Coil device

Abstract

To provide a coil device that can be made shorter and easily change a terminal height.SOLUTION: A coil device 10 includes a first terminal unit 50 and a second terminal unit 60 each of which includes a bobbin 40 around which a wire is wound, a core 12 attached to the bobbin, metal terminals 51a and 51b to which a metal case 80 that houses the bobbin and the core and wire ends 22a and 22b are fixed, and a resin terminal block 55 that holds the metal terminals. The upper opening edge of the case 80 is formed with a notch portion that is notched downward from the upper end of the case and to which the terminal block is attached, and joints 53a and 53b for fixing the wire ends 22a and 22b at the metal terminals 51a and 51b are arranged on the outside of the case and at a position lower than the upper end of the case.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a coil device that can be suitably used as a transformer, such as a leakage transformer. [Background technology]

[0002] For example, a coil device disclosed in Patent Document 1 is known as a coil device used in a transformer or the like. The coil device disclosed in Patent Document 1 has a case for housing a core and a coil wound around the core (middle leg), and the inside of the case is filled with a heat dissipating resin. Heat generated by the core and the coil can be dissipated via this heat dissipating resin. The case may be made of resin, but it is preferably made of metal from the viewpoint of heat dissipation.

[0003] In addition, there is a strong demand for miniaturization of coil devices used in vehicles and other applications, and it is required to reduce not only the projected area but also the height dimension. However, in conventional coil devices, the terminals and wires are arranged above the case so as not to interfere with the case, which poses a problem in terms of reducing the height. In addition, conventional terminal blocks are connected to bobbins, which poses a problem in that it is difficult to adjust the height of the terminal block. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-036194 A 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 provides a coil device that can be made low-profile and in which the design of the terminal height can be easily changed. [Means for solving the problem]

[0006] In order to achieve the above object, a coil device according to the present invention comprises: A bobbin with wire wound around it, A core attached to the bobbin; a metal case that houses the bobbin and the core; a terminal portion including a metal terminal to which a wire end portion, which is an end portion of the wire, is fixed and a resin terminal block that holds the metal terminal; The upper opening edge of the case is cut downward from the upper end of the case to form a cutout portion to which the terminal block is attached, A connection portion for fixing the wire end portion at the metal terminal is disposed outside the case and at a position lower than the upper end of the case.

[0007] In the coil device according to the present invention, a cutout is formed in the metal case, and a resin terminal block is attached to the cutout, so that the connection wire part can be arranged outside the case and the position of the metal terminal can be lowered, which is advantageous in terms of reducing the height. In addition, by changing the depth of the cutout, the design of the installation height of the metal terminal can be easily changed. Furthermore, since the case has a cutout, even if the position of the upper end of the case is raised, interference between the case and the terminal part can be avoided, and the wire can be drawn out while appropriately ensuring insulation between the case and the wire. In addition, for example, when a resin part is formed, the resin part can cover a wide area of ​​the bobbin or core, and such a coil device is also advantageous in terms of heat dissipation.

[0008] Also, for example, the terminal block may have a first wire passage that restricts the wire from at least above.

[0009] By providing the first wire passage, the wire can be regulated from above and guided from the bobbin to the connection portion below the upper end of the case, and also displacement of the wire can be prevented.

[0010] Also, for example, the first wire passage may restrict the wire at least in the up-down direction and may be formed across the upper opening edge from the inside to the outside of the case.

[0011] In such a coil device, it is possible to reliably ensure insulation from the metal case, prevent the wire from shifting, and guide the wire from the inside to the outside of the case.

[0012] Also, for example, the terminal block may have an inner portion disposed inside the case, The inner portion may extend to a position lower than a lower end of the cutout portion. Also, for example, the horizontal width of the inner portion may be greater than the horizontal width of the cutout portion.

[0013] By providing the terminal block with such an inner portion, the terminal block and the case can be firmly fixed together, and when a resin portion is formed, leakage of the resin during formation can be prevented.

[0014] For example, the coil device according to the present invention may further include a resin portion filled between the bobbin and the core and the case, An upper end of the resin portion may be located higher than a lower end of the cutout portion.

[0015] By positioning the upper end of the resin portion higher than the lower end of the cutout portion, it is possible for the resin portion to cover a wide area of ​​the bobbin and core, and such a coil device is advantageous in terms of heat dissipation.

