Coil device

Abstract

To provide a compact coil device that is excellent in insulation property between a core and a terminal.SOLUTION: A coil device 1 has: a coil 10 that has a wound part 11, and a lead-out part 12a led out from the wound part 11; a terminal 30a connected with the lead-out part 12a; a bobbin 40 that has a winding cylindrical part 41 on which the wound part 11 is formed, and a terminal installation part 42 formed at an end part in a first direction parallel to an axial direction, of the winding cylindrical part 41 and on which the terminal 30a is provided; and a core 70 attached to the bobbin 40. The terminal installation part 42 has a convex part 45 for separating the core 70 and the terminal 30a from each other.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] The present disclosure relates to a coil device used as a transformer or the like.

Background Art

[0002] As a coil device used as a transformer or the like, for example, there is a coil device shown in Patent Document 1. The coil device of Patent Document 1 has a bobbin and a core attached to the bobbin. The bobbin has a winding cylinder portion provided with a coil and a terminal installation portion formed at an axial end of the winding cylinder portion and provided with terminals.

[0003] In the coil device of Patent Document 1, the longitudinal end of the core is disposed in the terminal installation portion and is close to the terminal. Therefore, it is difficult to secure the creepage distance between the core and the terminal, and there is a risk that the insulation between the core and the terminal deteriorates. If the length of the terminal installation portion is extended along the axial direction of the winding cylinder portion in order to secure the creepage distance between the core and the terminal, it becomes difficult to miniaturize the coil device.

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 disclosure has been made, and an object thereof is to provide a small-sized coil device having excellent insulation between a core and a terminal.

Means for Solving the Problems

[0006] In order to achieve the above object, the coil device of the present disclosure includes a coil having a winding portion and a lead-out portion drawn from the winding portion, The terminal to which the aforementioned pull-out section is connected, A bobbin having a winding cylinder portion on which the winding portion is formed, and a terminal mounting portion formed at the end of the winding cylinder portion in a first direction parallel to the axial direction, on which the terminal is provided, The bobbin has a core that is attached to the bobbin, The terminal mounting portion has a protrusion that separates the core from the terminal.

[0007] In the coil device of this disclosure, the terminal mounting portion has a protrusion that separates the core and the terminal. In this case, since the core and the terminal are positioned on opposite sides of each other via the protrusion, the creepage distance or clearance distance (insulation distance) between the core and the terminal can be extended by the protrusion. Therefore, even if a part of the core is positioned close to the terminal, it is possible to ensure insulation between the core and the terminal, and a compact coil device with excellent (voltage-resistant) reliability can be realized.

[0008] The protrusion may project in a third direction perpendicular to the mounting surface of the bobbin on which the core is placed. In this case, the insulation distance between the core and the terminal can be extended according to the length of the protrusion in the third direction.

[0009] The protrusion may extend from one end to the other of the terminal mounting portion along a second direction perpendicular to the first and third directions. Furthermore, with respect to the second direction perpendicular to the first and third directions, the length of the protrusion may be equal to or greater than the length of the core. In this case, it becomes possible to form a wall-like protrusion on the terminal mounting portion, and the insulation distance between the end of the core in the first direction and the terminal can be extended according to the length of the protrusion along the second direction.

[0010] The terminal has a pair of terminals, and the protrusion may be formed at least between the pair of terminals. In this case, it is possible to prevent the insulation distance between the core and the terminals from becoming locally shorter between the pair of terminals.

[0011] The bobbin comprises a first bobbin and a second bobbin, wherein at least a portion of the second bobbin may be housed inside the first bobbin. By housing at least a portion of the second bobbin inside the first bobbin, the length of the bobbin along the first direction can be shortened, thereby enabling miniaturization of the coil device.

[0012] The coil comprises a first coil having a first winding portion and a second coil having a second winding portion, the first bobbin having a first winding cylinder portion on which the first winding portion is formed, and the second bobbin having a second winding cylinder portion on which the second winding portion is formed and into which the core is inserted, and the second winding cylinder portion may be inserted into the first winding cylinder portion. In this case, for example, the coil device can function as a transformer, and a particularly small transformer can be realized.

[0013] The aforementioned protrusion has a first protrusion and a second protrusion, and the terminal mounting portion has a first terminal mounting portion formed at one end of the first winding cylinder portion in the first direction and a second terminal mounting portion formed at the other end of the second winding cylinder portion in the first direction, and the first terminal mounting portion may have the first protrusion and the second terminal mounting portion may have the second protrusion. In this way, even if the first protrusion is provided on the first terminal mounting portion and the second protrusion is provided on the second terminal mounting portion, since the winding cylinder portion is divided into a first winding cylinder portion and a second winding cylinder portion, the core can be inserted into the inside of the winding cylinder portion (second winding cylinder portion) without being obstructed by the first protrusion and the second protrusion.

[0014] The core comprises a first core and a second core combined with the first core, wherein the first core is an I-shaped core and the second core is a U-shaped core, and the first core may be inserted into the winding cylinder portion. In this case, the first core and the second core can form an annular core, thereby improving the magnetic properties of the coil device.

[0015] The length of the first core along the first direction may be longer than the length of the second core along the first direction. In this case, even if a displacement in the position of the contact portion between the first core and the second core occurs due to a displacement of the first core and / or the second core in the first direction, it is possible to prevent a change in the area of ​​the contact portion (i.e., the cross-sectional area of ​​the magnetic path at the contact portion).

[0016] The end of the first core in the first direction may be connected to the terminal mounting portion via resin, outside the contact portion between the first core and the second core in the first direction. In this case, since the end of the first core in the first direction is fixed to the terminal mounting portion via resin, displacement of the first core can be prevented.

[0017] The terminal mounting portion is formed inward in the first direction from the protrusion and may have a first stopper that abuts against the end of the core in the first direction. In this case, the first stopper allows the core to be positioned in the first direction. Furthermore, it is possible to prevent the insulation distance between the core and the terminal from fluctuating (decreasing) due to misalignment of the core.

[0018] The first stopper may have a stepped portion, and a step may be formed between the surface of the stepped portion and the mounting surface of the bobbin on which the core is placed. In this case, the stepped portion can be used to position the core in the first direction. Furthermore, it is possible to prevent fluctuations (decreases) in the insulation distance between the core and the terminals due to misalignment of the core. In addition, the step between the surface of the stepped portion and the mounting surface of the bobbin can extend the insulation distance between the core and the terminals.

[0019] The core is inserted into the winding cylinder portion, and an end portion of the core in the first direction protrudes outward in the first direction from the winding cylinder portion. The terminal installation portion has a second stopper adjacent to the end portion of the core in the first direction on the outside of the core in the second direction, and a notch may be formed in the second stopper. In this case, the position of the core can be determined in the second direction by the second stopper. Further, by providing a notch in the second stopper, for example, when the end portion of the core in the first direction and the notch are joined with resin, the joining area between them can be increased and the joining strength can be improved.

[0020] The terminal has an external connection portion that can be connected to a substrate, and the external connection portion may protrude in a direction opposite to the protruding direction of the convex portion or in a direction perpendicular to the protruding direction. In this case, the coil device can be inserted and mounted or surface-mounted on the substrate via the external connection portion.

Brief Description of the Drawings

[0021] [Figure 1A] FIG. 1A is a perspective view of the coil device of the first embodiment. [Figure 1B] FIG. 1B is a perspective view of the coil device shown in FIG. 1A viewed from another angle. [Figure 2] FIG. 2 is an exploded perspective view of the coil device shown in FIG. 1A. [Figure 3] FIG. 3 is a cross-sectional view taken along line III-III of the coil device shown in FIG. 1A. [Figure 4A] FIG. 4A is a perspective view of the first bobbin shown in FIG. 2. [Figure 4B] FIG. 4B is a perspective view of the first bobbin shown in FIG. 4A viewed from another angle. [Figure 5] FIG. 5 is a perspective view of the second bobbin shown in FIG. 2. [Figure 6] FIG. 6 is a bottom view of the first bobbin and the second bobbin shown in FIG. 2. [Figure 7] FIG. 7 is a perspective view of the first cover member shown in FIG. 2. [Figure 8]Figure 8 is a bottom view of the first bobbin with the first cover member attached. [Figure 9] Figure 9 is a perspective view of the second cover member shown in Figure 2. [Figure 10] Figure 10 is a perspective view of the coil device of the second embodiment. [Modes for carrying out the invention]

[0022] Embodiments of this disclosure will be described with reference to the drawings. While the drawings will be referenced as necessary, the illustrations are provided for illustrative purposes only to aid in understanding this disclosure, and the appearance and dimensional ratios may differ from those of the actual objects. The disclosure will be described in detail below with reference to embodiments, but is not limited to these embodiments.

