Noise filter

Abstract

The purpose of the present invention is to provide a noise filter capable of securing a space extending in the axial direction of a lead wire on a substrate. This noise filter (100) according to the present disclosure comprises a terminal fitting (1), a substrate (2), and a coil (31). The terminal fitting (1) is provided with: an external terminal (11) that can be electrically connected to an external device; a coil connection part (12) that is electrically connected to the coil (31) via a first lead wire (41); and a substrate connection part (13) that is electrically connected to the substrate (2). When a direction orthogonal to the axial direction of the first lead wire (41) and parallel to the substrate (2) is defined as the width direction, the coil connection part (12) extends from an end (11d) of the external terminal (11) in the axial direction of the first lead wire (41) to the coil (31) side. The substrate connection part (13) bends from an end (12d) of the coil connection part (12) in the axial direction of the first lead wire (41) toward the substrate (2) side.

Description

Noise Filter

[0001] The present disclosure relates to noise filters.

[0002] The noise filter disclosed in Patent Document 1 includes a terminal fitting. The terminal fitting includes a coil connection portion and a board connection portion. The board connection portion is electrically connected to the board. The coil connection portion is electrically connected to the coil via a lead wire and crimps the lead wire.

[0003] Japanese Patent Application Laid-Open No. 2023-097601

[0004] The inventors of the present application have discovered the following problem. In this noise filter, the coil connection portion and the board connection portion are integrally formed by bending a single plate-like body. The board connection portion extends from one end and the other end in the width direction of the coil connection portion and bends toward the board. The board connection portion rises from the board and supports the coil connection portion. Furthermore, the board connection portion extends along the axial direction of the lead wire on the board. Therefore, it is difficult to secure a space on the board that expands in the axial direction of the lead wire.

[0005] In view of the above-mentioned problems, an object of the present invention is to provide a noise filter that can secure a space extending in the axial direction of the lead wires on a substrate.

[0006] The noise filter according to the present disclosure comprises a terminal fitting, a substrate, and a coil mounted on the substrate, wherein the terminal fitting comprises an external terminal electrically connectable to an external device, a coil connection portion electrically connecting to the coil via a first lead wire, and a substrate connection portion electrically connecting to the substrate, wherein, when a direction perpendicular to the axial direction of the first lead wire and parallel to the substrate is defined as a width direction, the coil connection portion extends from an end of the external terminal in the axial direction of the first lead wire toward the coil, and the substrate connection portion bends from an end of the coil connection portion in the axial direction of the first lead wire toward the substrate, and the terminal fitting comprises a crimping piece provided at an end in the width direction of the coil connection portion, and the crimping piece crimps one end of the first lead wire.

[0007] In the above-described noise filter, the substrate connection portion may include a plurality of substrate-side terminals electrically connected to the substrate, the plurality of substrate-side terminals may be arranged in the width direction, and the length of the substrate connection portion in the width direction may be shorter than the length of the coil connection portion in the width direction.

[0008] Furthermore, in the above-described noise filter, the crimping piece may comprise a main body and a tip portion, the main body extending from an end of the coil connection portion in the width direction in the axial direction of the first lead wire of the coil connection portion and bending in a direction away from the substrate, and the tip portion extending from the main body in a direction away from the substrate and bending toward the first lead wire in the width direction.

[0009] In the above-described noise filter, the expanded shape of the terminal fitting may be encompassed by a substantially rectangular shape, and the external terminal, the coil connection portion, and the substrate connection portion may extend along the longitudinal direction of the substantially rectangular shape in the expanded shape of the terminal fitting.

[0010] The noise filter may further include a relay terminal, the relay terminal including a lead wire relay portion that relays the electrical connection between the first lead wire and the second lead wire, and first and second relay board connection portions that are electrically connected to the substrate, the first relay board connection portion extending from one end of the lead wire relay portion in the axial direction of the first lead wire and bending toward the substrate, the second relay board connection portion extending from the other end of the lead wire relay portion in the axial direction of the first lead wire and bending toward the substrate, and the substrate may include a wiring pattern that crosses the space between the first relay board connection portion and the second relay board connection portion.

[0011] In the above-described noise filter, the wiring pattern may include a neutral line that crosses a space between the first relay board connection portion and the second relay board connection portion.