[0016] For example, the coil device according to the present invention may further include a resin portion filled between the bobbin and the core and the case, An upper end of the resin portion may be located above an upper end of a coil portion that is a portion of the wire that is wound around the bobbin.

[0017] By positioning the upper end of the resin part higher than the upper end of the coil part, it is possible to cover the entire coil part and a large area of ​​the bobbin and core, making such a coil device advantageous in terms of heat dissipation.

[0018] Also, for example, the terminal block may have a second wire passage that restricts the wire at least from a side and guides the wire along a vertical direction, The second wire passage may have a downward opening through which the wire can be temporarily guided out in a downward direction that is different from a direction in which the wire is guided out of the second wire passage.

[0019] By providing the second wire passage, the wire is guided vertically toward the connection section, thereby reducing the vertical projection area of ​​the terminal block. Also, by providing the second wire passage with a downward opening, the wire can be routed from the bobbin to the connection section without slack.

[0020] Furthermore, for example, the terminal block may have a third wire passage that restricts the wire led out from the second wire passage at least from above and guides the wire toward the wire connection portion.

[0021] By having the third wire passage, the direction in which the wire ends in the connection section are pulled out can be approximately horizontal, and a coil device having such a third wire passage and connection section can reliably and easily fix the wire ends to the connection section by fusing or the like.

[0022] Also, for example, the terminal block may have a first wire passage that restricts the wire at least from above, The wire may be guided from the bobbin to the wire connection portion through the first wire passage, the second wire passage, and the third wire passage in this order.

[0023] A coil device having such a wire passage guides the wire horizontally, vertically, and horizontally in that order, allowing the wire to be pulled around easily and without slack, and effectively preventing the wire from deviating from the first to third wire passages during and after manufacture. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 is a perspective view of a transformer as a coil device according to one embodiment of the present invention. [Diagram 2] FIG. 2 is an exploded perspective view of the transformer shown in FIG. [Diagram 3] FIG. 3 is a side view of the transformer shown in FIG. [Figure 4] FIG. 4 is a top view of the transformer shown in FIG. [Diagram 5] FIG. 5 is a cross-sectional view of the transformer shown in FIG. [Figure 6] FIG. 6 is a conceptual diagram showing a method for drawing out wires in the transformer shown in FIG. [Figure 7] FIG. 7 is a cross-sectional view showing a resin portion of the transformer shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

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

[0026] 1 is a perspective view of a coil device 10 according to an embodiment of the present invention. The coil device 10 is used, for example, as a transformer for an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a commuter vehicle. However, the use of the coil device 10 is not limited to an in-vehicle transformer.

[0027] As shown in FIG. 1, the coil device 10 has a core 12, a case 80, a first terminal portion 50 and a second terminal portion 60 as terminal portions, a first wire 20 and a second wire 30 as wires, and the like. Also, as shown in FIG. 7, which is a cross-sectional view of the coil device 10, the coil device 10 has a bobbin 40 around which the first wire 20 and the second wire 30 are wound, a bottom plate 88 that closes the bottom surface of the case 80, a resin portion 90 filled in the case 80, and the like. In the drawings, the X-axis, the Y-axis, and the Z-axis are mutually perpendicular, and the Z-axis corresponds to the height of the coil device 10. In this embodiment, the lower side of the coil device 10 in the Z-axis direction is the installation surface of the coil device 10. Also, the Y-axis coincides with the minor axis direction of the elliptical bobbin 40 (see FIG. 2). Furthermore, the X-axis coincides with the major axis direction of the bobbin 40.

[0028] Fig. 2 is an exploded perspective view of the coil device 10. However, in the exploded perspective view shown in Fig. 2, some members of the coil device 10, such as the first wire 20, the second wire 30, and the resin part 90, are not shown. As shown in Fig. 2, the coil device 10 has a core 12. The core 12 is divided into four and is composed of four core pieces. The core 12 is attached to the bobbin 40 using an adhesive or the like.

[0029] 2, the core 12 has a center leg 12c that penetrates the inside of the hollow cylinder portion 42 of the bobbin 40, and two side legs 12d that extend in the Z-axis direction substantially parallel to the center leg 12c. The two side legs 12d are arranged on the outside of the bobbin 40 so as to sandwich the center leg 12c from both sides in the Y-axis direction. Parts of a first coil portion 21 and second coil portions 31a and 31b (see FIG. 3), which will be described later, are arranged between the center leg 12c and the side legs 12d.