[0023] First Embodiment The coil device 1 of this embodiment, shown in Figures 1A and 1B, can be used, for example, as a transformer (such as a step-up transformer). As shown in Figure 2, the coil device 1 includes a first coil 10, a second coil 20, terminals 30a to 30d (Figure 1B), a first bobbin 40, a second bobbin 60, a first core 70, a second core 80, a first cover member 90, and a second cover member 100.

[0024] In the drawing, the X-axis corresponds to the longitudinal direction (axial direction) of the first bobbin 40. The Y-axis corresponds to the short direction of the first bobbin 40 (or the direction in which terminals 30a and 30b are positioned). The Z-axis is perpendicular to the X-axis and Y-axis.

[0025] In the following, the positive Z-axis direction will be referred to as "upward," and the negative Z-axis direction as "downward." Furthermore, for each of the X, Y, and Z axes, the direction toward the center of the coil device 1 will be referred to as "inward," and the direction away from the center of the coil device 1 will be referred to as "outward."

[0026] The coil device 1 is a horizontal coil device in which the axis of the first bobbin 40 is positioned parallel to the mounting substrate (not shown). In this embodiment, "parallel" is not limited to being strictly parallel, but allows for an error of ±10 degrees or less. Similarly, "perpendicular" is not limited to being strictly perpendicular, but allows for an error of ±10 degrees or less.

[0027] For example, the length of coil device 1 along the X-axis is 30-50 mm, the length along the Y-axis is 10-20 mm, and the length along the Z-axis is 10-25 mm. However, the size of coil device 1 is not limited to these dimensions.

[0028] The first coil 10 is formed on the first bobbin 40. The first coil 10 has a coil-shaped winding portion 11 and lead-out portions 12a and 12b drawn out from the winding portion 11. The second coil 20 is formed on the second bobbin 60. The second coil 20 has a coil-shaped winding portion 21 and lead-out portions 22a and 22b (Figure 1B) drawn out from the winding portion 21. In this embodiment, the first coil 10 constitutes the secondary coil and the second coil 20 constitutes the primary coil, but their relationship may be reversed.

[0029] As shown in Figure 3, the winding section 11 is formed of 5 layers along the radial direction of the first bobbin 40, but the number of layers in the winding section 11 may be 4 or less, or 6 or more. The winding section 21 is formed of 1 layer along the radial direction of the second bobbin 60, but the number of layers in the winding section 21 may be multiple.

[0030] The wires constituting the first coil 10 and the second coil 20 are insulated wires, although this is not particularly limited. The core material of the wire is, for example, copper wire. The wires may be single wires or paired wires. The wire diameter is not particularly limited, but is, for example, 0.1 to 1.0 mm. The wire diameter of the wires forming the second coil 20 is thicker than the wire diameter of the wires forming the first coil 10, but the wire diameters of each wire may be equal. In this embodiment, "equal" is not limited to being strictly equal, but allows for an error of ±10% or less between the comparison objects.

[0031] As shown in Figures 1A and 1B, the shapes of terminals 30a to 30d are the same, but they may be different. The shape of terminals 30a to 30d is not particularly limited, but it is L-shaped. Terminals 30a to 30d are made of a conductor such as metal. Terminals 30a to 30d may have connecting parts 31a to 31d and external connection parts 32a to 32d. One lead part 12a of the first coil 10 (Figure 2) is connected to connecting part 31a, and the other lead part 12b of the first coil 10 is connected to connecting part 31b. One lead part 22a of the second coil 20 (Figure 2) is connected to connecting part 31c, and the other lead part 22b of the second coil 20 is connected to connecting part 31d.

[0032] The external connection parts 32a to 32d are connected to an external substrate (not shown). The external connection parts 32a to 32d protrude downward, but the direction of protrusion of the external connection parts 32a to 32d is not limited to this. For example, the external connection parts 32a to 32d may protrude along the X-axis. Alternatively, the external connection parts 32a to 32d may protrude diagonally with respect to the Z-axis. In this embodiment, the coil device 1 can be inserted or surface mounted onto the external substrate via the external connection parts 32a to 32d.

[0033] As shown in Figure 2, the first core 70 is an I-shaped core with a rectangular parallelepiped shape. The second core 80 is a U-shaped core. The second core 80 has a main body 81 with a rectangular parallelepiped shape and leg portions 82 protruding from both ends of the main body 81 in the X-axis direction. The direction in which the leg portions 82 protrude is perpendicular to the main body 81.

[0034] The first core 70 and the second core 80 may be formed from a material containing a magnetic material and a resin, for example, or from a sintered body of a metallic magnetic material. Examples of magnetic materials for forming the first core 70 and the second core 80 include ferrite particles such as Mn-Zn ferrite, or metallic magnetic material particles.

[0035] As shown in Figure 1A, the first core 70 and the second core 80 are attached directly or indirectly to the first bobbin 40. As shown in Figure 3, the second core 80 is combined with the first core 70. More specifically, one leg 82 abuts against the surface of the first core 70 at one contact portion 120. The other leg 82 abuts against the surface of the first core 70 at the other contact portion 120. In this embodiment, since the first core 70 and the second core 80 can form an annular core, the magnetic properties of the coil device 1 can be improved.

[0036] The length L1 of the first core 70 along the X-axis may be longer than the length L2 of the second core 80 along the X-axis. In this case, the end of the first core 70 on the positive X-axis side may protrude outward along the X-axis by, for example, 1 mm or more than one of the contact portions 120. Also, the end of the first core 70 on the negative X-axis side protrudes outward along the X-axis than the other contact portion 120. If L1 > L2, even if a displacement occurs in the position of each contact portion 120 due to a displacement in the X-axis direction of the first core 70 and / or the second core 80, it is possible to prevent the area of ​​each contact portion 120 (the cross-sectional area of ​​the magnetic path of the annular core at the contact portion 120) from changing.

[0037] As shown in Figures 4A and 4B, the first bobbin 40 has a winding cylinder portion 41, a terminal mounting portion 42, and flange portions 43 and 44. The flange portions 43 and 44 may be omitted. The first bobbin 40 is made of a plastic such as PPS, PET, PBT, LCP, or other insulating material (for example, a heat-resistant material).

[0038] The winding cylinder portion 41 consists of a cylindrical body and has a through hole 410 and a partition wall 411. The axial direction of the winding cylinder portion 41 corresponds to the X-axis direction. The cross-sectional shape of the winding cylinder portion 41 perpendicular to the axial direction is rectangular, but is not limited to this. A winding portion 11 (Figure 2) is formed on the outer circumferential surface of the winding cylinder portion 41.

[0039] The through hole 410 is formed along the X-axis, from one end to the other of the winding cylinder portion 41. At least a portion of the second bobbin 60 (Figure 2) can be inserted (housed) inside the winding cylinder portion 41.

[0040] The partition wall 411 is formed on the outer circumferential surface of the winding cylinder portion 41. The partition wall 411 protrudes radially outward from the outer circumferential surface of the winding cylinder portion 41 and extends along the circumferential direction of the winding cylinder portion 41. The partition wall 411 may also extend around the winding cylinder portion 41 in a single rotation along its circumferential direction.

[0041] In this embodiment, multiple (for example, six) partition walls 411 are formed on the outer circumferential surface of the winding cylinder portion 41. The multiple partition walls 411 divide the outer circumferential surface of the winding cylinder portion 41 into multiple sections along the X-axis. Therefore, it is possible to form the winding portion 11 (Figure 2) in any of the multiple sections. In this embodiment, as shown in Figure 2, the winding portion 11 is formed on the winding cylinder portion 41 so as to span all the sections.