[0012] Furthermore, in the above-described noise filter, the relay terminal may include a first relay crimping piece that crimps the other ends of the first and second lead wires, the first relay crimping piece having a first base, a central portion, and a tip portion, the first base portion being provided at one end of the lead wire relay portion in the width direction, the central portion extending from the first base portion in the axial direction of the first lead wire and bending in a direction away from the substrate, and the tip portion extending from the central portion in a direction away from the substrate and bending toward the first and second lead wires in the width direction.

[0013] In addition, in the above-described noise filter, the relay terminal may further include a second relay crimping piece that crimps the other ends of the first and second lead wires, the second relay crimping piece having a second base provided at the other end in the width direction of the lead wire relay portion, the first base extending from one end in the width direction of the lead wire relay portion and rising toward the first and second lead wires, the second base extending from the other end in the width direction of the lead wire relay portion and rising toward the first and second lead wires, the first and second bases facing each other across the space between the first lead wire and the second lead wire, and the first and second bases being longer in the axial direction of the first lead wire than the distance between the first lead wire and the second lead wire.

[0014] Furthermore, the above-mentioned noise filter may include four of the first lead wires, and the coil may include one ring core, and the four first lead wires may be wound around the one ring core so that, when viewed from the main surface of the substrate facing the ring core, the four first lead wires extend in a cross shape from the center of the one ring core.

[0015] The present invention can ensure a space on the board that extends in the axial direction of the lead wires.

[0016] 1 is a perspective view showing an example of a configuration of a noise filter according to a first embodiment; FIG. 2 is a perspective view showing an example of a configuration of a noise filter according to a first embodiment with a lid removed; FIG. 3 is a perspective view showing an example of a configuration of a noise filter according to a first embodiment with a lid and electronic components removed; FIG. 4 is a top view showing an example of a configuration of a noise filter according to a first embodiment with a lid and electronic components removed; FIG. 5 is a top view showing a coil of an example of a configuration of a noise filter according to a first embodiment; FIG. 6 is a bottom view showing a coil of an example of a configuration of a noise filter according to a first embodiment; FIG. 7 is a perspective view showing a terminal block and its periphery of an example of a configuration of a noise filter according to a first embodiment; FIG. 8 is an exploded perspective view of a terminal fitting according to a first embodiment; FIG. 9 is a top view showing a terminal fitting according to a first embodiment and its periphery; FIG. 10 is a bottom view showing a board-side terminal of a terminal fitting according to a first embodiment and its periphery; FIG. 11 is a view showing a developed shape of a terminal fitting according to a first embodiment; FIG. 12 is a view showing a developed shape of a terminal fitting according to a first embodiment in a plate material; FIG. 13 is a perspective view showing a relay terminal according to a first embodiment; FIG. 14 is a top view showing a relay terminal according to a first embodiment and its periphery; FIG. 15 is a bottom view showing a relay board connection portion of a relay terminal according to a first embodiment and its periphery; FIG. 16 is a bottom view showing a wiring pattern on a board of a noise filter according to a first embodiment; FIG. 1 is a perspective view showing a modified example of a relay terminal according to embodiment 1. FIG. 2 is a top view showing a modified example of a relay terminal according to embodiment 1 and its periphery. FIG. 3 is a view showing a developed shape of a modified example of a relay terminal according to embodiment 1. FIG. 4 is a circuit diagram of a configuration example of a noise filter according to embodiment 1. FIG. 5 is a top view showing components in a circuit of a configuration example of a noise filter according to embodiment 1. FIG. 6 is a perspective view showing a terminal fitting according to related technology. FIG. 7 is a top view showing a terminal fitting according to related technology and its periphery. FIG. 8 is a bottom view showing a board-side terminal of a terminal fitting according to related technology and its periphery. FIG. 9 is a view showing a developed shape of a terminal fitting according to related technology on a plate material.

[0017] (Related Art) Prior to describing the embodiment, related art will be described with reference to FIGS.

[0018] 22 includes an external terminal 911, a coil connection portion 912, and board connection portions 913A and 913B. A portion of the external terminal 911, the coil connection portion 912, and the board connection portions 913A and 913B are integrally formed by molding a single plate-like body.

[0019] The board connection portions 913A, 913B extend from one end 912b and the other end 912c in the width direction (here, the Y-axis direction) of the coil connection portion 912 and bend toward the board (here, the negative Z-axis direction). The board connection portions 913A, 913B rise from the board and extend along the axial direction of the lead wire (here, the X-axis direction). The board connection portions 913A, 913B are disposed below the coil connection portion 912 on the board. Therefore, the space SP9 below the coil connection portion 912 on the board is reduced in the axial direction of the lead wire.