[0030] Core 12 has upper connection portion 12a connecting side leg 12d and center leg 12c on the positive side of the Z axis, and lower connection portion 12b connecting side leg 12d and center leg 12c on the negative side of the Z axis. Core 12 forms a magnetic path around first coil portion 21 and second coil portion 31a, 31b when a current flows through first coil portion 21 and second coil portion 31a, 31b (see FIG. 3).

[0031] Fig. 5 is a cross-sectional view of the coil device 10 shown in Fig. 1. However, Fig. 5 does not show the resin part 90. As shown in Fig. 2, which is an exploded view, and Fig. 5, which is a cross-sectional view, the bobbin 40 has a hollow cylinder part 42 having a substantially elliptical cylindrical shape, an upper flange part 41 connected to the hollow cylinder part 42 on the positive side of the Z axis, and a lower flange part 43 connected to the hollow cylinder part 42 on the negative side of the Z axis.

[0032] As shown in Fig. 5, the first coil portion 21 and the second coil portions 31a, 31b formed by winding the first wire 20 and the second wire 30 are disposed on the outer periphery of the hollow cylinder portion 42. The lower flange portion 43 protrudes in the outer radial direction from the hollow cylinder portion 42. The lower flange portion 43 is formed with a leg portion 43a that protrudes in the negative Z-axis direction. The leg portion 43a is located at the same height as the lower end of the core 12 or on the negative Z-axis direction side of the lower end of the core 12, and protects the core 12 from impacts and the like.

[0033] The upper flange portion 41, like the lower flange portion 43, protrudes in the outer radial direction from the hollow cylinder portion 42. As shown in Fig. 2, the upper flange portion 41 is formed with a guide portion 41a that guides the first wire 20 and the second wire 30. The guide portion 41a guides the first wire 20 and the second wire 30 to the first terminal portion 50 and the second terminal portion 60, and ensures insulation between the first wire 20 and the second wire 30 and peripheral members such as the core 12.

[0034] 2, the case 80 has a generally rectangular cylindrical outer shape and houses the bobbin 40 and the core 12. The case 80 is made of metal and has better heat dissipation properties than those made of resin. The material of the case 80 is preferably aluminum or an aluminum alloy, but may be other metals or alloys such as iron, copper, or nickel.

[0035] Cutouts 84, 85 are formed in an upper opening edge 82, which is the opening edge on the Z-axis positive direction side of the case 80. The cutouts 84, 85 are cut downward from a case upper end 86 (see FIG. 4) of the case 80, and the cutouts 84, 85 have a substantially U-shape.

[0036] The cutout portion 84 is formed in a portion of the upper opening edge 82 on the negative side in the X-axis direction, and the first terminal portion 50 is attached to the cutout portion 84. In contrast, the cutout portion 85 is formed in a portion of the upper opening edge 82 on the positive side in the X-axis direction, and the second terminal portion 60 is attached to the cutout portion 85.

[0037] The notch portion 84 and the notch portion 85 have different depths in the Z-axis direction (heights of the lower ends of the notches 84, 85). Fig. 3 is a side view of the coil device 10 shown in Fig. 1. As shown in Fig. 3, since the depths of the notches 84, 85 are different, the heights of the first terminal portion 50 and the second terminal portion 60 also differ depending on the depths of the notches 84, 85.

[0038] As shown in Fig. 2, a bottom plate 88 is attached to the lower opening edge, which is the opening edge on the Z-axis negative direction side of the case 80. The opening on the Z-axis negative direction side of the case 80 is closed by the bottom plate 88. The bottom plate 88 can receive uncured resin when forming the resin part 90 as shown in Fig. 7. The bottom plate 88 is preferably made of metal, and is made of, for example, the same material as the case 80. Note that the coil device 10 does not need to have the bottom plate 88, and the resin part 90 and the case 80 may be in direct contact with the object on which the coil device 10 is to be installed.

[0039] 1, the first terminal unit 50 has first metal terminals 51a, 51b and a resin first terminal block 55 that holds the first metal terminals 51a, 51b. The first terminal unit 50 is produced by insert molding in which the first metal terminals 51a, 51b are inserted to form the first terminal block 55, but the method of producing the first terminal unit 50 is not limited to insert molding. The material of the first terminal block 55 is not particularly limited as long as it is an insulating resin, and examples of the material include PPS, PET, and PBT.