[0042] As shown in Figure 4A, the flange portion 43 is formed at the end of the winding cylinder portion 41 on the positive X-axis side, and the flange portion 44 is formed at the end of the winding cylinder portion 41 on the negative X-axis side. The flange portions 43 and 44 protrude radially outward from the outer circumferential surface of the winding cylinder portion 41 and extend along the circumferential direction of the winding cylinder portion 41.

[0043] The flange portion 43 may have an engagement groove portion 430, an engagement projection portion 431, and side wall portions 433a and 433b. The engagement groove portion 430 is formed above the flange portion 43 and extends along the Y axis from one end to the other. The engagement projection portion 431 is formed on the upper end face of the flange portion 43 and protrudes outward in the X-axis direction. The side wall portion 433a is formed on the negative Y-axis side of the flange portion 43 and protrudes outward in the X-axis direction. The side wall portion 433b is formed on the positive Y-axis side of the flange portion 43 and protrudes in the same direction as the side wall portion 433a. As shown in Figure 6, engagement projection portions 432a and 432b may be formed below the flange portion 43. The engagement projection portions 432a and 432b protrude outward in the X-axis direction.

[0044] As shown in Figure 4B, the flange portion 44 may have an engagement groove portion 440, an engagement projection portion 441, engagement projection portions 442a and 442b, side wall portions 443a and 443b, and an engagement recess portion 444. The engagement groove portion 440 is formed above the flange portion 44 and extends along the Y axis from one end to the other. The engagement projection portion 441 is formed on the upper end face of the flange portion 44 and protrudes outward in the X-axis direction. The engagement projection portions 442a and 442b are formed on the lower end face of the flange portion 44 and protrude outward in the X-axis direction. The side wall portion 443a is formed on the negative Y-axis side of the flange portion 44 and protrudes outward in the X-axis direction. The side wall portion 443b is formed on the positive Y-axis side of the flange portion 44 and protrudes in the same direction as the side wall portion 443a. The engaging recess 444 is formed below the flange portion 44 and extends along the Y-axis from one end of the flange portion 44 to the other.

[0045] The second cover member 100 (Figure 2) is attached to the engagement grooves 430 and 440 and the engagement projections 431 and 441 shown in Figures 4A and 4B. In addition, the first cover member 90 (Figure 2) is attached to the engagement projections 432a and 432b and the engagement projections 442a and 442b shown in Figure 6.

[0046] As shown in Figure 4A, the terminal mounting portion 42 is formed continuously with respect to the winding cylinder portion 41 at the end of the winding cylinder portion 41 on the positive X-axis side. The terminal mounting portion 42 protrudes outward in the X-axis direction from the end of the winding cylinder portion 41 on the positive X-axis side.

[0047] As shown in Figure 1A, terminals 30a and 30b are provided in the terminal mounting section 42. Terminals 30a and 30b are spaced apart along the Y-axis. Terminals 30a and 30b may be integrally molded (insert molded) into the terminal mounting section 42, or they may be attached to the terminal mounting section 42 afterwards. The connecting wire sections 31a and 31b protrude outward from the terminal mounting section 42 in the X-axis direction, and the external connection sections 32a and 32b protrude downward from the terminal mounting section 42.

[0048] As shown in Figure 4A, the terminal mounting section 42 has a protrusion 45, first stoppers 46a and 46b, second stoppers 47a and 47b, guide sections 48a and 48b (Figure 6), protruding sections 49a and 49b, and a mounting surface 50. The first core 70 (Figure 3) is mounted on the mounting surface 50.

[0049] The protrusion 45 is integrally formed on the end of the terminal mounting portion 42 on the positive X-axis side and protrudes upward from the mounting surface 50. As shown in Figure 1A, the protrusion 45 is formed between the end of the first core 70 on the positive X-axis side and terminals 30a and 30b.

[0050] More specifically, at least a portion of the protrusion 45 is formed along the X-axis between the X-axis positive end of the first core 70 and the connecting wire portions 31a and 31b exposed from the terminal mounting portion 42. Also, at least a portion of the protrusion 45 is formed along the Z-axis between the X-axis positive end of the first core 70 and the external connection portions 32a and 32b exposed from the terminal mounting portion 42.

[0051] The protrusion 45 serves to extend the creepage distance and clearance distance (insulation distance) between the first core 70 and the terminals 30a and 30b by separating the first core 70 from the terminals 30a and 30b.

[0052] As shown in Figure 3, with respect to extending the insulation distance between the first core 70 and terminals 30a and 30b, the height H of the protrusion 45 may be equal to or greater than the thickness of the first core 70 in the Z-axis direction. The height H of the protrusion 45 may be greater than the width W of the protrusion 45 in the X-axis direction. The width W of the protrusion 45 in the X-axis direction is smaller than the thickness of the first core 70 in the Z-axis direction, but may be equal to or greater than this.

[0053] As shown in Figure 1A, the protrusion 45 extends linearly along the Y-axis from one end to the other of the terminal mounting portion 42. However, the protrusion 45 may extend in a curved manner from one end to the other of the terminal mounting portion 42. Also, although the protrusion 45 extends continuously from one end to the other of the terminal mounting portion 42, it may extend intermittently. Furthermore, the protrusion 45 may extend diagonally with respect to the Y-axis.

[0054] In terms of extending the insulation distance between the first core 70 and terminals 30a and 30b, the length L3 of the protrusion 45 along the Y-axis (Figure 4B) may be equal to or greater than the length of the first core 70 along the Y-axis. Also, in a similar view, the protrusion 45 may be formed at least between terminals 30a and 30b. Furthermore, the length L3 of the protrusion 45 (Figure 4B) may be equal to or greater than the distance between terminals 30a and 30b along the Y-axis. Also, the length L3 of the protrusion 45 (Figure 4B) may be shorter than the length of the terminal mounting portion 42 along the Y-axis.

[0055] The protrusion 45 may be formed inward in the X-axis direction from the end of the terminal mounting portion 42 on the positive X-axis side. For example, the protrusion 45 may be formed at any position between the end of the terminal mounting portion 42 on the positive X-axis side and the end on the negative X-axis side (the end of the winding cylinder portion 41 on the positive X-axis side).

[0056] The terminal mounting portion 42 has one protrusion 45, but multiple protrusions 45 may be formed. For example, multiple protrusions 45 may be spaced apart along the X-axis. Alternatively, multiple protrusions 45 may be arranged as a single unit. In this case, the insulation distance between the first core 70 and terminals 30a and 30b can be further extended. Notches 450 (Figure 4A) may be formed at both ends of the protrusion 45 in the Y-axis direction.

[0057] As shown in Figure 3, the protrusion 45 is above the connecting wire portion 31a and protrudes upward from the mounting surface 50. As shown in Figure 1A, the position of the protrusion 45 in the X-axis direction is close to the positions of the external connection portions 32a and 32b in the X-axis direction. The protrusion 45 may also be located outside the external connection portions 32a and 32b along the X-axis.

[0058] The projection direction of the protrusion portion 45 is opposite to the projection direction of the external connection portions 32a and 32b, but is not limited to this. The protrusion portion 45 may also protrude in the same direction as the connecting portions 31a and 31b. For example, the protrusion portion 45 may protrude outward in the X-axis direction from the end of the terminal mounting portion 42 on the positive X-axis side.

[0059] As shown in Figure 4A, the first stoppers 46a and 46b protrude upward from the mounting surface 50. Furthermore, the first stoppers 46a and 46b protrude inward in the X-axis direction from the inner surface of the protrusion 45 in the X-axis direction. The first stoppers 46a and 46b are located inward of the protrusion 45 with respect to the X-axis direction and are spaced apart along the Y-axis.

[0060] As shown in Figure 1A, the first stoppers 46a and 46b are positioned between the protrusion 45 and the end of the first core 70 on the positive X-axis side, with respect to the X-axis direction. The first stoppers 46a and 46b position the first core 70 with respect to the X-axis direction by contacting the end of the first core 70 on the positive X-axis side. The number of first stoppers may be one or three or more. Also, the first core 70 does not have to be in contact with the first stoppers 46a and 46b.

[0061] As shown in Figure 4A, the second stoppers 47a and 47b protrude upward from the mounting surface 50. Furthermore, the second stoppers 47a and 47b protrude outward in the X-axis direction from the flange portion 43. The second stoppers 47a and 47b are spaced apart along the Y-axis.

