Coil device

Abstract

To provide a coil device which not only allows reduction in height and has a smaller footprint of a case but also excels in heat dissipation.SOLUTION: A coil device 10 has: a bobbin 20 around which a wire 41a is wound; a conductive terminal 61a to which a lead part 43a1 of the wire 41a is connected; an insulative terminal block 70 to which the terminal 61a is fitted; and a case 90 in which the bobbin 20 is housed. The bobbin 20 is disposed inside the case 90 in such a manner that a winding axis of the wire 41a may be substantially parallel to a bottom surface 90b of the case 90. The case 90 has a terminal block support part 91 which protrudes outward from an edge 96 of an upper opening 90a of the case 90. Above the terminal block support part 91, the terminal block 70 is fitted via an insulation ensuring member 80.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] The present invention relates to a coil device suitably used, for example, as a transformer or the like.

Background Art

[0002] As a coil device used for a relatively large transformer or the like, for example, a coil device shown in Patent Document 1 below has been developed. In this developed coil device, a bobbin around which a wire is wound is housed inside a case, and the inside of the case is filled with a resin having excellent heat transfer properties such as potting resin, thereby enhancing heat dissipation.

[0003] However, in recent years, there has been a demand for reducing the height of coil devices such as transformers. In addition, it is required to improve the heat dissipation characteristics while reducing the installation area of the case.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In view of such a situation, the present invention has been made, and an object thereof is to provide a coil device that can be made low-profile, has a small installation area of the case, and has excellent heat dissipation properties.

Means for Solving the Problems

[0006] To achieve the above object, a coil device according to the present invention includes a bobbin around which a wire is wound, a conductive terminal to which a lead portion of the wire is connected, an insulating terminal block to which the terminal is attached, a case in which the bobbin is housed, A coil device having The bobbin is disposed inside the case such that the winding axis of the wire is substantially parallel to the bottom surface of the case. The case has a terminal block support portion that protrudes outward from the edge of the upper opening of the case. The terminal block is attached onto the terminal block support portion via an insulation securing member.

[0007] In the coil device according to the present invention, the bobbin is disposed inside the case such that the winding axis of the wire is substantially parallel to the bottom surface of the case. That is, the coil device of the present invention is a horizontal type coil device, and can be easily made lower-profile compared to a vertical type coil device in which the winding axis of the wire is substantially perpendicular to the bottom surface of the case.

[0008] Also, in the coil device of the present invention, the terminal block is supported on the terminal block support portion that protrudes outward from the edge of the upper opening of the case. Therefore, it is not necessary to increase the installation area of the case corresponding to the area of the terminal block, and the installation area of the case can be made small while being horizontal.

[0009] Furthermore, since the terminal block support portion formed by extending the outer wall of the case supports the terminal block, the strength and reliability of the terminal block can be improved. In particular, when connecting the terminals provided on the terminal block of the coil device to a substrate disposed above the coil device, the terminal block support portion facilitates the connection to the substrate and improves the reliability in order to reinforce the strength of the terminal block.

[0010] In addition, by filling the inside of the case with a heat-dissipating resin such as potting resin, heat from the wire or the bobbin (including the core) can be dissipated to the bottom surface of the case through the heat-dissipating resin, improving the heat dissipation performance. Further, since the terminal block is supported on the terminal block support portion that protrudes outward from the edge of the upper opening of the case, most of the bobbin (including the wire and the core) including at least the winding shaft of the wire can be brought into contact with the heat-dissipating resin inside the case without being obstructed by the terminal block. Therefore, the heat dissipation performance can be effectively enhanced with a minimum amount of necessary heat-dissipating resin.

[0011] Furthermore, in the coil device of the present invention, the terminal block is attached on the terminal block support portion via an insulation ensuring member. For this reason, after winding a plurality of wires around the bobbin and attaching a plurality of terminals to the terminal block, the operation of connecting the lead portions of the plurality of wires to the plurality of terminals at once becomes easy. For the connection of the lead portion of the wire to the terminal, for example, thermocompression bonding such as crimping is used.

[0012] When connecting the lead portion of the wire to the terminal, it is necessary to press a thermocompression bonding jig or the like from both sides of the lead portion. Before attaching the insulation ensuring member to the terminal block, it is easy to press a thermocompression bonding jig or the like from both sides of the lead portion. Further, after connecting the lead portion of the wire to the terminal, since the insulation ensuring member is disposed on one side of the joint portion between the terminal and the lead portion of the wire, the insulation between the joint portion and the core attached to the bobbin can be effectively ensured. In addition, the insulation ensuring member can also ensure the insulation between the lead portion and the joint portion of the terminal and the case.

[0013] Preferably, the insulation ensuring member has an insulation sheet portion, The insulation sheet portion is disposed between the joint portion of the terminal to which the lead portion of the wire is connected and the core attached to the bobbin. By configuring in this way, the insulation ensuring member can enhance the insulation between the joint portion of the lead portion and the terminal and the outer leg portion of the core attached to the bobbin. In addition, the insulation ensuring member can also improve the insulation between the lead portion and the joint portion of the terminal and the case.

[0014] Preferably, the insulation ensuring member is integrally formed with the insulation sheet portion and further has an intermediate portion sandwiched between the terminal block support portion and the terminal block. The intermediate portion has an intermediate engaging portion that engages with the terminal block. By engaging an intermediate engaging portion such as an engaging claw with the terminal block, it becomes easy to attach the terminal block while positioning it with respect to the insulation ensuring member. Also, it becomes possible to fix the terminal block and the insulation ensuring member without using an adhesive. However, an adhesive may be used.

[0015] Preferably, the intermediate portion has an intermediate convex portion that enters a support through-hole formed in the terminal block support portion. By the intermediate convex portion entering the support through-hole, it becomes easy to position the insulation ensuring member and the terminal block support portion.

[0016] The intermediate convex portion may have a receiving recess that opens toward the terminal block. The receiving recess may be configured such that a screw portion for connecting an external terminal such as a circuit board and a terminal of the terminal block enters therein. The receiving recess can accommodate metal dust and the like when screwing a screw portion such as a bolt to a nut or the like of the terminal block.

[0017] The terminal block may have an engaging convex portion that engages with an engaging hole formed in the terminal block support portion through an intermediate through-hole formed in the intermediate portion. By the engaging convex portion engaging with the engaging hole formed in the terminal block support portion through the intermediate through-hole, positioning between the terminal block and the insulation ensuring member is performed and attachment while positioning between the terminal block and the terminal block support portion becomes easy. Also, it becomes possible to fix the terminal block, the insulation ensuring member, and the terminal block support portion without using an adhesive. However, an adhesive may be used.

[0018] The case may be provided with a cover member that covers at least a part of the upper opening of the case with a predetermined gap. By covering a part of the upper opening of the case with a predetermined gap, when connecting the terminals of the coil device to a substrate or the like, it is possible to effectively prevent the protruding portion from the substrate or the substrate itself from contacting the protruding portion of the core or the lead portion of the wire and being damaged.

[0019] Preferably, the cover member covers at least a part of the wire wound around the bobbin housed inside the case. More preferably, the cover member covers the entire wound portion of the wire except for the lead portion of the wire. By forming the cover member of metal or the like, the effect of shielding the leakage magnetic flux from the wound portion (coil portion) of the wire is improved.

[0020] The cover member may be integrally formed with the case, or may be separately molded and attached by fitting or the like. By integrally forming the cover member and the case by bending a metal plate or the like, the manufacture of the cover member and the case becomes easy. Also, preferably, the terminal block support portion is integrally formed with the case. By integrally forming the terminal block support portion and the case by bending a metal plate or the like, the manufacture of the terminal block support portion and the case becomes easy.

[0021] Preferably, the bobbin has a winding core portion around which the wire is wound and a flange portion attached to an end of the winding core portion. Preferably, the flange portion has a protective hook portion that protrudes upward from the upper opening of the case and guides the lead of the wire to the terminal block. By hooking the lead of the wire on the protective hook portion, it becomes easier to guide the lead portion of the wire to the terminal attached to the terminal block.

[0022] Preferably, the protective hook portion has a height flush with or higher than the upper surface of the terminal, and the wire connection portion between the lead portion of the wire and the terminal is disposed at a position lower than the upper surface of the terminal. By arranging in this way, the protective hook portion can effectively protect the connection portion and prevent the protruding portion from the substrate or the substrate itself from contacting the connection portion.

[0023] Also, preferably, the protective hook portion is preferably lower than the lower surface of the cover member. By arranging it in this way, the cover member can protect the wire connection portion together with the protective hook portion, and effectively prevent the protrusion from the substrate or the substrate itself from contacting the wire connection portion.