[0040] 1, the first terminal portion 50 has two metal terminals, a first metal terminal 51a and a first metal terminal 51b. The first metal terminal 51a and the first metal terminal 51b have shapes that are approximately symmetrical to each other with respect to an axis of symmetry parallel to the X-axis, with the first metal terminal 51a located in the negative direction of the Y-axis and the first metal terminal 51b located in the positive direction of the Y-axis.

[0041] The first wire end 22a, which is one end of the first wire 20, is fixed to the first metal terminal 51a, and the first wire end 22b, which is the other end of the first wire, is fixed to the first metal terminal 51b. The first metal terminal 51a has a connection part 53a that protrudes outward (away from the case 80, in the negative X-axis direction) from the first terminal block 55, an upward protrusion 54a that protrudes upward (positive Z-axis direction) from the first terminal block 55, and an embedded part (not shown) that connects the connection part 53a and the upward protrusion 54a and is embedded in the first terminal block 55. The first metal terminal 51b also has a connection part 53b, an upward protrusion 54b, and an embedded part (not shown) similar to those of the first metal terminal 51a.

[0042] As shown in Fig. 1, first wire ends 22a, 22b are fixed to connection parts 53a, 53b of first metal terminals 51a, 51b. That is, as shown in Fig. 4, first lead part 22 of first wire 20 is guided by first terminal block 55 and drawn out to the outside of case 80, and first wire ends 22a, 22b, which are both ends, are fixed to connection parts 53a, 53b located at the ends in the X-axis direction of coil device 10.

[0043] 3 and 5, the connection parts 53a, 53b of the first metal terminals 51a, 51b are disposed outside the case 80 at a position lower than the case upper end 86, which is the upper end of the case 80. Such a coil device 10 is advantageous in terms of reducing the height, compared to the conventional technology in which a terminal block is provided on the upper flange 41 exposed from the case 80. Also, in the coil device 10, the upper protrusions 54a, 54b that function as user terminals, which are connection parts to the outside, can ensure an upward protruding length while suppressing their height.

[0044] 2, in the coil device 10, the attachment position of the first terminal portion 50 relative to the case 80 can be easily changed by changing the depth of the cutout portion 84 of the case 80, so that it is possible to flexibly respond to design changes regarding the arrangement of the user terminals. Also, since the embedded portions of the first metal terminals 51a, 51b are located between the upper protrusions 54a, 54b and the connection portions 53a, 53b, insulation between the connection portions 53a, 53b and other members attached to the upper protrusions 54a, 54b can be reliably ensured.

[0045] As shown in FIG. 5, the first terminal block 55 of the first terminal unit 50 has an inner portion 56 disposed inside the case 80. The inner portion 56 extends inside the case 80 to a position lower than the lower end of the notch portion 84. In addition, the first terminal block 55 has a mounting groove 555a between the inner portion 56 disposed inside the case 80 and the outer support portion 555 disposed outside the case 80. The portion of the case 80 below the notch portion 84 is inserted into the mounting groove 555a of the first terminal block 55, thereby sandwiching the case 80 between the inner portion 56 and the outer support portion 555. As a result, the first terminal block 55 is stably supported by the case 80.

[0046] The inner portion lower end 56a, which is the lower end of the inner portion 56, is located below the notch portion 84 and the outer support portion 555. Moreover, the inner portion upper end 56b, which is the upper end of the inner portion 56, is located above the lower end of the notch portion 84, and the inner portion 56 of the first terminal block 55 closes at least a part of the notch portion 84. It is preferable that the inner portion upper end 56b is located above the upper ends of the first coil portion 21 and the second coil portions 31a, 31b, but this is not particularly limited.

[0047] Fig. 4 is a plan view of the coil device 10 shown in Fig. 1 as viewed from above. As shown in Fig. 4, it is preferable that the width W1 in the horizontal direction (Y-axis direction) of the inner portion 56 of the first terminal block 55 is wider than the width W2 in the horizontal direction (Y-axis direction) of the cutout portion 84 to which the terminal block 55 is attached. This makes it possible to prevent a problem in which uncured resin leaks out of the cutout portion 84 during formation of the resin portion 90 inside the case 80 as shown in Fig. 7.

[0048] As shown in FIG. 5, the first wire 20 and the second wire 30 are wound around the hollow cylinder 42 of the bobbin 40. The second wire 30 has two wires, one of which is wound inside the first wire 20 to form the second coil portion 31a, and the other wire is wound outside the first wire to form the second coil portion 31b. The first wire 20 is wound between the two second coil portions 31a and 31b to form the first coil portion 21. Also, as shown in FIG. 5, an insulating tape 46 is wound around the outer periphery of the second coil portions 31a and 31b and the first coil portion 21.