[0062] As shown in Figure 1A, the second stoppers 47a and 47b are positioned on the outside of the first core 70 in the Y-axis direction, adjacent to the end of the first core 70 on the positive X-axis side. The second stoppers 47a and 47b may also contact both ends of the first core 70 in the Y-axis direction, and have the role of positioning the first core 70 with respect to the Y-axis direction.

[0063] The second stoppers 47a and 47b are connected to the end of the first core 70 on the positive X-axis side by resin 110. Furthermore, the end of the first core 70 on the positive X-axis side is connected to the mounting surface 50 via resin 110. More specifically, the end of the first core 70 on the positive X-axis side is connected to the mounting surface 50 via resin 110 outside the contact portion 120 (Figure 3) in the X-axis direction. Note that instead of resin 110, fixing means such as adhesive tape may be used.

[0064] As shown in Figure 4A, the second stoppers 47a and 47b may each have notches 470 formed therein. This increases the bonding area between the notches 470 and the end of the first core 70 (Figure 1A) on the positive X-axis side when they are joined with resin 110, thereby improving the bonding strength. The height position of the second stoppers 47a and 47b may be equal to the position of the upper surface of the first core 70 at the location of the notches 470.

[0065] As shown in Figure 6, the guide portions 48a and 48b are formed at the bottom of the terminal mounting portion 42 and protrude downward from the bottom of the terminal mounting portion 42. The direction of protrusion of the guide portions 48a and 48b is opposite to the side on which the first core 70 and the second core 80 are installed. As shown in Figure 3, the guide portion 48a (and similarly the guide portion 48b) extends along the X axis. The downward protrusion length of the guide portions 48a and 48b may be greater than the wire diameter (diameter) of the lead portions 12a and 12b.

[0066] As shown in Figure 6, the lead-out sections 12a and 12b are drawn outwards in the X-axis direction around the winding section 11 toward the terminals 30a and 30b on the bottom side of the winding cylinder section 41 (opposite to the first core 70 and the second core 80). By drawing out the lead-out sections 12a and 12b along the guide sections 48a and 48b, respectively, the lead-out sections 12a and 12b can be guided in the desired direction (the direction in which the guide sections 48a and 48b extend). In addition, the lead-out sections 12a and 12b can be protected from external loads.

[0067] As shown in Figure 4A, the protrusions 49a and 49b are formed at the bottom of the terminal mounting portion 42 and protrude downward from the bottom of the terminal mounting portion 42. The direction of protrusion of the protrusions 49a and 49b is the same as the direction of protrusion of the guide portions 48a and 48b, but is not limited to this.

[0068] As shown in Figure 6, the protrusions 49a and 49b, together with the guide portions 48a and 48b, for example, serve to guide the extension portions 12a and 12b in the desired direction (the direction in which the protrusions 49a and 49b extend). In addition, the protrusions 49a and 49b, together with the guide portions 48a and 48b, serve to protect the extension portions 12a and 12b from external loads.

[0069] As shown in Figure 5, the second bobbin 60 has a winding cylinder portion 61 and a terminal mounting portion 62. The second bobbin 60 is made of the same material as the first bobbin 40, but it may be made of a different material.

[0070] The winding cylinder portion 61 consists of a cylindrical body and has a through hole 610 and partition walls 611a to 611d. The axial direction of the winding cylinder portion 61 corresponds to the X-axis direction. The cross-sectional shape of the winding cylinder portion 61 perpendicular to the axial direction is rectangular, but is not limited to this. A winding portion 21 (Figure 2) is formed on the outer circumferential surface of the winding cylinder portion 61.

[0071] The through hole 610 is formed along the X-axis, extending from one end to the other of the winding cylinder portion 61. At least a portion of the first core 70 (Figure 2) can be inserted (housed) inside the winding cylinder portion 61.

[0072] The partitions 611a to 611d are formed on the outer circumferential surface of the winding cylinder portion 61. The partitions 611a to 611d protrude radially outward from the outer circumferential surface of the winding cylinder portion 61 and extend along the circumferential direction of the winding cylinder portion 61. The partitions 611a to 611d may also form a complete circle along the circumferential direction of the winding cylinder portion 61.

[0073] The partitions 611a to 611d divide the outer surface of the winding cylinder portion 61 into multiple sections along the X-axis. In this embodiment, the winding portion 21 (Figure 2) is formed in the section between partition 611b and partition 611c. The reason why the winding portion 21 is not formed in the other sections is to ensure an insulating distance between the first core 70 (Figure 3) protruding from both ends of the winding cylinder portion 61 in the X-axis direction and the winding portion 21. If necessary, the winding portion 21 may be formed on the winding cylinder portion 61 so as to span other sections.

[0074] The terminal mounting portion 62 is formed continuously with respect to the winding cylinder portion 61 at the end of the winding cylinder portion 61 on the negative X-axis side. The terminal mounting portion 62 protrudes outward in the X-axis direction from the end of the winding cylinder portion 61 on the negative X-axis side.

[0075] As shown in Figure 1B, terminals 30c and 30d are provided in the terminal mounting section 62. Terminals 30c and 30d are spaced apart along the Y-axis. Terminals 30c and 30d may be integrally molded (insert molded) into the terminal mounting section 62, or they may be added to the terminal mounting section 62 afterwards. The connecting wire sections 31c and 31d protrude outward from the terminal mounting section 62 in the X-axis direction, and the external connection sections 32c and 32d protrude downward from the terminal mounting section 62.

[0076] As shown in Figure 5, the terminal mounting portion 62 has a mounting surface 63, a protrusion 65, a first stopper 66, second stoppers 67a and 67b, a guide portion 68 (Figure 6), and protruding portions 69a and 69b (Figure 6). As shown in Figure 3, the first core 70 is mounted on the mounting surface 63. The mounting surface 63 may be flush with the bottom surface of the through hole 610 and the mounting surface 50. In this embodiment, "flush" is not limited to being strictly flush, and an error of ±10% or less is permitted.

[0077] As shown in Figure 5, the protrusion 65 is integrally formed on the end of the terminal mounting portion 62 on the negative X-axis side and protrudes upward from the mounting surface 63. As shown in Figure 1B, the protrusion 65 is formed between the end of the first core 70 on the negative X-axis side and terminals 30c and 30d.

[0078] Specifically, at least a portion of the protrusion 65 is formed along the X-axis between the X-axis negative end of the first core 70 and the connecting wire portions 31c and 31d exposed from the terminal mounting portion 62. Also, at least a portion of the protrusion 45 is formed along the Z-axis between the X-axis negative end of the first core 70 and the external connection portions 32c and 32d exposed from the terminal mounting portion 62.

[0079] The protrusion 65 serves to extend the creepage distance and clearance distance (insulation distance) between the first core 70 and the terminals 30c and 30d by separating the first core 70 from the terminals 30c and 30d.

[0080] The shape and size of the protrusion 65 are the same as those of the protrusion 45 (Figure 4A). Therefore, the matters described above regarding the shape, formation position, size (height H, width W, length L3, etc.) of the protrusion 45 and their variations can also be applied to the protrusion 65. However, the shape and size of the protrusion 65 may differ from those of the protrusion 45. For example, the length of the protrusion 65 along the Y-axis may be shorter than the length of the protrusion 45 along the Y-axis. Also, the height of the protrusion 65 may be lower than the height of the protrusion 45. Notches 650 may be formed at both ends of the protrusion 65 in the Y-axis direction.

[0081] As shown in Figure 3, the protrusion 65 is above the connecting wire portion 31c and protrudes upward from the mounting surface 63. As shown in Figure 1B, the position of the protrusion 65 in the X-axis direction is close to the position of the external connection portions 32c and 32d in the X-axis direction. The protrusion 65 may also be located outward along the X-axis compared to the external connection portions 32c and 32d.

[0082] The projection direction of the protrusion portion 65 is opposite to the projection direction of the external connection portions 32c and 32d, but is not limited to this. The protrusion portion 65 may also protrude in the same direction as the connecting portions 31c and 31d. For example, the protrusion portion 65 may protrude outward in the X-axis direction from the end of the terminal mounting portion 62 on the negative X-axis side.

