding shaft portion is configured by attaching at least a part of a core made of the magnetic material to a recess of a bobbin having an opening, the first conductor portion and the second conductor portion are wound around and in contact with both the core and the bobbin, a partition wall is formed in the winding shaft portion to separate the first section from the second section, The partition wall includes a bobbin side partition wall formed integrally with the bobbin, a core-side partition wall that is integrally formed with the core at a position corresponding to the bobbin-side partition wall so as to be combined with the bobbin-side partition wall to form the partition wall, the core-side partition wall having a width substantially equal to the width of a bottom wall of the core; a notch is formed in the bobbin side partition wall, the notch communicating the first section and the second section that are partitioned by the bobbin side partition wall and the core side partition wall, A composite coil device in which the first conductor portion is wound continuously around the first section and the second section through the notch.

2. The composite coil device according to claim 1 , further comprising a third conductor section, which is different from the first conductor section and which is wound continuously around the first section and the second section.

3. 3. The composite coil device according to claim 1 or 2, wherein a folded portion is formed on the winding shaft portion, and the first conductor portion is wound in opposite directions around the winding shaft portion in the first section and the second section.

4. 4. The composite coil device according to claim 1, wherein, in at least the second section, the first conductor portion and the second conductor portion are wound in different layers.

5. 5. The composite coil device according to claim 1, wherein the notch is formed on a mounting surface side.

6. 6. The composite coil device according to claim 5, wherein the bobbin is disposed on a mounting surface side.

7. 7. The composite coil device according to claim 1, wherein the core is configured by combining separable members.

8. The composite coil device according to any one of claims 1 to 7, wherein the magnetic body has a shape that forms a closed magnetic circuit in the first section and / or the second section.

9. The composite coil device according to any one of claims 1 to 8, wherein the magnetic body has a plate-shaped member in the first section and / or the second section.

10. 10. The composite coil device according to claim 1, wherein the second conductor portion is composed of at least two conductor wires bifilarly wound around the winding shaft portion.

11. A composite coil device as described in any one of claims 1 to 10, wherein a spacer is arranged on the outer periphery of the winding shaft portion located inside the first section or the second section to prevent winding irregularities of the first conductor portion or the second conductor portion.

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