[0049] Both ends of the first wire 20 are drawn out from the hollow cylinder portion 42 to form two first lead portions 22, as shown in Fig. 4. First wire ends 22a, 22b which are the ends of the first wire 20 and the first lead portion 22 are fixed to connection portions 53a, 53b of the first metal terminals 51a, 51b.

[0050] As shown in Fig. 4, the first lead portion 22 of the first wire 20 is drawn out from the bobbin 40 via the guide portion 41a and guided to the first terminal portion 50. The terminal block 55 of the first terminal portion 50 has first wire passages 57a, 57b through which the first lead portion 22 of the first wire 20 passes. The first wire passage 57a and the first wire passage 57b are formed substantially symmetrically with respect to an axis of symmetry that passes through the center of the coil device 10 and is parallel to the X-axis direction, and each of the first lead portions 22 of the first wire 20 is disposed therein. A central partition portion 556 that separates the first wire passage 57a and the first wire passage 57b is formed in the central portion of the first terminal block 55 in the Y-axis direction.

[0051] 6(a) to 6(c) are conceptual diagrams showing an example of a procedure for forming the first lead portion 22 of the first wire 20. As shown in Fig. 4 and Fig. 6(A), the first wire passage 57a is a wire passage through which the first lead portion 22 drawn out from the guide portion 41a is first guided in the first terminal portion 50.

[0052] 6(a), the first wire passage 57a has a visor portion 57aa that restricts the first lead portion 22 of the first wire 20 from above (Z-axis positive direction), a first passage bottom wall 57ac that restricts the first lead portion 22 from below (Z-axis negative direction), and a first passage side wall 57ab that restricts the first lead portion 22 from the side. The first wire passage 57a is formed in an L-shape along the XY plane.

[0053] 1, the overhanging portion 57aa restricts the first lead portion 22 that has entered the first wire passage 57a from the guide portion 41a from above, thereby preventing the first lead portion 22 from escaping upward from the first wire passage 57a. Because the first wire passage 57a has the overhanging portion 57aa, even when the height of the lower end of the cutout portion 84 shown in FIG. 2 is lowered to position the first terminal portion 50 downward, the first lead portion 22 can be appropriately engaged with the first wire passage 57a.

[0054] As shown in Fig. 4, the portion of the L-shaped first wire passage 57a that is formed along the X-axis direction is formed straddling the upper opening edge 82 from the inside to the outside of the case 80. As shown in Fig. 6(a), in the first wire passage 57, the eaves portion 57aa and the first passage bottom wall 57ac restrict the first lead portion 22 from the top and bottom directions, thereby ensuring insulation with the upper opening edge 82 of the case 80 and preventing the first lead portion 22 from departing from the first wire passage 57a.

[0055] As shown in Fig. 6(a), the first passage side wall 57ab is formed in an L-shape along the shape of the first wire passage 57a. When arranging the first lead portion 22 in the first wire passage 57a, as shown in Fig. 6(a), the first lead portion 22 can be appropriately arranged along the first wire passage 57a by pulling the first lead portion 22 while pressing it against the first passage side wall 57ab.

[0056] The first wire passage 57b shown in FIG. 4 has a shape symmetrical to the first wire passage 57a, and therefore, detailed description of the first wire passage 57b will be omitted.

[0057] As shown in Fig. 3 and Fig. 6(b), the first terminal block 55 has second wire passages 58a, 58b that restrict the first lead portion 22 from the side and guide the first lead portion 22 in the up-down direction. As shown in Fig. 6(b), the second wire passage 58a is formed substantially perpendicular to the first wire passage 57a that is aligned along the XY plane. The first lead portion 22 is drawn out by changing its direction by approximately 90 degrees at the connection position between the first wire passage 57a and the second wire passage 58a.

[0058] As shown in Fig. 6(b), the second wire passages 58a, 58b have a lower opening 58aa through which the first wire 20 can be temporarily led out in a downward direction (Z-axis negative direction) which is a direction different from the X-axis negative direction in which the first lead portion 22 is led out from the first wire passages 57a, 57b. As shown in Fig. 6(c), before leading out the first lead portion 22 along the third wire passage 59a, as shown in Fig. 6(b), the first wire 20 is once led out from the lower opening 58aa and pulled, so that the first lead portion 22 can be arranged in the first and second wire passages 58a, 58b without loosening, even if the first wire 20 has high rigidity.