Brief Description of the Drawings

[0024]

Figure 1A

Figure 1B

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 6A

Figure 6B

Figure 6C

Figure 7

Figure 8

Figure 9A

Figure 9B

Figure 10

Embodiments for Carrying Out the Invention

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

[0026] First Embodiment As an example of the coil device 10 according to the present embodiment shown in FIG. 1A, the coil device 10 functions as, for example, a transformer and is used in an in-vehicle charger for an EV (Electric Vehicle), a PHV (Plug-in Hybrid Vehicle), or a commuter (vehicle), or a power supply circuit for household or industrial electrical equipment, or a power supply circuit for computer equipment.

[0027] Hereinafter, the detailed configuration of the coil device 10 will be described. In the following description, in the drawings, the X-axis, Y-axis, and Z-axis are perpendicular to each other. Also, the side facing the center of the coil device 10 is defined as the inner side or inward, and the side away from the center of the coil device 10 is defined as the outer side or outward.

[0028] As shown in FIG. 2, the coil device 10 includes a bobbin 20, wires 41a, 41b, cores 50a and 50b, terminals 61a, 61b, 62a, 62b, a terminal block 70, an insulation securing member 80, and a case 90. The coil device 10 is a horizontal coil device arranged such that the winding axes C of the coil portions 42a, 42b of the wires 41a, 41b are parallel to the bottom surface 90b of the case 90.

[0029] In this embodiment, the X-axis is parallel to the winding axis C of the wires 41a and 41b, and the Y-axis substantially coincides with the direction in which the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b are drawn out. The Z-axis corresponds to the height (thickness) direction of the coil device 10. In this embodiment, the upper side along the Z-axis of the coil device 10 is the installation surface of the circuit board to which the terminals 61a, 61b, 62a, and 62b of the coil device 10 (transformer) are connected.

[0030] As shown in FIG. 2, the coil portion 42a is formed by winding the wire 41a around the outer peripheral surface of the bobbin core portion 21 of the bobbin 20 shown in FIG. 5A. The coil portion 42b is formed by winding the wire 41b around the outer peripheral surface of the bobbin core portion 21 of the bobbin 20 shown in FIG. 5A. The wires 41a and 41b are wound around the outer peripheral surface of the core portion 21 using, for example, an automatic winding machine.

[0031] As shown in FIG. 10, the coil portion 42a (42b) formed by the wire 41a (41b) is one layer or two or more layers in the direction (radial direction) orthogonal to its winding axis. As shown in FIG. 2, the winding axes C of the coil portions 42a and 42b substantially coincide and are each parallel to the X-axis.

[0032] As shown in FIG. 2, the coil portion 42a is wound on one side along the X-axis of the core portion, and the coil portion 42b is wound on the other side along the X-axis of the core portion. Either one of the coil portions 42a and 42b constitutes the primary coil, and the other of the coil portions 42a and 42b constitutes the secondary coil. The arrangement of each of the primary coil and the secondary coil in the core portion may be either on one side or the other side along the X-axis of the core portion.

[0033] Wires 41a and 41b are each composed of, for example, insulated wires, and are composed of conductive wires such as copper wires coated with an insulating layer. The conductive wires of wires 41a and 41b may each be composed of a single wire or a stranded wire. The wire diameter (diameter) of wires 41a and 41b is not particularly limited and is, for example, 1.0 to 3.0 mm. The wire diameters of wires 41a and 41b may be equal to each other or different. For example, among wires 41a and 41b, the wire diameter of the wire through which a large current flows may be made thicker than the wire diameter of the other wire.

[0034] A lead portion 43a1 is formed at one end of wire 41a, and a lead portion 43a2 is formed at the other end of wire 41a. Also, a lead portion 43b1 is formed at one end of wire 41b, and a lead portion 43b2 is formed at the other end of wire 41b.

[0035] As shown in FIG. 2, cores 50a and 50b are each a so-called E-shaped core and are attached to bobbin 20. The materials of cores 50a and 50b include magnetic materials such as metal and ferrite, but are not particularly limited.

[0036] Cores 50a and 50b each have the same shape (for example, E-shaped and E-shaped), but may have different shapes (for example, E-shaped and I-shaped). In the present embodiment, core 50a has a base portion 51a, a pair of outer leg portions 52a, and a middle leg portion 53a. Core 50b has a base portion 51b, a pair of outer leg portions 52b, and a middle leg portion 53b. Hereinafter, the configuration of core 50a will be described, but the description of core 50a also applies to core 50b. Therefore, the description of the configuration of core 50b will be omitted unless particularly necessary.

[0037] The base portion 51a has a predetermined thickness along the X-axis and has a predetermined length along each of the Y-axis and the Z-axis as shown in FIG. 7. Hereinafter, as shown in FIG. 2, in the base portion 51a, the outer surface along its X-axis is referred to as the outer surface 510a, the inner surface along its X-axis is referred to as the inner surface 511a, the upper surface is referred to as the upper surface 512a, and the lower surface is referred to as the lower surface 513a. Further, in the base portion 51b, the outer surface along its X-axis is referred to as the outer surface 510b, the inner surface along its X-axis is referred to as the inner surface 511b, the upper surface is referred to as the upper surface 512b, and the lower surface is referred to as the lower surface 513b.

[0038] The upper surface 512a and the lower surface 513a are surfaces orthogonal to the outer surface 510a and the inner surface 511a. The upper surface 512b and the lower surface 513b are surfaces orthogonal to the outer surface 510b and the inner surface 511b. As shown in FIG. 7, the upper surface 512a of the base portion 51a is at the same height as the outer leg upper surface 522a of the outer leg portion 52a.

[0039] On the lower surface 513a of the base portion 51a, a concave portion 55a that is recessed upward along the Z-axis is formed at the position of the middle leg portion 53a. The concave portion 55a is formed substantially at the center of the base portion 51a with respect to the Y-axis and has a predetermined width along the X-axis and the Y-axis. The width of the concave portion 55a along the Y-axis is smaller than the width of the middle leg portion 53a along the Y-axis and is substantially equal to the width of the concave bottom portion 37a or 37b of the bobbin 20 shown in FIG. 5B along the Y-axis. The concave portion 55a shown in FIG. 7 is formed so as to penetrate from the inner surface to the outer surface of the base portion 51a.

[0040] As shown in FIG. 7, the concave portion 55a is recessed upward from the lower surface 513a by a predetermined depth. The upper end of the inner peripheral surface 550a of the concave portion 55a is located below the lower end outer peripheral surface of the middle leg portion 53a, but may be flush. In the present embodiment, the inner peripheral surface 550a has a substantially flat ceiling surface, but may be curved, triangular, or polygonal.

[0041] The inner peripheral surface 550a of the concave portion 55a may have tapered surfaces 551a on both sides along the Y-axis. The tapered surfaces 551a are formed such that the width of the concave portion 55a along the Y-axis becomes narrower as it goes upward from the lower surface 513a. The shape of the concave portion 55a substantially coincides with the shape of the concave bottom 37a or 37b of the bobbin 20 shown in FIG. 5B, but may be different.

[0042] As shown in FIG. 2, the middle leg portion 53a is disposed between a pair of outer leg portions 52a and is connected to the inner surface 511a of the base portion 51a. The middle leg portion 53a extends along the X-axis from the inner surface 511a by a predetermined length and is disposed inside the through hole 211 of the bobbin 20. The middle leg portion 53a of the core 50a and the middle leg portion 53b of the core 50b are disposed inside the through hole 211 with their respective end faces 531a and 531b abutted against each other. A gap may be formed along the X-axis between the end face 531a of the middle leg portion 53a and the end face 531b of the middle leg portion 53b.

[0043] As shown in FIG. 7, in the present embodiment, the cross section (a section perpendicular to the X-axis) of the middle leg portion 53a (53b) has a downwardly bulging shape. That is, at an intermediate horizontal plane P0 passing through the midpoint of the vertical distance line that shortest connects between the upper horizontal plane P1 including the upper end (along the Z-axis) E1 of the middle leg portion 53a (53b) and the lower horizontal plane P2 including the lower end (along the Z-axis) E2 of the middle leg portion 53a (53b), the middle leg portion 53a (53b) is divided into an upper half ML1 and a lower half ML2. The intermediate horizontal plane P0 is a plane including the central axis (center along the Z-axis) O of the middle leg portion 53a (53b).

[0044] In this case, in the coil device 10 of the present embodiment, the cross-sectional area (CA2) of the lower half ML2 of the middle leg portion 53a (53b) of the core 50a (50b) is larger than the cross-sectional area (CA1) of the upper half ML1. Alternatively, the volume (V2) of the lower half ML2 of the middle leg portion 53a (53b) of the core 50a (50b) is larger than the volume (V1) of the upper half ML1. Alternatively, the outer peripheral surface area (OA2) of the lower half ML2 of the middle leg portion 53a (53b) of the core 50a (50b) is larger than the outer peripheral surface area (OA1) of the upper half ML1.