[0020] Terminal fittings 91a and 91b shown in Fig. 23 are an example of the terminal fitting 91 shown in Fig. 22. The terminal fittings 91a and 91b are arranged on the substrate 902 with a distance W911 between them. The terminal fittings 91a and 91b each have a width W945. The width W945 is the length of the terminal fittings 91a and 91b in the width direction (here, the Y-axis direction).

[0021] As shown in FIG. 24 , on the lower surface 902a of the substrate 902, a solder layer 98a is formed on the board-side terminals 913c and 913d of the terminal fitting 91a. A solder layer 98b is formed on the board-side terminals 913c and 913d of the terminal fitting 91b. The length W98 of the solder layers 98a and 98b in the width direction (here, the Y-axis direction) is longer than the width W945 between the terminal fittings 91a and 91b. Therefore, the distance W988 between the solder layers 98a and 98b is shorter than the distance W911 between the terminal fittings 91a and 91b. Therefore, the arrangement of the terminal fittings 91a and 91b needs to be determined based on the distance W988 between the solder layers 98a and 98b. In other words, it is difficult to shorten the distance W911 between the terminal metal fittings 91a and 91b while ensuring insulation between the terminal metal fittings 91a and 91b.

[0022] The unfolded shape E91 shown in FIG. 25 is the shape of the terminal fitting 91 shown in FIG. 22 unfolded in a predetermined plane (here, the XY plane). The workpiece WK9 shown in FIG. 26 is a substantially rectangular plate having a width WW and a length LL. The unfolded shape E91 is encompassed by the main surface of the workpiece WK9. The unfolded shape E91 is encompassed by the substantially rectangular shape. In the unfolded shape E91 of the terminal fitting 91, the external terminal 911 and the coil connection portion 912 extend along the short side of the workpiece WK9 (here, the X-axis direction). Meanwhile, the board connection portions 913A and 913B extend along the longitudinal direction of the workpiece WK9 (here, the Y-axis direction). It is also preferable that multiple unfolded shapes E91 be arranged side by side in the longitudinal direction of the workpiece WK9 on the main surface of the workpiece WK9. In the example shown in FIG. 26, three unfolded shapes E91 can be arranged on the workpiece WK9. In other words, three terminal fittings 91 can be obtained from one workpiece WK1. Since a certain amount of workpieces is discarded, there is room for consideration of the yield.

[0023] Hereinafter, specific embodiments to which the present invention is applied will be described in detail with reference to the drawings. However, the present invention is not limited to the following embodiments. In addition, the following description and drawings have been simplified as appropriate for clarity of explanation.

[0024] First Embodiment The configuration of a noise filter according to a first embodiment will be described with reference to FIGS.

[0025] Fig. 1 is a perspective view showing an example of the configuration of a noise filter according to embodiment 1. Fig. 2 is a perspective view showing the example of the configuration of the noise filter shown in Fig. 1 with a lid removed. Fig. 3 is a perspective view showing the example of the configuration of the noise filter shown in Fig. 1 with a lid and electronic components removed.

[0026] It should be understood that the right-handed XYZ coordinate system shown in Figure 1 and other drawings is for the convenience of explaining the positional relationships of the components. Normally, the positive direction of the Z axis is vertically upward, and the XY plane is the horizontal plane, which is common among the drawings.

[0027] 1 to 3, the noise filter 100 includes a terminal fitting 1, a substrate 2, and coils 31 and 32. The noise filter 100 according to this embodiment further includes an electronic component 5, a resistor 5a, a terminal block 6, and a metal case 7.

[0028] The metal case 7 houses the coils 31, 32 and the electronic component 5. The metal case 7 covers at least a portion of the terminal fittings 1, the substrate 2, and the terminal block 6. The metal case 7 may have an opening. It is preferable that at least a portion of the terminal fittings 1 and the terminal block 6 is exposed through the opening. An example of the metal case 7 shown in FIG. 1 is a substantially rectangular parallelepiped.

[0029] The metal case 7 includes a bottom plate 71 and a lid 72. The bottom plate 71 supports the substrate 2. The lid 72 is detachably provided on the bottom plate 71.

[0030] The substrate 2 has a predetermined printed wiring pattern. An example of the printed wiring pattern will be described later. The substrate 2 carries coils 31 and 32. The coil 31 is electrically connected to the terminal fitting 1 via a first lead wire 41. The coil 32 is electrically connected to the terminal fitting 1 via a second lead wire 42. The relay terminal 21 relays the electrical connection between the first lead wire 41 and the second lead wire 42. The terminal fitting 1, the coils 31 and 32, the electronic component 5, and the resistor 5a are electrically connected to each other via the printed wiring pattern of the substrate 2. The first lead wire 41 and the second lead wire 42 may include multiple strands.