[0059] 6(c), the first terminal block 55 has a third wire passage 59a that restricts the first lead portion 22 led out from the second wire passage 58a at least from above and guides it toward the connection portion 53a. The first lead portion 22 changes direction again by approximately 90 degrees at the connection position between the second wire passage 58a and the third wire passage 59a, and is led out toward the negative X-axis direction.

[0060] 6(c), the first terminal block 55 has a curved wall 557 connecting a side wall of the second wire passage 58a and an upper wall of the third wire passage 59a. The radius of curvature of the curved wall 557 is greater than the radius of the first wire 29. Since the radius of curvature of the curved wall 557 is greater than or equal to a predetermined value, when the first lead portion 22 is led from the second wire passage 58a to the third wire passage 59a, the first wire end portion 22a can be led to the connection portion 53a without loosening by bending the first lead portion 22 while pressing it against the curved wall 557, even if the first wire 20 has high rigidity.

[0061] As shown in Figures 6(a) to 6(c), the first lead portion 22 of the first wire 20 is guided from the guide portion 41a of the bobbin 40 toward the connection portion 53a of the first metal terminal 51a, in that order, through the first wire passage 57a, the second wire passage 58a, and the third wire passage 59a, and engages with the first terminal block 55.

[0062] In addition, since the second wire passage 58b (including the lower opening 58ba) and the third wire passage 59b shown in FIG. 3 have shapes symmetrical to the second wire passage 58a and the third wire passage 59a, detailed explanations thereof will be omitted.

[0063] 2, the second terminal portion 60 has second metal terminals 61a, 61b and a second terminal block 65 made of resin that holds the second metal terminals 61a, 61b. Like the first terminal portion 50, the second terminal portion 60 is also produced by insert molding or the like.

[0064] As shown in Fig. 4, the second metal terminals 61a, 61b each have connection parts 63a, 63b that fix the second wire ends 32a of the two second wires 32. As shown in Fig. 4, the second lead part 32 of the second wire 30 is guided by the second terminal block 65 and drawn out to the outside of the case 80, and the second wire ends 32a, 32b, which are both ends, are fixed to the connection parts 63a, 63b located at the ends in the X-axis direction of the coil device 10.

[0065] 3 and 5, the second metal terminals 61a, 61b have upward protrusions 64a, 64b that protrude upward (positive direction of the Z axis) from the second terminal block 65, similar to the first metal terminals 51a, 51b. As shown in Fig. 4, when viewed from the Z direction, the second metal terminals 61a, 61b are disposed substantially symmetrically with respect to the first metal terminals 51a, 51b, with respect to a symmetry axis parallel to the Y axis. Regarding the features of the second metal terminals 61a, 61b, a description of the parts common to the first metal terminals 51a, 51b will be omitted.

[0066] As shown in Fig. 2, the second terminal block 65 of the second terminal unit 60 is attached to a cutout portion 85 of the case 80. As shown in Fig. 5, the second terminal unit 60 has an inner portion 66 arranged inside the case 80 and an outer support portion 655 arranged outside the case 80. The second terminal block 65 has a different mounting height from the first terminal block 55, but has a shape that is approximately symmetrical to the first terminal block 55. Note that, regarding the characteristics of the second terminal block 65, a description of the parts that are common to the first terminal block 55 will be omitted.

[0067] As shown in Fig. 4, the second terminal block 65 also has first wire passages 67a, 67b, and the first wire passage 67a and the first wire passage 67b are separated by a central partition 656. The first wire passages 67a, 67b of the second terminal block 65 have a shape that is substantially symmetrical to the first wire passages 57a, 57b of the first terminal block 55, except that they do not have a structure equivalent to the overhanging portion 57aa. As shown in Fig. 3, the second lead portion 32 is drawn out from the guide portion 41a of the bobbin 40 toward the first wire passages 67a, 67b in a substantially horizontal direction, so that the second terminal block 65 does not need a member that restricts the first wire 20 from above, such as the overhanging portion 57aa.

[0068] 3, the second terminal block 65 has a second wire passage 68b (including a downward opening 68ba) and a third wire passage 69b, similar to the first terminal block 55. The second lead portion 32 is guided and led through the first wire passages 67a, 67b, the second wire passage 68b, the third wire passage 69b, etc. from the guide portion 41a of the bobbin 40 toward the connection portion 63b of the second metal terminal 61a, and engages with the second terminal block 65.