[0045] In addition, in the present embodiment, as shown in FIG. 7, although the cross section of the middle leg portion 53a (53b) has a downwardly bulging shape, other cross-sectional shapes, for example, a circular cross section, an elliptical cross section, or a polygonal cross-sectional shape may also be used. Further, in the present embodiment, the liquid level S of the potting resin described later is lower than a predetermined height T1 from the upper end E1 (along the Z-axis) of the middle leg portion 53a (53b). By doing so, it is possible to reduce the height of the coil device 10 including the case 90 shown in FIG. 1A.

[0046] Further, in the present embodiment, the Z-axis position of the upper end E1 of the outer peripheral surface of the middle leg portion 53a is substantially the same as the Z-axis position with the upper surface 512a of the base portion 51a, and it is preferable that the upper vertex along the Z-axis of the middle leg portion 53a is connected to the upper surface 512a of the base portion 51a without a step. However, the Z-axis position of the upper end E1 of the outer peripheral surface of the middle leg portion 53a may be different from the Z-axis position with the upper surface 512a of the base portion 51a. Further, the lower portion including the lower end E2 of the outer peripheral surface of the middle leg portion 53a is disposed at a position close to the inner peripheral surface 550a of the concave portion 55a, and is preferably located above the inner peripheral surface 550a, but is not limited thereto.

[0047] As shown in FIG. 2, the pair of outer leg portions 52a are arranged at a predetermined interval along the Y-axis and are connected to the inner surface 511a of the base portion 51a. One of the pair of outer leg portions 52a is disposed at one end along the Y-axis of the inner surface 511a, and the other of the pair of outer leg portions 52a is disposed at the other end along the Y-axis of the inner surface 511.

[0048] As shown in FIG. 7, the outer leg inner surface 520a of the outer leg portion 52a is curved inward along the Y-axis as it goes upward and downward from the intermediate horizontal plane P0 along the Z-axis of the outer leg portion 52a. Further, the curved portion of the outer leg inner surface 520a is curved at a predetermined interval along the outer peripheral surface of the middle leg portion 53a. Further, the curved portion of the outer leg inner surface 520a is curved along the outer peripheral edge of the flange portion 22a (flange portion main body 220a) of the bobbin 20 shown in FIG. 5A.

[0049] Note that the outer surface of the outer leg portion 52a, which is located on the opposite side of the inner surface 520a of the outer leg shown in FIG. 7 along the Y-axis, has a plane perpendicular to the Y-axis and has a shape different from the curved shape of the inner surface 520a of the outer leg. Also, at the lower end of each of the pair of outer leg portions 52a (52b) along the Z-axis, a thick portion 56a having a greater thickness in the Y-axis direction than the upper end of the outer leg portion 52a is formed. The inner surface 520a (520b) of the thick portion 56a protrudes inward along the Y-axis and forms a plane perpendicular to the Y-axis.

[0050] In this embodiment, by forming the thick portion 56a in the outer leg portion 52a, it is possible to sufficiently secure the area covered by the potting resin of the outer leg portion 52, and a coil device 10 having good inductance characteristics can be obtained.

[0051] Also, in this embodiment, when each of the outer leg portions 52a (52b) is divided into an upper half OL1 of the outer leg and a lower half OL2 of the outer leg by the intermediate horizontal plane P0, the outer leg portion 52a (52b) has a shape in which the volume (OV2) of the lower half OL2 of the outer leg is larger than the volume (OV1) of the upper half OL1 of the outer leg. Similar to the middle leg portions 53a (53b), by making the volume of the lower half OL2 of the outer leg larger than the volume of the upper half OL1 of the outer leg, it is possible to reduce the height and size while improving the heat dissipation. Also, the balance of the magnetic flux is improved and the characteristics are enhanced. Note that the volume may be replaced with the cross-sectional area or the area of the outer peripheral surface, similar to the middle leg portions 53a (53b).

[0052] As shown in FIG. 2, the pair of outer leg portions 52a extend along the X-axis from the inner surface 511a by a predetermined length, similar to the middle leg portion 53a, and are arranged outside the bobbin portion 21 of the bobbin 20. Also, the middle leg portion 53a is inserted into the through hole 211 of the bobbin 20.

[0053] As shown in FIGS. 5A and 5B, the bobbin 20 has a core portion 21 and flange portions 22a and 22b. The core portion 21 of the bobbin 20 extends along the X-axis, and flange portions 22a and 22b are formed at both ends along the X-axis of the core portion 21. At the central portion along the X-axis of the core portion 21, protrusions 33 and 34 protruding outward along the Z-axis are formed on opposite sides of the Z-axis, respectively.

[0054] Wire 41a and 41b shown in FIG. 2 are wound around the outer peripheral surface of the core portion 21 to form coil portions 42a and 42b. Coil portion 42a is disposed between flange portion 22a and protrusion 33 (34) on one side along the X-axis of the core portion 21 shown in FIG. 5A. Also, coil portion 42b shown in FIG. 2 is disposed between flange portion 22b and protrusion 33 (34) on the other side along the X-axis of the core portion 21 shown in FIG. 5A.

[0055] As shown in FIG. 2, one end along the winding axis of coil portion 42a is disposed at a position adjacent to flange portion 22a, and the other end along the winding axis of coil portion 42a is disposed at a position adjacent to protrusions 33 and 34. Also, one end along the winding axis of coil portion 42b is disposed at a position adjacent to flange portion 22b, and the other end along the winding axis of coil portion 42b is disposed at a position adjacent to protrusions 33 and 34.

[0056] As shown in FIG. 5B, the core portion 21 is a cylindrical body, and the through hole 211 of the core portion 21 has a lower-expanded shape in its cross-section corresponding to the cross-section of the middle leg portion 53a shown in FIG. 7. The axis of the core portion 21 is parallel to the X-axis. Inside the through hole 211, the middle leg portions 53a and 53b of cores 50a and 50b can be accommodated while creating a predetermined gap (which may be partially 0) on its outer peripheral surface.

[0057] As shown in Fig. 5A, a through hole 35 penetrating the inside and outside of the core portion 21 is formed in the upper portion of the outer peripheral surface of the core portion 21. The through hole 35 is located at a substantially central portion of the core portion 21 with respect to the X-axis and the Y-axis, and is located between the protruding portions 33, 33. The through hole 35 has a substantially elliptical opening having a long diameter along the X-axis. The cross-sectional shape of the through hole 35 has a shape corresponding to the cross-sectional shapes of the middle leg portions 53a and 53b, and the middle leg portions 53a and 53b can be inserted into the through hole 35 with a predetermined gap.

[0058] As shown in Fig. 5B, a through hole 36 penetrating the inside and outside of the core portion 21 is also formed in the lower portion of the outer peripheral surface of the core portion 21. The through hole 36 is located at a substantially central portion of the core portion 21 with respect to the X-axis and the Y-axis, and is located between the protruding portions 34, 34. The through hole 36 has a substantially elliptical opening having a long diameter along the X-axis. Along the Z-axis, the through hole 36 is formed at a position opposite to the through hole 35.

[0059] By forming the through holes 35 and 36 in the core portion 21, it becomes possible to circulate the potting resin 210 (see Fig. 10) inside and outside the bobbin 20 (core portion 21) through these through holes 35, 36, and the potting resin 210 can be spread to every corner in the case 90.

[0060] As shown in Fig. 5A, the flange portion 22a is formed at one end along the axis of the core portion 21, and the flange portion 22b is formed at the other end along the axis of the core portion 21. The flange portion 22a and the flange portion 22b have the same shape respectively, but they may be different. The flange portion 22a has a flange body 220a extending in the circumferential direction along the outer peripheral surface of the core portion 21 at one end along the X-axis of the core portion 21. The flange portion 22b has a flange body 220b extending in the circumferential direction along the outer peripheral surface of the core portion 21 at the other end along the Y-axis of the core portion 21.

[0061] The flange body 220a is formed of a plate having a predetermined thickness in the X-axis direction and protrudes outward along the radial direction of the core part 21. The flange body 220b is formed of a plate having a predetermined thickness along the X-axis direction and protrudes outward along the radial direction of the core part 21.