[0083] As shown in Figure 5, the first stopper 66 protrudes upward from the mounting surface 63. Furthermore, the first stopper 66 protrudes inward in the X-axis direction from the inner surface of the protrusion 65 in the X-axis direction. With respect to the X-axis direction, the first stopper 66 is located inward from the protrusion 65 and is positioned in the center of the terminal mounting portion 62 in the Y-axis direction.

[0084] As shown in Figure 1B, the first stopper 66 is positioned between the protrusion 65 and the end of the first core 70 on the negative X-axis side, with respect to the X-axis direction. The first stopper 66 positions the first core 70 with respect to the X-axis direction by contacting the end of the first core 70 on the negative X-axis side. Note that there may be multiple first stoppers 66.

[0085] As shown in Figure 5, the second stoppers 67a and 67b protrude upward from the mounting surface 63. Furthermore, the second stoppers 67a and 67b protrude outward in the X-axis direction from the partition wall 611d. The second stoppers 67a and 67b are spaced apart along the Y-axis.

[0086] As shown in Figure 1B, the second stoppers 67a and 67b are positioned on the outside of the first core 70 in the Y-axis direction, adjacent to the end of the first core 70 on the negative X-axis side. The second stoppers 67a and 67b may also contact both ends of the first core 70 in the Y-axis direction, and have the role of positioning the first core 70 with respect to the Y-axis direction.

[0087] The second stoppers 67a and 67b are connected to the end of the first core 70 on the negative X-axis side by resin 110. The end of the first core 70 on the negative X-axis side is also connected to the mounting surface 63 via resin 110. More specifically, the end of the first core 70 on the negative X-axis side is connected to the mounting surface 63 via resin 110 on the negative X-axis side of the contact portion 120 (Figure 3).

[0088] As shown in Figure 5, notches 670 may be formed in the second stoppers 67a and 67b, respectively. The function of the notches 670 is the same as that of the notches 470 (Figure 4A).

[0089] As shown in Figure 6, the guide portion 68 is formed at the bottom of the terminal mounting portion 62 and protrudes downward from the bottom of the terminal mounting portion 62. The direction of protrusion of the guide portion 68 is opposite to the side on which the first core 70 and the second core 80 are installed. As shown in Figure 3, the guide portion 68 extends along the X axis. The downward protrusion length of the guide portion 68 may be greater than the wire diameter (diameter) of the lead-out portions 22a and 22b.

[0090] As shown in Figure 6, the lead-out sections 22a and 22b are drawn outwards in the X-axis direction around the winding section 21 toward terminals 30c and 30d on the bottom side of the winding cylinder section 61 (opposite side from the first core 70 and the second core 80). By drawing out the lead-out sections 22a and 22b along the guide section 68, the lead-out sections 22a and 22b can be guided in the desired direction (the direction in which the guide section 68 extends). In addition, the lead-out sections 22a and 22b can be protected from external loads.

[0091] The protrusions 69a and 69b are formed at the bottom of the terminal mounting portion 62 and protrude downward from the bottom surface of the terminal mounting portion 62. The direction of protrusion of the protrusions 69a and 69b is the same as the direction of protrusion of the guide portion 68, but is not limited to this.

[0092] The protruding portions 69a and 69b, for example together with the guide portion 68, serve to guide the extension portions 22a and 22b in the desired direction (the direction in which the protruding portions 69a and 69b extend). In addition, the protruding portions 69a and 69b, for example together with the guide portion 68, serve to protect the extension portions 22a and 22b from external loads.

[0093] The winding cylinder portion 61 is inserted into the interior (through hole 410) of the winding cylinder portion 41 in the direction indicated by the arrow in Figure 6. As shown in Figure 3, the first core 70 is housed inside the through hole 610, and the winding cylinder portion 61 with the winding portion 21 wound around it is housed inside the through hole 410. The end of the winding cylinder portion 61 on the positive X-axis side abuts against the flange portion 43 (the end of the winding cylinder portion 41 on the positive X-axis side). In other words, the flange portion 43 functions as a stopper that restricts the position of the winding cylinder portion 61 in the X-axis direction.

[0094] At least a portion of the winding portion 11 and the winding portion 21 may be facing each other in the radial direction. The first core 70 is mounted across the mounting surface 50 of the first bobbin 40, the bottom surface of the through hole 610, and the mounting surface 63 of the second bobbin 60.

[0095] As shown in Figure 7, the first cover member 90 has a cover body 91, an opening 92, a guide portion 93, engaging portions 94a to 94d, and an engaging projection 95. As shown in Figure 8, the first cover member 90 is attached to the first bobbin 40 on the bottom side of the winding cylinder portion 41 (opposite side from the first core 70 and the second core 80). The first cover member 90 may be made of the same material as the first bobbin 40.

[0096] As shown in Figure 7, the cover body 91 may be composed of a plate having a rectangular parallelepiped shape. The cover body 91 has a first surface 91a and a second surface 91b opposite to the first surface 91a. The first surface 91a is the surface opposite to the winding cylinder portion 41 (Figure 4A) and faces outward in the Z-axis direction. The second surface 91b is the surface on the winding cylinder portion 41 side.

[0097] As shown in Figure 8, the cover body 91 is positioned between the winding portion 11 and the lead portion 12a that passes around the winding portion 11 along the X-axis. The cover body 91 serves to extend the creepage distance and clearance distance (insulation distance) between the winding portion 11 and the lead portion 12a by separating them.

[0098] The length of the cover body 91 along the X-axis may be equal to or greater than the length of the winding cylinder portion 41 (Figure 4A) along the X-axis, or the length of the winding portion 11 (Figure 2) along the X-axis. In either case, the insulation between the winding portion 11 and the lead portion 12a can be improved.

[0099] The length of the cover body 91 along the Y-axis is equal to the length of the winding cylinder portion 41 (Figure 4A) along the Y-axis, but may be shorter. Also, the length of the cover body 91 along the Y-axis is equal to the length of the winding portion 11 (Figure 2) along the Y-axis, but may be shorter. In either case, the insulation between the winding portion 11 and the lead portion 12a can be improved. The cover body 91 may also be locally positioned at the lead-out location of the lead portion 12a.

[0100] As shown in Figure 3, the second surface 91b of the cover body 91 is in contact with a plurality of partition walls 411 formed on the outer circumferential surface of the winding cylinder portion 41. Therefore, the distance between the cover body 91 and the outer circumferential surface of the winding cylinder portion 41 is equal to the radial length of the partition walls 411. However, the distance between the cover body 91 and the outer circumferential surface of the winding cylinder portion 41 may be greater than the radial length of the partition walls 411.

[0101] As shown in Figure 7, the opening 92 penetrates between the first surface 91a and the second portion 92b of the cover body 91 and extends (is cut out) along the Y axis from the outer edge on the negative Y-axis side of the cover body 91 toward the inside in the Y-axis direction. The opening 92 has a first portion 92a and a second portion 92b. The first portion 92a extends along the Y axis from the outer edge on the negative Y-axis side of the cover body 91 toward the inside in the Y-axis direction. The first portion 92a may extend in a direction inclined with respect to the Y axis. The first portion 92a has the role of guiding the pull-out portion 12a from the outer edge on the negative Y-axis side of the cover body 91 toward the inside in the Y-axis direction.

[0102] The second portion 92b is continuous with the first portion 92a and extends along the X-axis. The second portion 92b may also extend in a direction inclined with respect to the X-axis. The length of the second portion 92b is shorter than the length of the first portion 92a, but may be equal to or greater than it. The width of the second portion 92b in the Y-axis direction is smaller than the width of the first portion 92a in the X-axis direction, but may be equal to or greater than it. The second portion 92b has the role of guiding the pull-out portion 12a toward the positive X-axis direction.

[0103] As shown in Figure 8, the pull-out portion 12a is pulled out from the winding portion 11 towards the first surface 91a through the opening 92. For example, the pull-out portion 12a is pulled out from the outer edge on the negative Y-axis side of the cover body 91 towards the inside in the Y-axis direction of the cover body 91 via the first portion 92a. Furthermore, the pull-out portion 12a is pulled out along the X-axis on the first surface 91a via the second portion 92b from the inside in the Y-axis direction of the cover body 91 towards the terminal 30a. Note that the pull-out portion 12b is pulled out along the X-axis on the second surface 91b side (Figure 7) of the cover body 91 towards the terminal 30a.