[0069] Fig. 7 is a cross-sectional view of the coil device 10 shown in Fig. 1, and unlike Fig. 5, illustrates a resin part 90. As shown in Fig. 7, the resin part 90 is filled between the core 12 and the bobbin 40 and the case 80. The resin part 90 fills the gap between the core 12 and the bobbin 40 and the metal case 80, and efficiently transfers heat from the first coil part 21, the second coil parts 31a and 31b and their surroundings to the case 80 and the bottom plate 88, thereby improving the heat dissipation of the coil device 10.

[0070] The resin contained in the resin part 90 is not particularly limited, but is preferably a resin with excellent heat dissipation properties, for example, a thermal conductivity of 0.5 to 5, preferably 1 to 3 W / m·K. Examples of resins with excellent heat dissipation properties include silicone resins, urethane resins, and epoxy resins, with silicone resins and urethane resins being particularly preferred. Furthermore, in order to improve heat dissipation properties, the resin part 90 may contain a filler with high thermal conductivity.

[0071] The resin portion 90 can be formed, for example, by using a potting resin, filling the inside of the case 80 with uncured resin, and then curing the resin. However, the resin portion 90 is not limited to only the potting resin.

[0072] As shown in Fig. 7, the resin part 90 is formed inside the case 80 to a predetermined height from the bottom plate 88. The upper end of the resin part 90 is located above the lower ends of the cutout parts 84, 85 of the case 80. The cutout parts 84, 85 are closed by the first and second terminal blocks, and further, the inner parts 56, 66 can prevent uncured resin from leaking out of the cutout parts 84, 85. Therefore, in the coil device 10, the upper end of the resin part 90 is made higher than the cutout parts 84, 85, thereby improving heat dissipation.

[0073] The upper end of the resin part 90 is not particularly limited as long as it is at a height equal to or lower than the case upper end 86, but for example, it is preferable that it is located above the upper ends of the first coil part 21 and the second coil parts 31a, 31b which are the parts of the first wire 20 and the second wire 30 that are wound around the bobbin 40. Since heat generation in the coil device 10 is likely to occur in and around the first coil part 21 and the second coil parts 31a, 31b, by forming the resin part 90 up to a position that covers these, the coil device 10 has particularly good heat dissipation properties.

[0074] The coil device 10 can be fabricated, for example, by the following procedure. First, the first wire 20 and the second wire 30 are wound around the bobbin 40 shown in Fig. 2 to form the first coil portion 21 and the second coil portions 31a and 31b on the outer periphery of the hollow cylinder portion 42 of the bobbin 40. Next, the core 12 is set on the bobbin 40, which is then housed in the case 80, and the first terminal portion 50 and the second terminal portion are attached to the cutout portions 84 and 85 of the case 80.

[0075] Furthermore, the first lead portion 22 of the first wire 20 is routed to the first terminal block 55 of the first terminal portion 50, and the second lead portion 32 of the second wire 30 is routed to the second terminal block 65 of the second terminal portion 60, and engaged with them (see Figs. 4 and 6). Finally, the first wire ends 22a and 22b, which are the ends of the first wire 20, and the second wire ends 32b and 32b, which are the ends of the second wire 30, are fixed to the connecting wire portions 53a, 53b, 63a and 63b, respectively, to obtain the coil device 10 shown in Fig. 1. Note that the coil device 10 in which the connecting wire portions 53a, 53b, 63a and 63b are disposed at the ends in the X-axis direction can easily perform the process of fixing the first and second wire ends 22a, 22b, 32b and 32b by fusing or the like.

[0076] 7 can be formed by filling the case 80 with uncured resin before storing the bobbin 40 and the core 12 in the case 80, and curing the resin after storing the bobbin 40 and the core 12. However, the resin part 90 may also be formed by filling the case 80 with uncured resin and curing it after storing the bobbin 40 and the core 12 in the case 80.

[0077] As described above, in the coil device 10, the bobbin 40, the first and second terminal portions 50, 60, and the case 80 are each separate bodies. While the coil device 10 employs a metal case 80 that has good heat dissipation properties, by fixing the resin first and second terminal blocks 55, 65 to the case 80, it is possible to appropriately ensure insulation between the first and second wires 20, 30 and the case 80 and to arrange the connection portions 53a, 53b, 63a, 63b at low positions on the outside of the case 80.