[0062] As shown in FIG. 5B, below the flange body 220a, a pair of mounting portions 32a are formed so as to protrude downward from the body 220a along the Z-axis. One mounting portion 32a is formed on one side of the flange body 220a along the Y-axis, and the other mounting portion 32a is formed on the other side of the flange body 220a along the Y-axis. One mounting portion 32a and the other mounting portion 32a are arranged at a predetermined interval along the Y-axis. The pair of mounting portions 32a extend substantially parallel to the YZ plane with respect to the flange body 220a, and the bottom surfaces of the pair of mounting portions 32a are substantially flat surfaces in the same plane. The pair of mounting portions 32a are placed on the bottom surface 90b of the case 90 shown in FIG. 2.

[0063] As shown in FIG. 5B, below the flange body 220b, a pair of mounting portions 32b are formed in the same manner as the pair of mounting portions 32a. Since the configuration and function of the pair of mounting portions 32b are the same as those of the pair of mounting portions 32a, detailed description thereof will be omitted. It is possible to support the core part 21 of the bobbin 20 and the like via the pair of mounting portions 32a and the pair of mounting portions 32b.

[0064] A concave bottom 37a is formed between each of the pair of mounting portions 32a, and a concave bottom 37b is formed between each of the pair of mounting portions 32b. The concave bottoms 37a and 37b have a shape recessed upward from the positions of the bottom surfaces of the mounting portions 32a and 32b. Tapered inclined portions are formed on both sides of the inner peripheral surfaces of the concave bottoms 37a and 37b.

[0065] The inner peripheral surface shapes of the concave bottoms 37a and 37b preferably correspond to the inner peripheral surface shapes of the recesses 55a (55b) formed in the cores 50a (50b) shown in FIG. 7 and are substantially the same shape, but they may be larger or smaller than that. As shown in FIG. 5B, the upper ends of the concave bottoms 37a and 37b may be at the same height as the lower end of the outer peripheral surface of the bobbin core portion 21, or may be lower than that.

[0066] By forming the concave bottoms 37a and 37b in the flange body portions 220a and 220b, the concave bottoms 37a and 37b function as flow paths for the potting resin 210 (FIG. 10) during the filling of the potting resin 210. For example, the potting resin 210 flows through the inside of the concave bottom 37a (37b) from the inner side (outer side) to the outer side (inner side) along the X-axis of the concave bottom 37a (37b), and the potting resin 310 can be spread particularly below the bobbin 20.

[0067] From the viewpoint of improving the heat dissipation by facilitating the flow of the potting resin in the X-axis direction, the larger the sizes of the concave bottoms 37a and 37b are, the more preferable they are, but it is determined by the balance with the strength of the mounting portions 32a and 32b, etc. The same applies to the recesses 55a (55b) formed in the cores 50a (50b) shown in FIG. 7.

[0068] As shown in FIG. 5A, above the flange body portion 220a, protective hook portions 23a and 24a are formed side by side along the Y-axis. The protective hook portions 23a and 24a are connected above the flange body portion 220a via protective hook holding portions 23a1 and 24a1. Core separation walls 25a and 26a are formed in the protective hook holding portions 23a1 and 24a1. The core separation walls 25a and 26a protrude outward along the X-axis and face the protective hook portions 23a and 24a.

[0069] Above the flange body 220a, an extended flange portion 27a is formed. The extended flange portion 27a is integrally connected above the flange body 220a and extends substantially parallel to the YZ plane with respect to the flange body 220a. That is, the extended flange portion 27a has a shape that extends the flange body 220a upward and constitutes a part of the flange body 220a. The extended flange portion 27a has a predetermined thickness along the X axis and has a surface substantially parallel to the YZ plane.

[0070] A notch portion 28a is formed between the respective protection hook portions 23a, 24a. The lead portions 43a1, 43a2 of the wire 41a shown in FIG. 2 can be inserted through the notch portion 28a. Also, the lead portion 43a1 shown in FIG. 2 can be inserted between the core separation wall 25a and the protection hook portion 23a. Further, the lead portion 43a2 can be inserted between the core separation wall 26a and the protection hook portion 24a.

[0071] In the present embodiment, as shown in FIG. 2, among the lead portions 43a1, 43a2, the lead portion 43a1 passes through the notch portion 28a shown in FIG. 5A, passes between the core separation wall 25a and the protection hook portion 23a, and is drawn out toward the terminal 61a. Also, the lead portion 43a2 shown in FIG. 2 passes through the notch portion 28a, passes between the core separation wall 26a and the protection hook portion 24a, goes around the outside along the Y axis of the protection hook portion 24a, and is drawn out toward the terminal 62a. The core separation walls 25a, 26a can ensure good insulation of the lead portions 43a1, 43a2 from the core 50a.

[0072] As shown in FIG. 5A, above the flange body 220b, protection hook portions 23b, 24b are formed side by side along the Y axis. The protection hook portions 23b, 24b are connected above the flange body 220b via protection hook holding portions 23b1, 24b1. Core separation walls 25b, 26b are formed in the protection hook holding portions 23b1, 24b1. The core separation walls 25b, 26b project outward along the X axis and face the protection hook portions 23b, 24b.

[0073] Above the flange body 220b, an extended flange portion 27b is formed. The extended flange portion 27b is integrally connected above the flange body 220b and extends substantially parallel to the flange body 220b along the YZ plane. That is, the extended flange portion 27b has a shape that extends the flange body 220b upward and constitutes a part of the flange body 220b. The extended flange portion 27b has a predetermined thickness along the X axis and has a surface substantially parallel to the YZ plane.

[0074] A notch portion 28b is formed between the respective protection hook portions 23b and 24b. The lead portions 43b1 and 43b2 of the wire 41b (FIG. 2) can be inserted through the notch portion 28b. Further, the lead portion 43b1 can be inserted between the core separation wall 25b and the protection hook portion 23b. Also, the lead portion 43b2 can be inserted between the core separation wall 26b and the protection hook portion 24b.

[0075] In the present embodiment, as shown in FIG. 2, among the lead portions 43b1 and 43b2, the lead portion 43b1 passes through the notch portion 28b, passes between the core separation wall 25b and the protection hook portion 23b, and is drawn out toward the terminal 61b. Also, the lead 43b2 passes through the notch portion 28b, passes between the core separation wall 26b and the protection hook portion 24b, turns outside along the Y axis of the protection hook portion 24b, and is drawn out toward the terminal 62b. The core separation walls 25b and 26b can ensure good insulation between the lead portions 43b1 and 43b2 and the core 50b.

[0076] As shown in FIG. 6A, the case 90 is formed by bending a single plate-like member such as a metal excellent in heat dissipation such as aluminum. The case 90 is composed of a plate-like member constituting the lower bottom surface 90b along the Z axis, plate-like members constituting the side surfaces 90c and 90c on both sides along the X axis, and plate-like members constituting the side surfaces 90d and 90d on both sides along the Y axis. The upper side along the Z axis is an upper opening 90a. There is a gap between the plate-like members on the side surface 90c, and there is also a gap between the plate-like members between the side surface 90c and the bottom surface 90b.

[0077] Case 90 has a terminal block support portion 91. The terminal block support portion 91 is disposed on the upper side along the Z-axis of one side surface 90d along the Y-axis, and protrudes outward along the X-axis from the opening edge 96 of the upper opening 90a. The terminal block support portion 91 is formed with support through holes 92a, 92b, 93a, 93b, engagement holes 94a, 94b, and a central hole 95.

[0078] Case 90 is further integrally formed with a cover member 100. The side cover portion 102 of the cover member 100 is connected to the other side surface 90d of the case 90 along the Y-axis. The opening cover portion 101 of the cover member 100 is connected to the side cover portion 102 and covers a part of the upper side along the Z-axis of the upper opening 90a.

[0079] As shown in FIG. 2, the terminal block 70 is formed separately from the bobbin 20 and is attached to the upper side along the Z-axis of the terminal block support portion 91 via an insulation securing member 80. The terminal block 70 may be composed of the same insulating member as the bobbin 20, but is preferably composed of an insulating member having better moldability (or heat resistance or insulation). Further, the insulation securing member 80 may be composed of the same insulating member as the bobbin 20, but is preferably composed of an insulating member having better insulation. Note that the bobbin 20 is composed of, for example, plastics such as PPS, PET, PBT, LCP, or other insulating members (preferably materials having heat resistance).

[0080] As shown in FIG. 8, the terminal block 70 has a terminal block base portion 701 extending along the X-axis. Fastener placement holes 71a, 71b, 72a, 72b are formed along the X-axis in the terminal block base portion 701. Fasteners 78a, 78b, 79a, 79b can be respectively embedded in the fastener placement holes 71a, 71b, 72a, 72b.