[0104] The guide portion 93 is formed on the first surface 91a and protrudes outward from the first surface 91a in the Z-axis direction. The height of the guide portion 93 is equal to or greater than the wire diameter of the lead portion 12a, but may be lower.

[0105] The guide portion 93 has a first extending portion 93a and a second extending portion 93b, and extends in an L-shape. The first extending portion 93a extends along the first portion 92a of the opening 92 from the outer edge on the negative Y-axis side of the cover body 91 toward the inside in the Y-axis direction of the cover body 91. The length of the first extending portion 93a toward the Y-axis may be equal to the length of the first portion 92a toward the Y-axis. The first extending portion 93a may extend in a direction inclined with respect to the Y-axis. The first extending portion 93a has the role of guiding the pull-out portion 12a toward the inside in the Y-axis direction from the outer edge on the negative Y-axis side of the cover body 91, while hooking it onto the pull-out portion 12a. The first extending portion 93a also has the role of extending the creepage distance between the pull-out portion 12a and the winding portion 11.

[0106] The second extension portion 93b is continuous with the first extension portion 93a and extends along the X-axis. A portion of the second extension portion 93b extends along the second portion 92b of the opening 92. The second extension portion 93b may also extend in a direction inclined with respect to the X-axis. The second extension portion 93b has the role of guiding the lead-out portion 12a toward the positive X-axis direction while hooking it. The second extension portion 93b also has the role of extending the creepage distance between the lead-out portion 12a and the winding portion 11.

[0107] The length of the second extension portion 93b along the X-axis is longer than the length of the first extension portion 93a along the Y-axis, but it may be equal to or less than the length of the first extension portion 93a. The length of the second extension portion 93b along the X-axis may be, for example, 1 / 2 or more of the length of the cover body 91 along the X-axis. The second extension portion 93b extends to the outer edge of the cover body 91 on the positive X-axis side, but it may extend to just before that point.

[0108] The pull-out portion 12a is pulled out from the winding portion 11 toward the first surface 91a side and toward the terminal 30a through the opening 92 on one side (negative direction side) of the center of the cover body 91 in the Y-axis direction. However, the pull-out position of the pull-out portion 12a is not particularly limited and may be at the center of the cover body 91 in the Y-axis direction.

[0109] The second extending portion 93b protrudes in the same direction as the guide portion 48a and extends along the X-axis direction together with the guide portion 48a. Therefore, the lead-out portion 12a can be pulled out from the winding portion 11 to the terminal 30a along the second extending portion 93b and the guide portion 48a. The guide portion 93 may also extend diagonally from the outer edge on the negative Y-axis side of the cover body 91 toward the outer edge on the positive X-axis side of the cover body 91.

[0110] As shown in Figure 7, the engaging portions 94a to 94d are formed at the four corners of the cover body 91 and protrude toward the second surface 91b of the cover body 91. The engaging portions 94a and 94b are positioned on the outer edge of the cover body 91 on the positive X-axis side, spaced apart in the Y-axis direction. The engaging portions 94c and 94d are positioned on the outer edge of the cover body 91 on the negative X-axis side, spaced apart in the Y-axis direction.

[0111] Engagement holes 940 are formed in engagement portions 94a to 94d, respectively. The engagement holes 940 penetrate through the engagement portions 94a to 94d. As shown in Figure 8, the engagement holes 940 of engagement portions 94a and 94b engage with the engagement projections 432a and 432b of the first bobbin 40, respectively. The engagement holes 940 of engagement portions 94c and 94d engage with the engagement projections 442a and 442b of the first bobbin 40, respectively. This allows the first cover member 90 to be attached to the first bobbin 40.

[0112] As shown in Figure 7, the engaging projection 95 is formed on the second surface 91b of the cover body 91 and protrudes from the second surface 91b. The engaging projection 95 extends from one end to the other in the Y-axis direction of the cover body 91, but the length of the engaging projection 95 along the Y-axis is not particularly limited. A portion of the engaging projection 95 extends along the first portion 92a of the opening 92.

[0113] As shown in Figure 1A, the engaging projection 95 engages with the engaging recess 444 of the flange 44. By engaging the engaging projection 95 and the engaging recess 444, misalignment of the first cover member 90 relative to the first bobbin 40 can be prevented. In addition, the insulation distance between the winding portion 11 and the lead-out portion 12a can be extended.

[0114] As shown in Figure 9, the second cover member 100 has a cover body 101, engaging projections 102a and 102b, core restricting portions 103a and 103b, a lateral projection 104, engaging portions 105a and 105b, and an engaging hole 106. The second cover member 100 may be made of the same material as the first cover member 90. As shown in Figure 1B, the second cover member 100 is attached to the first bobbin 40 on the upper side of the winding cylinder portion 41 (the side where the second core 80 is placed).

[0115] As shown in Figure 9, the cover body 101 may be composed of a plate having a rectangular parallelepiped shape. The cover body 101 has a first surface 101a and a second surface 101b opposite to the first surface 101a. The first surface 101a is the surface facing outward in the Z-axis direction, and the second surface 101b is the surface facing the winding cylinder portion 41 (Figure 4A).

[0116] As shown in Figures 1B and 3, the cover body 101 is positioned between the winding portion 11 and the main body portion 81 of the second core 80. The cover body 101 serves to extend the creepage distance and spatial distance (insulation distance) between the winding portion 11 and the main body portion 81 by separating them.

[0117] The thickness of the cover body 101 in the Z-axis direction is not particularly limited, but may be equal to the thickness of the cover body 91 of the first cover member 90 in the Z-axis direction. The length of the cover body 101 along the X-axis may be equal to or greater than the length of the winding cylinder portion 41 of the first bobbin 40 along the X-axis, or the length of the winding portion 11 along the X-axis. In either case, the insulation between the winding portion 11 and the main body portion 81 can be improved.

[0118] The length of the cover body 101 along the Y-axis may be equal to the length of the winding cylinder portion 41 along the Y-axis, or the length of the winding portion 11 along the Y-axis. Alternatively, the length of the cover body 101 along the Y-axis may be equal to the length of the main body portion 81 along the Y-axis. In either case, the insulation between the winding portion 11 and the main body portion 81 can be improved.

[0119] As shown in Figure 3, the second surface 101b of the cover body 101 abuts against a plurality of partition walls 411 formed on the outer circumferential surface of the winding cylinder portion 41. Therefore, the distance between the cover body 101 and the outer circumferential surface of the winding cylinder portion 41 is equal to the radial length of the partition walls 411. However, the distance between the cover body 101 and the outer circumferential surface of the winding cylinder portion 41 may be greater than the radial length of the partition walls 411.

[0120] As shown in Figure 9, the engaging projections 102a and 102b protrude inward from the second surface 101b in the Z-axis direction. The engaging projection 102a is formed on the end of the cover body 101 on the positive X-axis side, and the engaging projection 102b is formed on the end of the cover body 101 on the negative X-axis side. The engaging projections 102a and 102b extend from one end to the other in the Y-axis direction of the cover body 101, but the length of the engaging projections 102a and 102b along the Y-axis is not particularly limited.

[0121] The core restricting portions 103a and 103b protrude outward from the first surface 101a in the Z-axis direction. The core restricting portion 103a is formed at the end of the cover body 101 on the negative Y-axis side, and the core restricting portion 103b is formed at the end of the cover body 101 on the positive Y-axis side. The core restricting portions 103a and 103b extend from one end to the other in the X-axis direction of the cover body 101, but the length of the core restricting portions 103a and 103b along the X-axis is not particularly limited.

[0122] As shown in Figure 1B, the core restricting portions 103a and 103b extend along one and the other end of the second core 80 in the Y-axis direction, respectively, and abut against the one and the other end of the second core 80 in the Y-axis direction. This prevents the core restricting portions 103a and 103b from shifting position in the Y-axis direction of the second core 80. In addition, the core restricting portions 103a and 103b extend the creepage distance between the winding portion 11 and the second core 80.

[0123] As shown in Figure 9, the lateral projection 104 protrudes outward in the Z-axis direction from the first surface 101a. The lateral projection 104 is also formed on the outer surfaces of the core restricting portions 103a and 103b in the Y-axis direction, and protrudes outward in the Y-axis direction from these surfaces. The lateral projection 104 serves, for example, to improve the strength of the cover body 101.