[0078] The coil device 10 is merely one embodiment of the present invention, and the present invention includes many other embodiments and modifications. For example, as shown in Fig. 3, the first terminal portion 50 and the second terminal portion 60 may be installed at different heights, but, unlike this, the first terminal portion 50 and the second terminal portion 60 may be installed at the same height. Furthermore, the coil device 10 may have only one of the first terminal portion 50 and the second terminal portion 60, and only one of the first terminal portion 50 and the second terminal portion 60 may be attached to the cutout portions 84, 85.

[0079] 5, in the coil device 10, two second coil parts 31a, 31b are arranged to sandwich one first coil part 21 from inside and outside, but the arrangement of the second coil parts 31a, 31b and the first coil part 21 is not limited to this, and may be arranged, for example, in the Z-axis direction. The number of coil parts that the coil device 10 has is also not particularly limited. The shape of the hollow tube part 42 in the bobbin 40 is also not limited to only an elliptical tube, and may be a cylinder, a prismatic column, or other shape.

[0080] 10...Coil device 12…Core 12a…Upper connection part 12b…Lower connection 12c…middle leg 12d…side leg 20…First wire 21…First coil section 22…First lead section 22a, 22b, ... first wire end 30…Second wire 31a, 31b...Second coil section 32…Second lead section 32a, 32b...Second wire end 40…Bobbin 41…Upper flange 41a…Guide section 42...Hollow cylinder part 43…Lower tsuba 46…Insulating tape 50...1st terminal section 60…Second terminal section 51a, 51b...first metal terminal 61a, 61b…Second metal terminal 53a, 53b, 63a, 63b...Connection section 54a, 54b, 64a, 64b...Upward protrusion 55...1st terminal block 65…Second terminal block 56, 66…Inner part 56a…Inner lower end 57a, 57b, 67a, 67b...First wire passage 57aa…Eave part 57ab…1st aisle side wall 57ac…1st aisle bottom wall 58a, 58b, 68b...Second wire passage 58aa, 58ba, 68ba…Downward opening 59a, 59b, 69b...Third wire passage 555, 655...Outer support part 555a…Mounting groove 556, 656…Central partition 557…Curved wall 80…case 82…Upper opening edge 84, 85…Notch 86…Top of case 88…Bottom plate 90…Resin part

Claims

1. A bobbin with wire wound around it, a core attached to the bobbin; a metal case that houses the bobbin and the core; a terminal portion including a metal terminal to which a wire end portion, which is an end portion of the wire, is fixed and a resin terminal block that holds the metal terminal; The upper opening edge of the case is cut downward from the upper end of the case to form a cutout portion to which the terminal block is attached, a connecting portion for fixing the wire end portion at the metal terminal is disposed outside the case and at a position lower than the upper end of the case; the terminal block has an inner portion disposed inside the case and an outer support portion disposed outside the case, A coil device in which the inner portion extends to a position lower than the lower end of the cutout portion and the outer support portion.

2. The coil device according to claim 1 , wherein the terminal block has a first wire passage that restricts the wire at least from above.

3. The coil device according to claim 2 , wherein the first wire passage restricts the wire at least in the vertical direction and is formed across the upper opening edge from the inside to the outside of the case.

4. 4. The coil device according to claim 3, wherein the horizontal width of the inner portion is greater than the horizontal width of the notch.

5. a resin portion filled between the bobbin and the core and the case, 5. The coil device according to claim 1, wherein an upper end of the resin portion is positioned higher than a lower end of the notch portion.

6. a resin portion filled between the bobbin and the core and the case, 6. The coil device according to claim 1, wherein an upper end of the resin portion is located above an upper end of a coil portion that is a portion of the wire that is wound around the bobbin.

7. the terminal block has a second wire passage that restricts the wire at least laterally and guides the wire along a vertical direction outside the case, The coil device according to any one of claims 1 to 6, wherein the second wire passage has a downward opening through which the wire can be temporarily led out in a downward direction that is different from the direction in which the wire is led out from the second wire passage.

8. The coil device according to claim 7, wherein the terminal block has a third wire passage that restricts the wire led out from the second wire passage at least from above and guides the wire toward the connection portion that is positioned lower than the lower end of the cutout portion.

9. the terminal block has a first wire passage that restricts the wire at least from above, The coil device according to claim 8 , wherein the wire is guided from the bobbin to the connection portion through the first wire passage, the second wire passage, and the third wire passage in this order.

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