[0081] The fasteners 78a, 78b, 79a, and 79b may be integrally formed with the terminal block base portion 701. Bolts or the like for fixing external terminals from a circuit board or the like can be detachably attached to each of the fasteners 78a, 78b, 79a, and 79b. The fastener arrangement holes 71a, 71b, 72a, and 72b penetrate from the upper surface along the Z-axis of the terminal block base portion 701 downward along the Z-axis.

[0082] In the present embodiment, the fasteners 78a, 78b, 79a, and 79b are, for example, hexagonal nuts and have a hexagonal outer shape corresponding to the fastener arrangement holes 71a, 71b, 72a, and 72b. Around each of the fastener arrangement holes 71a, 71b, 72a, and 72b, mounting claw holes 73a1 to 73a4, 73b1 to 73b4, 74a1 to 74a4, and 74b1 to 74b4 are formed from the upper surface along the Z-axis of the terminal block base portion 701 downward along the Z-axis. By inserting the mounting claws of the terminals described later into the mounting claw holes 73a1 to 73a4, 73b1 to 73b4, 74a1 to 74a4, and 74b1 to 74b4, the terminals and the terminal block 70 can be fixed.

[0083] As shown in FIG. 9A, in the present embodiment, on the inner surface along the Y-axis of the terminal block base portion 701, a terminal separation wall fitting groove 77 is formed along the Z-axis. The terminal separation wall fitting groove 77 is formed so that the terminal separation wall 87 can be fitted. Also, at the middle of the fastener arrangement holes 72a and 72b, on the outer surface along the Y-axis of the terminal block base portion 701, an engaging notch 76 is formed. By engaging claws 861 of the middle engaging portion 86 of the insulation ensuring member 80 being caught in the engaging notch 76, the terminal block 70 and the insulation ensuring member 80 can be fixed.

[0084] As shown in FIG. 9A, on the lower surface along the Z-axis of the terminal block base portion 701 of the terminal block 70, engaging convex portions 75a and 75b are formed. The engaging convex portions 75a and 75b extend downward along the Z-axis. The engaging convex portions 75a and 75b are formed at positions corresponding to the middle through holes 85a and 85b of the insulation ensuring member 80 shown in FIG. 9B and the support through holes 94a and 94b of the terminal block support portion 91 shown in FIG. 6A.

[0085] The engaging convex portions 75a and 75b are inserted into the intermediate through-holes 85a and 85b of the insulation ensuring member 80 shown in FIG. 9B and the support through-holes 94a and 94b of the terminal block support portion 91 shown in FIG. 6A, and as shown in FIG. 4B, they are caught by the lower surface along the Z-axis of the terminal block support portion 91. In this way, the terminal block 70, the insulation ensuring member 80, and the terminal block support portion 91 can be fixed.

[0086] As shown in FIG. 2, the insulation ensuring member 80 has an intermediate portion 82 disposed between the terminal block 70 and the terminal block support portion 91, and an insulation sheet portion 81 disposed between the outer leg portions 52a and 52b of the cores 50a and 50b and the terminals 61a, 61b, 62a, and 62b. The intermediate portion 82 and the insulation sheet portion 81 are integrally formed into a thin sheet along a plane perpendicular to the Z-axis. The intermediate portion 82 is connected to the outside along the Y-axis of the insulation sheet portion 81.

[0087] As shown in FIG. 9A, a terminal separation wall 87 extending upward along the Z-axis is formed in the intermediate portion of the insulation ensuring member 80 along the X-axis. As shown in FIG. 1A, the terminal separation wall 87 is disposed between the terminals 62a and 62b, and can ensure insulation between the terminals 62a and 62b where the voltage difference tends to be large.

[0088] As described above, intermediate through-holes 85a and 85b through which the engaging convex portions 75a and 75b of the terminal block 70 can be inserted are formed in the intermediate portion 82 of the insulation ensuring member 80 shown in FIG. 9A. Also as described above, an intermediate engaging portion 86 is formed in the intermediate portion 82 at a position corresponding to the engaging notch 76 of the terminal block 70.

[0089] Although not shown in FIG. 9A, as shown in FIG. 9B, a central convex portion 88 protruding downward along the Z-axis is integrally formed at the central position along the X-axis on the lower surface of the intermediate portion 82. As shown in FIG. 4, the central convex portion 88 of the insulation ensuring member 80 is inserted into the central hole 95 of the terminal block support portion 91, and the insulation ensuring member 80 and the case 90 are positioned.

[0090] As shown in FIG. 9B, intermediate convex portions 83a, 83b, 84a, and 84b are formed in the intermediate portion 82 of the insulation securing member 80. The intermediate convex portions 83a, 83a, 84a, and 84b each project downward along the Z axis. Each of the intermediate convex portions 83a, 83b, 84a, and 84b corresponds to the positions of the support through holes 92a, 92b, 93a, and 93b of the terminal block support portion 91 shown in FIG. 4 and is formed side by side along the X axis.

[0091] The intermediate convex portions 83a, 83a, 84a, and 84b of the insulation securing member 80 shown in FIG. 9B may be aligned with the support through holes 92a, 92b, 93a, and 93b shown in FIG. 6A by being inserted therethrough.

[0092] As shown in FIG. 9B, fixing protrusions 83a2 and 83b2 whose outer diameter becomes smaller on the lower end side along the Z axis may be formed on the outer peripheral surfaces of the intermediate convex portions 83a and 83b. By forming such intermediate convex portions 83a and 83b, it becomes easier to insert the intermediate convex portions 83a, 83a, 84a, and 84b of the insulation securing member 80 into the corresponding support through holes 92a, 92b, 93a, and 93b while positioning them. Also, their connection becomes stronger.

[0093] As shown in FIG. 9A, accommodation recesses 83a1, 83b1, 84a1, and 84b1 that are recessed downward and open upward along the Z axis are formed in the intermediate convex portions 83a, 83a, 84a, and 84b, respectively. The accommodation recesses 83a1, 83b1, 84a1, and 84b1 correspond to the positions of the fastener arrangement holes 71a, 71b, 72a, and 72b of the terminal block 70.

[0094] Each of the accommodation recesses 83a1, 83b1, 84a1, and 84b1 is configured such that the threaded portion of a bolt for connecting an external terminal such as a circuit board (not shown) to the terminals 61a, 61b, 62a, and 62b of the terminal block 70 can enter. Also, each of the accommodation recesses 83a1, 83b1, 84a1, and 84b1 can accommodate metal dust and the like when a bolt (not shown) is screwed to the fasteners 78a, 78b, 79a, and 79b.

[0095] As shown in FIG. 1A, terminal 61a has a terminal main part 63a and a connection wire part 63a. Also, terminal 61b has a terminal main part 63b and a connection wire part 63b. Also, terminal 62a has a terminal main part 64a and a connection wire part 64a. Also, terminal 62b has a terminal main part 64b and a connection wire part 64b. Hereinafter, the configuration of terminal 61a will be described, but the description of terminal 61a also applies to terminals 61b, 62a, and 62b. Therefore, unless particularly necessary, the description of the configurations of terminals 61b, 62a, and 62b will be omitted.

[0096] As shown in FIG. 1A, the terminal main part 63a of the terminal 61a is placed on the upper surface along the Z-axis of the terminal block base part 701. On the terminal main part 63a of the terminal 61a, a connection hole 65a and attachment claws 63a1 to 63a4 are formed. The connection hole 65a is arranged at a position corresponding to the fasteners 78a, 78b, 79a, and 79b shown in FIG. 9A. By inserting the attachment claws 63a1 to 63a4 shown in FIG. 1A or FIG. 2 into the attachment claw holes 73a1 to 73a4 shown in FIG. 9A respectively, the terminal 61a is fixed to the terminal block 70.

[0097] The terminal main part 63a shown in FIG. 1A is connected to the connection wire part 67a on the inner side along the Y-axis. The connection wire part 67a has a folded-back piece 67a1 and can be fixed with the lead part sandwiched therebetween. As shown in FIG. 3, the connection wire part 67a is arranged at a position h2 lower than the terminal main part 63a along the Z-axis. Also, the connection wire part 67a is arranged above the insulating sheet part 81 along the Z-axis.

[0098] As shown in FIG. 1A, the terminals 61a, 61b, 62a, and 62b are attached to the terminal fixing parts 71a1, 71b1, 72a1, and 72b1 shown in FIG. 9A at a predetermined interval along the X-axis on the terminal block 70.

[0099] In this embodiment, as shown in FIG. 1A, the terminal 61a is connected to the lead part 43a1. Also, the terminal 61b is connected to the lead part 43b1. Also, the terminal 62a is connected to the lead part 43a2. Also, the terminal 62b is connected to the lead part 43b2.

[0100] The coil device 10 of this embodiment can be assembled as follows, for example.