[0124] The core restricting portion 103a has three lateral protrusions 104, which are located at each end and the center of the core restricting portion 103a in the X-axis direction. Similarly, the core restricting portion 103b also has three lateral protrusions 104, which are located at each end and the center of the core restricting portion 103b in the X-axis direction. However, the number and arrangement of the lateral protrusions 104 are not limited to these. Furthermore, not all lateral protrusions 104 need to have the same shape; for example, the size of the lateral protrusion 104 located in the center of the core restricting portion 103a in the X-axis direction may be reduced.

[0125] The engaging portions 105a and 105b (Figure 1B) are formed at both ends of the cover body 101 in the X-axis direction and protrude toward the second surface 101b. Engaging holes 106 are formed in the engaging portions 105a and 105b, respectively. The engaging holes 106 penetrate the engaging portions 105a and 105b. As shown in Figure 1B, the engaging holes 106 of the engaging portions 105a and 105b engage with the engaging projections 431 (Figure 4A) and 441 of the first bobbin 40, respectively. This allows the second cover member 100 to be attached to the first bobbin 40.

[0126] Next, the manufacturing method of the coil device 1 will be described. First, prepare the components shown in Figure 2. Terminals 30a and 30b are attached to the terminal mounting portion 42 of the first bobbin 40, for example, by insert molding. Similarly, terminals 30c and 30d (Figure 1B) are attached to the terminal mounting portion 62 of the second bobbin 60.

[0127] Next, a winding section 21 is formed on the winding cylinder section 61. Then, as shown in Figure 6, the lead-out sections 22a and 22b are pulled out from the bottom side of the winding cylinder section 61 toward the terminals 30c and 30d, and connected to the connecting sections 31c and 31d, respectively.

[0128] Next, the first core 70 is inserted into the through hole 610 of the winding cylinder portion 61 shown in Figure 2. Then, in the direction indicated by the arrow in Figure 6, the winding cylinder portion 61 with the first core 70 inserted is inserted into the through hole 410 of the winding cylinder portion 41.

[0129] Next, the winding section 11 is formed on the winding cylinder section 41 shown in Figure 2. However, the winding section 11 may be formed on the winding cylinder section 41 when the winding section 21 is formed on the winding cylinder section 61. Next, as shown in Figure 6, the lead-out section 12b is pulled out from the bottom side of the winding cylinder section 41 toward the terminal 30b and connected to the connecting section 31b.

[0130] Next, as shown in Figure 8, the first cover member 90 is attached to the first bobbin 40. At this time, the lead-out portion 12b is positioned inside the cover body 91. Next, the lead-out portion 12a is pulled out from the winding portion 11 toward the first surface 91a of the cover body 91 through the opening 92. At this time, the lead-out portion 12a is pulled out along the first portion 92a of the opening 92 from the outer edge on the negative Y-axis side of the cover body 91 toward the inside in the Y-axis direction. In addition, the lead-out portion 12a is pulled out along the second portion 92b, and the lead-out portion 12a is pulled toward the terminal 30a along the second extended portion 93b of the guide portion 93. Next, the lead-out portion 12a is connected to the connecting portion 31a. Note that when connecting the lead-out portion 12a to the connecting portion 31a, the connection of the lead-out portion 12b to the connecting portion 31b as described above may also be performed.

[0131] Next, as shown in Figure 1B, the second cover member 100 is attached to the first bobbin 40. Then, the second core 80 is attached from above the second cover member 100. Then, as shown in Figure 3, the legs 82 of the second core 80 are brought into contact with the surface of the first core 70 at the contact portion 120.

[0132] Next, as shown in Figure 1A, resin 110 is attached to the end of the first core 70 protruding from the winding cylinder portion 41 on the positive X-axis side. Then, via the resin 110, the end of the first core 70 on the positive X-axis side, together with the leg portion 82 of the second core 80, is connected to the second stoppers 47a and 47b and the mounting surface 50 (Figure 4A).

[0133] Similarly, as shown in Figure 1B, resin 110 is attached to the end of the first core 70 protruding from the winding cylinder portion 61 on the negative X-axis side. Then, via the resin 110, the end of the first core 70 on the negative X-axis side, together with the leg portion 82 of the second core 80, is connected to the second stoppers 67a and 67b and the mounting surface 63. In this manner, the coil device 1 can be manufactured.

[0134] As shown in Figures 1A and 1B, in the coil device 1 of this embodiment, the first core 70 and terminals 30a and 30b are arranged on opposite sides in the X-axis direction via a protrusion 45. Therefore, the protrusion 45 can extend the creepage distance or clearance distance (insulation distance) between the first core 70 and terminals 30a and 30b and the terminals. Thus, even if the end of the first core 70 on the positive X-axis side is positioned close to terminals 30a and 30b, it is possible to ensure insulation between them, and a compact coil device 1 with excellent (voltage-resistant) reliability can be realized.

[0135] Furthermore, since the protrusion 45 protrudes upward, the insulation distance between the first core 70 and terminals 30a and 30b can be extended according to the length of its protrusion.

[0136] Furthermore, since the protrusion 45 extends along the Y-axis from one end to the other of the terminal mounting portion 42, it is possible to form a wall-like protrusion on the terminal mounting portion 42. Therefore, the insulation distance between the first core 70 and the terminals 30a and 30b can be extended according to the length of the protrusion 45 along the Y-axis.

[0137] Furthermore, since the protrusion 45 is formed at least between terminals 30a and 30b, it is possible to prevent the insulation distance between the first core 70 and terminals 30a and 30b from becoming locally shorter in that area.

[0138] Furthermore, as shown in Figure 3, by housing the winding cylinder portion 61 within the winding cylinder portion 41, the overall length of the bobbin along the X-axis can be shortened, thereby enabling miniaturization of the coil device 1. In particular, this embodiment allows for the realization of a compact transformer.

[0139] Furthermore, as shown in Figure 2, even if a protrusion 45 is provided on the terminal mounting portion 42 and a protrusion 65 is provided on the terminal mounting portion 62, the winding cylinder portion is divided into a winding cylinder portion 41 and a winding cylinder portion 61, so the first core 70 can be inserted into the winding cylinder portion 61 without being obstructed by the protrusions 45 and 65.

[0140] Furthermore, as shown in Figures 1A and 3, the end of the first core 70 on the positive X-axis side is fixed to the mounting surface 50 via the resin 110, outside the contact portion 120 in the X-axis direction, thus preventing displacement of the first core 70.

[0141] Furthermore, as shown in Figure 1A, by bringing the first stoppers 46a and 46b into contact with the end of the first core 70 on the positive X-axis side, the first stoppers 46a and 46b can be used to position the first core 70 in the X-axis direction. In addition, it is possible to prevent the insulation distance between the first core 70 and the terminals 30a and 30b from fluctuating (decreasing) due to misalignment of the first core 70.

[0142] Second Embodiment The coil device 1A of this embodiment has the same configuration as the coil device 1 of the first embodiment, except for the points shown below. Components that overlap with the coil device 1 of the first embodiment are denoted by the same reference numerals, and their detailed descriptions are omitted.

[0143] As shown in Figure 10, the coil device 1A has a first bobbin 40A and a second bobbin 60A. The first bobbin 40A has a terminal mounting section 42A, and the second bobbin 60A has a terminal mounting section 62A. The terminal mounting section 42A has a first stopper 46A, and the terminal mounting section 62A has a first stopper 66A.

[0144] The first stopper 46A differs from the first stopper 46 of the first embodiment in that it has a stepped portion 460. The first stopper 66A differs from the first stopper 66 of the first embodiment in that it has a stepped portion 660.

[0145] The stepped portion 460 protrudes upward from the mounting surface 50 and also protrudes inward in the X-axis direction from the inner surface of the convex portion 45 in the X-axis direction. The stepped portion 460 extends continuously along the Y-axis from one end to the other of the terminal mounting portion 42A. The length of the stepped portion 460 along the Y-axis is equal to the length of the convex portion 45 along the Y-axis. However, the shape and size of the stepped portion 460 are not limited to this. The stepped portion 460 may be formed intermittently along the Y-axis. Also, the length of the stepped portion 460 along the Y-axis may be shorter than the length of the terminal mounting portion 42A along the Y-axis or the length of the convex portion 45 along the Y-axis. The upper surface of the stepped portion 460 is flat, but may have irregularities. A step perpendicular to the mounting surface 50 is formed between the upper surface of the stepped portion 460 and the mounting surface 50.