[0101] First, as shown in FIG. 2, wires 41a and 41b are wound around the bobbin portion 21 of the bobbin 20 using, for example, an automatic winding machine. Before, after, or simultaneously with this, the mounting claws 63a1 to 63a4 (63b1 to 63b4, 64a1 to 64a4, 64b1 to 64b4) of the terminals 61a (61b, 62a, 62b) are inserted into the mounting claw holes 73a1 to 73a4 (73b1 to 73b4, 74a1 to 74a4, 74b1 to 74b4), and the terminals 61a (61b, 62a, 62b) are attached to the terminal block 70.

[0102] Next, the lead portions 43a1 (43a2, 43b1, 43b2) are sandwiched and temporarily fixed between the connection portions 67a (67b, 68a, 68b) of the terminals 61a (61b, 62a, 62b) and the folded-back pieces 67a1 (67b1, 68a1, 68b1). Next, the connection portions 67a (67b, 68a, 68b) are pressed from above along the Z-axis with an electrode, and the folded-back pieces 67a1 (67b1, 68a1, 68b1) are pressed from below along the Z-axis with another electrode, and a voltage is applied between the electrodes to electrically and mechanically connect the terminals 61a (61b, 62a, 62b) and the lead portions 43a1 (43a2, 43b1, 43b2) by fusing.

[0103] In this embodiment, during fusing, there are no components above and below the connection portions 67a (67b, 68a, 68b) along the Z-axis, and the connection portions 67a (67b, 68a, 68b) and the folded-back pieces 67a1 (67b1, 68a1, 68b1) can be pressed by electrodes from above and below.

[0104] Next, the insulation ensuring member 80 is attached to the terminal block 70. Before that, the fasteners 78a, 78b, 79a, 79b are attached to the terminal block 70. When attaching the insulation ensuring member 80 to the terminal block 70, as shown in FIG. 9A, the engaging claws 861 of the intermediate engaging portion 86 are engaged with the engaging cutouts 76, and the terminal separation wall 87 is fitted into the terminal separation wall fitting groove 77.

[0105] Next, as shown in FIG. 2, the middle leg portions 53a and 53b of the cores 50a and 50b are inserted into the through holes 21 of the bobbin 20, and the bobbin 20 and the cores 50a and 50b are fixed, for example, with an adhesive or the like. Preferably, a thermosetting adhesive can be used as the adhesive.

[0106] Next, the bobbin 20 combined with the cores 50a and 50b is housed in a case 90 in which a potting resin (resin excellent in heat dissipation) 210 has been previously injected (filled). At this time, as shown in FIG. 4, the insulation securing member 80 to which the terminal block 70 is attached is attached to the terminal block support portion 91. Note that after the bobbin 20 and the cores 50a and 50b are housed in the case 90, the potting resin may be injected from the opening 90a.

[0107] When attaching the insulation securing member 80 to which the terminal block 70 is attached to the terminal block support portion 91, the intermediate convex portions 83a (83b, 84a, 84b) are inserted into the support through holes 92a (92b, 93a, 93b). Further, the central convex portion 88 is inserted through the central hole 95. Further, the engaging convex portions 75a and 75b are inserted through the intermediate through holes 85a and 85b, and the claws formed on the engaging convex portions 75a and 75b are hooked on the terminal block support portion 91. In this way, the terminal block 70 and the insulation securing member 80 are fixed to the terminal block support portion 91.

[0108] After housing the bobbin 20 in the case 90, as shown in FIG. 2, the cover member 100 of the case 90 is bent to form the open cover portion 101 shown in FIG. 1A. By forming the open cover portion 101 in this way, it is not necessary to separately form and attach the cover member 100 to the case 90, and the assembly can be simplified.

[0109] In this embodiment, as shown in FIG. 2, in the coil device 10, the bobbin 20 is disposed inside the case 90 such that the winding axes C of the wires 41a and 41b are substantially parallel to the bottom surface 90b of the case 90. That is, the coil device 10 of this embodiment is a horizontal coil device and is also substantially parallel to the mounting surface of the coil device 10 or the mounting substrate (not shown). This coil device 10 can easily achieve a lower profile compared to a vertical coil device in which the winding axes of the wires 41a and 41b are substantially perpendicular to the bottom surface 90b of the case 90.

[0110] Also, as shown in FIG. 1A, in the coil device 10 of this embodiment, the terminal block 70 is supported on the terminal block support portion 91 that protrudes outward along the Y-axis from the opening edge 96 of the upper opening 90a of the case 90. Therefore, it is not necessary to increase the installation area of the case 90 corresponding to the area of the terminal block 70, and the installation area of the case 90 can be reduced while being horizontal. Furthermore, compared with the case where the terminal blocks are provided on both sides along the X-axis, it is also possible to reduce the installation area of the case along the X-axis.

[0111] Furthermore, since the terminal block support portion 91 formed by extending the outer wall of the case 90 supports the terminal block 70, the strength and reliability of the terminal block 70 can be improved. In particular, when connecting the terminals 61a, 61b, 62a, and 62b provided in the terminal block 70 of the coil device 10 to a substrate (not shown) disposed on the coil device 10, the terminal block support portion 91 facilitates connection to the substrate and improves reliability in order to reinforce the strength of the terminal block 70.

[0112] Also, as shown in FIG. 10, by filling the inside of the case 90 with a heat-dissipating resin (potting resin 210) or the like, heat from the wires 42 and 44 or the bobbin 20 (including the cores 50a and 50b) can be released to the bottom surface of the case 90 through the potting resin 210, improving heat dissipation. Note that a cooling mechanism or the like is disposed on the bottom surface of the case 90.

[0113] Also, as shown in FIG. 1A, since the terminal block 70 is supported on the terminal block support portion 91 that protrudes outward from the opening edge 96 of the upper opening 90a of the case 90, most of the bobbin 20 (including the wire and the core) including at least the winding shafts of the wires 41a and 41b can be brought into contact with the potting resin 210 inside the case 90 without being obstructed by the terminal block 70. Therefore, the heat dissipation can be effectively enhanced with a minimum amount of potting resin required.

[0114] In the present embodiment, as shown in FIG. 6A, position adjusting portions 97a and 97b may be formed on the side surface 90d of the case 90. As shown in FIG. 10, the position adjusting portion 97a (97b) protrudes inward along the Y-axis inside the case 90.

[0115] When the bobbin 20 and the cores 50a and 50b are housed in the case 90, the elastic force of the lead portions of the wires or the like may act to press the terminal block 70 against the side surface 90d of the case 90 on the opposite side along the Y-axis. By the position adjusting portion 97a (97b) abutting against the outer leg portions 52a (52b) of the core 50a (50b), a gap can be formed for the potting resin 210 to enter between the side surface 90d and the core 50a.

[0116] Furthermore, as shown in FIG. 1A, in the coil device 10 of the present embodiment, the terminal block 70 is attached on the terminal block support portion 91 via an insulation ensuring member 80. Therefore, after winding the wires 41a and 41b around the bobbin 20 and attaching the terminals 61a, 61b, 62a, and 62b to the terminal block 70, the operation of connecting the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, and 62b at once becomes easy. The connection of the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, and 62b is appropriately performed using, for example, thermocompression bonding such as crimping.

[0117] When connecting the lead portions 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b to the terminals 61a, 61b, 62a, 62b, it is necessary to press a thermocompression bonding jig or the like from both sides of the lead portions 43a1, 43a2, 43b1, 43b2. In the present embodiment, as described above, before attaching the insulation ensuring member 80 to the terminal block 70, it is easy to press a thermocompression bonding jig or the like from both sides of the lead portions 43a1, 43a2, 43b1, 43b2.

[0118] Also, after connecting the lead portions 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b to the terminals 61a, 61b, 62a, 62b, the insulation ensuring member 80 is disposed on one side of the joint portions 67a, 67b, 68a, 68b of the wires 41a, 41b. Therefore, the insulation between the joint portions 67a, 67b, 68a, 68b and the cores 50a, 50b attached to the bobbin 20 can be effectively ensured.

[0119] Also, the insulation ensuring member 80 can ensure the insulation between the lead portions 43a1, 43a2, 43b1, 43b2 and the joint portions 67a, 67b, 68a, 68b of the terminals 61a, 61b, 62a, 62b and the case 90.

[0120] As shown in FIG. 3, in the present embodiment, the insulation ensuring member 80 has an insulation sheet portion 81. The insulation sheet portion 81 is disposed between the joint portions 67a, 67b, 68a, 68b of the lead portions 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b and the terminals 61a, 61b, 62a, 62b and the cores 50a, 50b attached to the bobbin 20.

[0121] By configuring it in this way, the insulation ensuring member 80 can enhance the insulation between the connection parts 62b, 63b, 65b, 66 of the lead parts 43a1, 43a2, 43b1, 43b2 and the terminals 61a, 61b, 62a, 62b, and the outer leg parts 52a, 52b of the cores 50a, 50b mounted on the bobbin 20. Also, the insulation ensuring member 80 can improve the insulation between the connection parts 67a, 67b, 68a, 68b of the lead parts 43a1, 43a2, 43b1, 43b2 and the terminals 61a, 61b, 62a, 62b and the case 90.

[0122] As shown in FIG. 3, in the present embodiment, the insulation ensuring member 80 has an intermediate portion 82 integrally formed with the insulation sheet portion 81. The intermediate portion 82 is sandwiched between the terminal block support portion 91 and the terminal block 70. As shown in FIG. 9A, the insulation ensuring member 80 has an intermediate engaging portion 86 that engages with the terminal block 70, and the intermediate engaging portion 86 has engaging claws 861. By the intermediate engaging portion 86 engaging with the terminal block 70, it becomes easy to attach the terminal block 70 and the insulation ensuring member 80 while positioning them. Also, it becomes possible to fix the terminal block 70 and the insulation ensuring member 80 without using an adhesive. However, an adhesive may be used.

[0123] As shown in FIG. 4, in the present embodiment, the intermediate portion 82 has intermediate convex portions 83a, 83b, 84a, 84b that enter the support through holes 92a, 92b, 93a, 93b formed in the terminal block support portion 91. By the intermediate convex portions 83a, 83b, 84a, 84b entering the support through holes 92a, 92b, 93a, 93b, it becomes easy to position the insulation ensuring member 80 and the terminal block support portion 91.

[0124] As shown in FIG. 9A, the intermediate convex portions 83a, 83b, 84a, 84b have accommodation recesses 83a1, 83b1, 84a1, 84b1 that open toward the terminal block 70. The accommodation recesses 83a1, 83b1, 84a1, 84b1 can accommodate metal dust and the like when screws for mechanically and electrically connecting the terminals 61a, 61b, 62a, 62b and a substrate or the like are screw-coupled. The accommodation recesses 83a1, 83b1, 84a1, 84b1 are configured such that screw portions for attaching external terminals of a circuit board (not shown) and the like to the terminals 61a, 61b, 62a, 62b of the terminal block can enter.

[0125] As shown in FIG. 4, the terminal block 70 has engagement convex portions 75a, 75b. Further, as shown in FIG. 9A, intermediate through-holes 85a, 85b are formed in an intermediate portion 82 of the insulation securing member 80. As shown in FIG. 4, the engagement convex portions 75a, 75b engage with engagement holes 94a, 94b formed in the terminal block support portion 91 through the intermediate through-holes in the intermediate portion.

[0126] By configuring in this way, the positioning between the terminal block 70 and the insulation securing member 80 is achieved, and the attachment while positioning between the terminal block 70 and the terminal block support portion 91 becomes easy. Further, without using an adhesive, the terminal block 70, the insulation securing member 80, and the terminal block support portion can be fixed. However, an adhesive may be used.

[0127] As shown in FIG. 1A, the case 90 is provided with a cover member 100. The opening cover portion 101 of the cover member 100 covers at least a part of the upper opening 90a of the case 90 with a predetermined gap H1 shown in FIG. 3. The predetermined gap H1 is larger than the protruding height of the protruding portion 33 of the bobbin 20 from the upper opening 90a of the case 90 and larger than the protruding heights of the protection hook portions 23a, 23b, 24a, 24b.

[0128] The opening cover part 101 covers a part of the upper opening 90a of the case 90 with a predetermined gap H1, thereby protecting the protruding parts of the cores 50a, 50b and the lead parts 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b, etc. For example, when connecting the terminals 61a, 61b, 62a, 62b of the coil device 10 to a substrate or the like, it is possible to effectively prevent the protruding parts from the substrate or the substrate itself from contacting and damaging the protruding parts of the cores 50a, 50b and the lead parts 43a1, 43a2, 43b1, 43b2 of the wires 41a, 41b, etc.

[0129] As shown in FIG. 3, in the present embodiment, the cover member 100 covers at least a part of the wire 44 (41) wound around the bobbin 20 housed inside the case 90. The cover member 100 preferably covers the entire winding part of the wires 41a, 41b excluding the lead parts 45, 46 (42, 43) of the wire. By forming the cover member 100 of metal or the like, the effect of shielding the leakage magnetic flux from the winding part (coil part) of the wires 41a, 41b is improved.

[0130] As shown in FIG. 3, in the present embodiment, the cover member 100 is integrally formed with the case 90. By integrally forming the cover member 100 and the case 90 by bending a metal plate or the like, the manufacture of the cover member 100 and the case 90 becomes easy. Further, in the present embodiment, the terminal block support part 91 is integrally formed with the case 90. By integrally forming the terminal block support part 91 and the case 90 by bending a metal plate or the like, the manufacture of the terminal block support part 91 and the case 90 becomes easy.

[0131] As shown in FIG. 5A, in the present embodiment, the bobbin 20 has a winding core part 21 around which a wire is wound, and flange parts 22a, 22b attached to the ends of the winding core part 21. Further, the flange parts 22a, 22b have protection hook parts 23a, 23b, 24a, 24b.

[0132] The protective hook portions 23a, 23b, 24a, and 24b protrude upward from the upper opening 90a of the case 90 and guide the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminal block 70 as shown in FIG. 1A. By hooking the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b on the protective hook portions 23a, 23b, 24a, and 24b, it becomes easier to guide the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b to the terminals 61a, 61b, 62a, and 62b mounted on the terminal block 70.

[0133] As shown in FIG. 3, in the present embodiment, the protective hook portions 23a, 23b, 24a, and 24b have a height h1 that is flush with or higher than the upper surface of the terminals 61a, 61b, 62a, and 62b. Further, the wire connection portions 67a, 67b, 68a, and 68b of the terminals 61a, 61b, 62a, and 62b to which the lead portions 43a1, 43a2, 43b1, and 43b2 of the wires 41a and 41b are connected are arranged at a position lower by a height h2 than the upper surface of the terminals. By arranging them in this way, the protective hook portions 23a, 23b, 24a, and 24b can effectively protect the wire connection portions 67a, 67b, 68a, and 68b, and can effectively prevent a protruding portion from the substrate (not shown) or the substrate itself from contacting the wire connection portions 67a, 67b, 68a, and 68b.

[0134] Also, in the present embodiment, the opening cover portion 101 is located at a position higher by H1 than the opening 90a of the case 90, and the protective hook portions 23a, 23b, 24a, and 24b are arranged between the opening cover portion 101 and the opening 90a. By arranging them in this way, the opening cover portion 101, together with the protective hook portions 23a, 23b, 24a, and 24b, can protect the wire connection portions 67a, 67b, 68a, and 68b, and can effectively prevent a protruding portion from the substrate or the substrate itself from contacting the wire connection portions 67a, 67b, 68a, and 68b.

[0135] Second Embodiment As shown in FIGS. 1B, 6B, and 6C, the coil device 20 according to this embodiment is the same as the coil device 10 of the first embodiment except that the structures of the case 190 and the cover member 200 are different, and similar operational effects can be expected. In the following description, the description of the parts common to the first embodiment will be omitted.

[0136] As shown in FIGS. 6B and 6C, in this embodiment, the case 190 and the cover member 200 are each formed separately from a metal plate or the like and assembled as shown in FIG. 1B.

[0137] On the upper side along the Z-axis of two side surfaces 90c, 90c located on opposite sides along the X-axis of the case 190, a pair of locking pieces 90c1, 90c2 are integrally formed. Locking holes 198a, 198b are respectively formed in each of the locking pieces 90c1, 90c2.

[0138] As shown in FIG. 6C, in this embodiment, the cover member 200 has an opening cover portion 201, a side cover portion 202, and a pair of cover support portions 203, 203. The side cover portion 202 is formed so as to protrude downward along the Z-axis from one end along the Y-axis of the opening cover portion 201. As shown in FIG. 1B, the side cover portion 202 has an outer surface substantially perpendicular to the Y-axis, and the outer surface of the side cover portion 202 may be substantially flush with the side surface 90d of the case 90, or may be recessed inside the side surface 90d or slightly protrude.

[0139] The cover support portions 203 and 203 that protrude downward along the Z-axis from both ends along the X-axis of the opening cover portion 201 each have the same shape.

[0140] In each cover support portion 203, a locking piece 204 having an engaging convex portion formed at its tip is formed so as to extend upward along the Z-axis in a reverse U-shaped groove. The engaging convex portion is formed by bending the upper tip of the locking piece 204 so as to protrude outward along the X-axis. The cover support portions 203 located on the upper side along the Z-axis and both sides along the Y-axis of the locking piece 204 are cut out to form a reverse U-shaped groove.