[0146] The stepped portion 660 protrudes upward from the mounting surface 63 and also protrudes inward in the X-axis direction from the inner surface of the convex portion 65 in the X-axis direction. The stepped portion 660 extends continuously along the Y-axis from one end to the other of the terminal mounting portion 62A. The length of the stepped portion 660 along the Y-axis is equal to the length of the convex portion 65 along the Y-axis. However, the shape and size of the stepped portion 660 are not limited to this. The stepped portion 660 may be formed intermittently along the Y-axis. Also, the length of the stepped portion 660 along the Y-axis may be shorter than the length of the terminal mounting portion 62A along the Y-axis or the length of the convex portion 65 along the Y-axis. The upper surface of the stepped portion 660 is flat, but may have irregularities. A step perpendicular to the mounting surface 63 is formed between the upper surface of the stepped portion 660 and the mounting surface 63.

[0147] In this embodiment, the same effects as in the first embodiment can be obtained. In particular, in this embodiment, the stepped portions 460 and 660 allow for the positioning of the first core 70 in the X-axis direction. Furthermore, it is possible to prevent the insulation distance between the first core 70 and terminals 30a and 30b (or terminals 30c and 30d) from fluctuating (decreasing) due to misalignment of the first core 70. In addition, the step difference between the surfaces of the stepped portions 460 and 660 and the mounting surfaces 50 and 63 allows for the extension of the insulation distance between the first core 70 and terminals 30a and 30b (or terminals 30c and 30d).

[0148] This disclosure is not limited to the embodiments described above, and can be modified in various ways within the scope of this disclosure. In the embodiments described above, examples of application of the coil device 1 to a transformer were explained, but it can be applied not only to transformers but also to other coil devices.

[0149] In each of the above embodiments, a second core 80 (Figure 1A) may be formed by combining I-shaped cores. Also, as shown in Figure 3, in each of the above embodiments, an annular core was formed by combining an I-shaped core and a U-shaped core, but an annular core may be formed by combining two U-shaped cores.

[0150] In each of the above embodiments, components other than the bobbin, coil, core, and terminals may be omitted as needed. Also, as shown in Figure 2, the bobbin consisted of a first bobbin 40 and a second bobbin 60, but the number of bobbins is not particularly limited. For example, the coil device 1 may be equipped with one bobbin. Also, the coil consisted of a first coil 10 and a second coil 20, but the number of coils is not particularly limited. For example, the coil device 1 may be equipped with one coil. Also, the core consisted of a first core 70 and a second core 80, but the number of cores is not particularly limited. Also, the terminal consisted of four terminals 30a to 30d, but the number of terminals is not particularly limited.

[0151] In each of the above embodiments, members other than the protrusion 45 may be omitted from the terminal mounting portion 42 as necessary. Similarly, members other than the protrusion 65 may be omitted from the terminal mounting portion 62 as necessary. [Explanation of symbols]

[0152] 1.1A... Coil device 10…First coil 11...Route 12a, 12b...Drawer part 20... Second coil 21... Volume 2 22a, 22b...Drawer part 30a~30d... Terminals 31a~31d...Connection section 32a~32d...External connection section 40, 40A…First bobbin 41... Winding tube section 410…Through hole 411…Bulkhead 42,42A…Terminal installation part 43, 44... Tsuba (guard) 430, 440…Engagement groove 431,432a,432b,441,442a,442b...Engagement protrusion 433a, 433b, 443a, 443b...Side wall part 444...Engagement recess 45... protruding part 450... Notch 46a, 46b, 46A... First stopper 460... Step section 47a, 47b... Second stopper 470... Notch 48a, 48b... Guide section 49a, 49b...Protruding part 50… Mounting surface 60, 60A…Second bobbin 61... Winding tube section 610…Through hole 611a~611d…Bulkhead 62,62A…Terminal installation part 63… Mounting surface 65... protruding part 650... Notch 66, 66A... First stopper 660... Step section 67a, 67b... Second stopper 670... Notch 68… Guide section 69a, 69b...Protruding part 70…First Core 80...Second core 81...Main body 82...legs 90...First cover member 91...Cover body 91a...Side 1 91b…Second side 92…Opening 92a…Part 1 92b…Second part 93... Guide Section 93a...first extension part 93b…Second extension part 94a~94d...Engagement part 940…Engagement hole 95…Engagement convex portion 100...Second cover member 101...Cover body 102a, 102b...Engagement protrusion 103a, 103b... Core regulatory section 104... Lateral protrusion 105a, 105b...Engagement part 106…tie hole 110…resin 120… (when receiving part)

Claims

1. A coil having a winding portion and a lead portion drawn out from the winding portion, The terminal to which the aforementioned pull-out section is connected, A bobbin having a winding cylinder portion on which the winding portion is formed, and a terminal mounting portion formed at the end of the winding cylinder portion in a first direction parallel to the axial direction, on which the terminal is provided, The bobbin has a core that is attached to the bobbin, The terminal mounting portion has a protrusion that separates the core and the terminal, The core comprises a first core and a second core combined with the first core. The terminal mounting portion has a first stopper that abuts against the end of the core in the first direction, The terminal mounting portion has a second stopper located on the outside of the first direction perpendicular to the first direction of the first core and the second core, adjacent to the first direction ends of the first core and the second core. The first stopper protrudes inward in the first direction from the inner surface of the protrusion in the first direction, The second stopper, separate from the first stopper, protrudes outward in the first direction from the flange of the bobbin. A coil device in which the length of the first core along the first direction is longer than the length of the second core along the first direction.

2. The coil device according to claim 1, wherein the protrusion projects toward a third direction perpendicular to the mounting surface of the bobbin on which the first core is mounted.

3. The coil device according to claim 2, wherein the protrusion extends from one end to the other end of the terminal mounting portion along a second direction perpendicular to the first and third directions.

4. The coil device according to claim 2, wherein, with respect to a second direction perpendicular to the first and third directions, the length of the protrusion is equal to or greater than the length of the first core or the second core.

5. The terminal has a pair of terminals, The coil device according to any one of claims 1 to 4, wherein the protrusion is formed at least between a pair of terminals.

6. The bobbin comprises a first bobbin and a second bobbin. The coil device according to any one of claims 1 to 4, wherein at least a portion of the second bobbin is housed inside the first bobbin.

7. The coil comprises a first coil having a first winding portion and a second coil having a second winding portion. The first bobbin has a first winding cylinder portion on which the first winding portion is formed, The second bobbin has a second winding cylinder portion into which the second winding portion is formed and into which the first core is inserted. The coil device according to claim 6, wherein the second winding cylinder portion is inserted into the first winding cylinder portion.

8. The aforementioned protrusion has a first protrusion and a second protrusion. The terminal mounting portion includes a first terminal mounting portion formed at one end of the first winding cylinder portion in the first direction, and a second terminal mounting portion formed at the other end of the second winding cylinder portion in the first direction. The first terminal mounting portion has the first protrusion, The coil device according to claim 7, wherein the second terminal mounting portion has the second protrusion.

9. The first core is an I-type core, The second core is a U-shaped core, The coil device according to any one of claims 1 to 4, wherein the first core is inserted into the winding cylinder portion.

10. The coil device according to claim 1, wherein the end of the first core in the first direction is connected to the terminal installation portion via resin, outside the contact portion between the first core and the second core in the first direction.

11. The coil device according to any one of claims 1 to 4, wherein the terminal mounting portion is formed inward in the first direction from the protrusion.

12. The first stopper has a stepped portion, The coil device according to claim 11, wherein a step is formed between the surface of the stepped portion and the mounting surface of the bobbin on which the first core is placed.

13. The first core is inserted into the winding cylinder portion, The end of the first core in the first direction protrudes outward from the winding cylinder portion in the first direction. The coil device according to claim 3, wherein a notch is formed in the second stopper.

14. The terminal has an external connection part that can be connected to a circuit board. The coil device according to any one of claims 1 to 4, wherein the external connection portion protrudes in a direction opposite to the protruding direction of the convex portion, or in a direction perpendicular to the protruding direction.

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