[0141] By configuring in this way, the locking piece 204 is held in a cantilever support beam shape with respect to the main part of the cover support part 203 and can be elastically deformed by bending, and the engaging convex part can be elastically moved outward and inward along the X axis. Therefore, when the cover member 200 is inserted into the case 190 from the upper opening, the engaging convex part of the locking piece 204 shown in FIG. 6C can be easily engaged with the locking hole 198a (198b), and the cover member 200 and the case 190 can be connected.

[0142] In addition, each cover support part 203 has a wide part in which openings 206 penetrating the front and back surfaces are formed on both sides along the Y axis of an inverted U-shaped groove penetrating the front and back surfaces. A cover placement part 205 is formed on the lower side along the Z axis of the wide part of each cover support part 203, and a notch recessed from bottom to top is formed at a substantially central part along the Y axis of the cover placement part 205.

[0143] Including this notch, the opening 206 and the U-shaped groove also serve as passages for the potting resin filled inside the case 190, and the inside of the case 190 can be easily filled with the potting resin. In the coil device 20 of the present embodiment, since the cover member 200 and the case 190 are separated, when accommodating a bobbin or the like around which a coil is wound inside the case 190, the cover member does not get in the way, and there is no need to perform an operation of bending and forming the cover member with respect to the case.

[0144] Note that the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the present invention. For example, the heat-dissipating resin is not limited to the potting resin, and other resins having excellent heat dissipation may be used. The heat-dissipating resin is preferably composed of, for example, a silicone resin, a urethane resin, an epoxy resin, etc. that are soft even after injection. The longitudinal elastic modulus of the resin is preferably 0.1 to 100 MPa, and the Shore A hardness is preferably 100 or less, more preferably 60 or less. Further, in order to enhance the heat dissipation, the resin may be filled with a filler having high thermal conductivity.

[0145] Also, in the above-described embodiments, as shown in FIG. 7, the liquid surface S of the potting resin is lower than a predetermined height T1 from the upper end (along the Z-axis) E1 of the middle leg portion 53a (53b), but it is not limited thereto. For example, if the height along the Z-axis of the case 90 shown in FIG. 1A is increased, the liquid surface S of the potting resin may be flush with or higher than the upper end (along the Z-axis) E1 of the middle leg portion 53a (53b).

[0146] Furthermore, in the above-described embodiments, as shown in FIG. 6A or FIG. 6B, the terminal block support portion 91 is formed only at one location on one side in the Y-axis direction of the upper opening portion 90a of the case 90 or 190, but it is not limited thereto. For example, a plurality of terminal block support portions 91 may be formed at two or more locations on both sides in the Y-axis direction, or at two or more locations on both sides in the X-axis direction of the upper opening portion 90a of the case 90 or 190, in the same manner as in the above-described embodiments. Alternatively, separately from the above-described terminal block support portion 91, another terminal block support portion may be formed at any position of the upper opening portion 90a of the case 90 or 190 facing outward from the opening, and a plurality of terminal block support portions 91 may be formed in the same manner as in the above-described embodiments.

[0147] In any case, when forming a plurality of terminal block support portions in the case, correspondingly, a plurality of terminal blocks 70 and insulation ensuring members 80 as shown in FIG. 9A may also be prepared and attached to each terminal block support portion.

Explanation of Reference Numerals

[0148] 10... Coil device (transformer) 20... Bobbin 21... Winding core portion 211... Through hole 22a, 22b... Flange portions 220a, 220b... Flange portion main bodies 23a, 23b, 24a, 24b... Protection hook portions 23a1, 23b1, 24a1, 24b1... Hook support portions 25a, 25b, 26a, 26b... Core separation walls 27a, 27b... Extended flange portion 28a, 28b... Notch portion 32a, 32b... Mounting portion 33, 34... Protrusion 35, 36... Through hole 37a, 37b... Concave bottom 41a, 41b... Wire 42a, 42b... Coil portion 43a1, 43a2, 43b1, 43b2... Lead portion 50a, 50b... Core 51a, 51b... Base portion 510a, 510b... Outer surface 511a, 511b... Inner surface 512a, 512b... Upper surface 513a, 513b... Lower surface 52a, 52b... Outer leg 520a, 520b... Inner side surface of outer leg 521a, 521b... End surface of outer leg 53a, 53b... Middle leg 531a, 531b... End surface of middle leg 55a, 55b... Recess 550a, 550b... Inner peripheral surface 551a, 551b... Tapered surface 56a, 56b... Thick portion 61a, 61b, 62a, 62b... Terminal 63a, 63b, 64a, 64b... Main terminal portion 63a1~63a4, 63b1~63b4, 64a1~64a4, 64b1~64b4... Mounting claw 65a, 65b, 66a, 66b... Connection hole 67a, 67b, 68a, 68b... Jumper portion 67a1, 67b1, 68a1, 68b1... Folded-back piece 70... Terminal block 701... Terminal block base portion 71a, 71b, 72a, 72b... Fastener placement hole 71a1, 71b1, 72a1, 72b1... Terminal fixing portion 73a1~73a4, 73b1~73b4, 74a1~74a4, 74B1~74b4... Mounting claw hole 75a, 75b... engaging convex portions 76... engaging notch 77... terminal separation wall fitting groove 78a, 78b, 79a, 79b... fasteners 80... insulation ensuring member 81... insulation sheet portion 82... intermediate portion 83a, 83b, 84a, 84b... intermediate convex portions 83a1, 83b1, 84a1, 84b1... receiving recesses 83a2, 83b2... fixing protrusions 83a3, 83b3, 84a3, 84b3... fastener placement portions 85a, 85b... intermediate through holes 86... intermediate engaging portion 861... engaging claws 87... terminal separation wall 88... central convex portion 90, 190... cases 90a... upper opening 90b... bottom surface 90c, 90d... side surfaces 91... terminal block support portion 92a, 92b, 93a, 93b... support through holes 94a, 94b... engaging holes 95... central hole 96... opening edge 97a, 97b... position adjusting portions 198a, 198b... locking holes 100, 200... cover members 101, 201... opening cover portions 102, 202... side cover portions 203... cover support portion 204... locking piece 205... cover placement portion 206... opening 210... potting resin

Claims

1. A bobbin around which a wire is wound, a conductive terminal to which a lead portion of the wire is connected, an insulating terminal block to which the terminal is attached, a case in which the bobbin is accommodated, A coil device having: The bobbin is disposed inside the case such that the winding axis of the wire is substantially parallel to the bottom surface of the case, The case has a terminal block support portion that protrudes outward from the edge of the upper opening of the case, The terminal block is attached on the terminal block support portion via an insulation ensuring member, The insulation ensuring member has an insulating sheet portion, The insulating sheet portion is disposed between a connecting portion of the terminal to which the lead portion of the wire is connected and a core attached to the bobbin Coil device.

2. The insulation ensuring member further has an intermediate portion that is integrally formed with the insulating sheet portion and is sandwiched between the terminal block support portion and the terminal block, The coil device according to claim 1, wherein the intermediate portion has an intermediate engaging portion that engages with the terminal block.

3. The coil device according to claim 2, wherein the intermediate portion has an intermediate convex portion that enters a support through hole formed in the terminal block support portion.

4. The coil device according to claim 3, wherein the intermediate convex portion has a receiving recess that opens toward the terminal block.

5. The coil device according to any one of claims 2 to 4, wherein the terminal block has an engaging convex portion that engages with an engaging hole formed in the terminal block support portion through an intermediate through hole formed in the intermediate portion.

6. The coil device according to any one of claims 1 to 5, wherein the inside of the case can be filled with a heat-dissipating resin.

7. The case is provided with a cover member that covers at least a part of the upper opening of the case with a predetermined gap, The coil device according to any one of claims 1 to 6, wherein the cover member covers at least a part of the wire wound around the bobbin accommodated inside the case.

8. The coil device according to claim 7, wherein the cover member is integrally formed with the case.

9. The coil device according to any one of claims 1 to 8, wherein the terminal block support portion is integrally formed with the case.

10. The bobbin has a winding core portion around which the wire is wound and a flange portion attached to an end of the winding core portion, The coil device according to any one of claims 1 to 9, wherein the flange portion has a protective hook portion that protrudes upward from the upper opening of the case and guides the lead of the wire to the terminal block.

11. The coil device according to claim 10, wherein the protective hook portion has a height flush with or higher than the upper surface of the terminal, and the wire connection portion of the terminal to which the lead portion of the wire is connected is disposed at a position lower than the upper surface of the terminal.

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