[0031] (Interior) Next, the interior of one example of the noise filter 100 will be described in detail with reference to Figs. 4 to 7. Fig. 4 is a top view showing one example of the noise filter shown in Fig. 1 with the cover and electronic components removed. Fig. 5 is a top view showing a coil of one example of the noise filter shown in Fig. 1. Fig. 6 is a bottom view showing the coil shown in Fig. 5. Fig. 7 is a perspective view showing a terminal block and its periphery of one example of the noise filter shown in Fig. 1.

[0032] As shown in FIG. 4 , terminal fittings 1a, 1b, 1c, 1d, 1e, 1f, 1g, and 1h, an electronic component 5, and a resistor 5a are mounted on a substrate 2. Terminal fittings 1a to 1h are an example of the terminal fitting 1 shown in FIG. 2. An example of the substrate 2 is a substantially rectangular plate. Terminal fittings 1a, 1b, 1c, and 1d are arranged at one end of the substrate 2 in the longitudinal direction (here, the X-axis direction). Terminal fittings 1a, 1b, 1c, and 1d are lined up in this order in the lateral direction of the substrate 2 (here, the Y-axis direction). Terminal fittings 1e, 1f, 1g, and 1h are arranged at the other end of the substrate 2 in the longitudinal direction. Terminal fittings 1e, 1f, 1g, and 1h are lined up in this order in the lateral direction of the substrate 2. Coils 31 and 32 are arranged at a predetermined interval in the longitudinal direction of the substrate 2 between the terminal fittings 1a, 1b, 1c, and 1d and the terminal fittings 1e, 1f, 1g, and 1h. The relay terminals 21 a , 21 b , 21 c , and 21 d are arranged in this order in the short-side direction of the substrate 2 between the coil 31 and the coil 32 .

[0033] Terminal fitting 1a is electrically connected to coil 31 via first lead wire 41a. Similarly, terminal fittings 1b, 1c, and 1d are electrically connected to coil 31 via first lead wires 41b, 41c, and 41d, respectively. First lead wires 41a to 41d are an example of the first lead wire 41 shown in FIG. 2. First lead wires 41a, 41b, 41c, and 41d are arranged in parallel on substrate 2 in the short direction of substrate 2. First lead wire 41a extends in the longitudinal direction of substrate 2 near terminal fitting 1a. Similarly, first lead wires 41b to 41d extend in the longitudinal direction of substrate 2 near terminal fittings 1b to 1d, respectively. Terminal fitting 1e is electrically connected to coil 32 via second lead wire 42a. Similarly, terminal fittings 1f, 1g, and 1h are electrically connected to coil 32 via second lead wires 42b, 42c, and 42d, respectively. Second lead wires 42a to 42d are an example of second lead wire 42 shown in FIG. 2. Second lead wires 42a, 42b, 42c, and 42d are arranged in parallel on substrate 2 in the short direction of substrate 2. Second lead wire 42a extends in the longitudinal direction of substrate 2 near terminal fitting 1e. Similarly, second lead wires 42b to 42d extend in the longitudinal direction of substrate 2 near terminal fittings 1f to 1h, respectively.

[0034] The relay terminal 21a relays the electrical connection between the first lead wire 41a and the second lead wire 42a. Similarly, the relay terminal 21b relays the electrical connection between the first lead wire 41b and the second lead wire 42b. The relay terminal 21c relays the electrical connection between the first lead wire 41c and the second lead wire 42c. The relay terminal 21d relays the electrical connection between the first lead wire 41d and the second lead wire 42d.

[0035] The electronic components 5 are arranged in the longitudinal direction of the substrate 2 at both ends in the short direction of the substrate 2. The electronic components 5 are, for example, capacitors. The resistors 5a are arranged in the longitudinal direction of the substrate 2 between the electronic component 5 and the first lead wire 41a, the second lead wire 42a, the first lead wire 41d, or the second lead wire 42d.

[0036] As shown in Figures 4 and 5, the coil 31 includes a ring core 31a. When viewed from the main surface of the substrate 2 facing the ring core 31a, the first lead wires 41a, 41b, 41c, and 41d are each wound around one ring core 31a so that they extend in a cross shape from the center of the ring core 31a. When viewed from the main surface of the substrate 2 facing the ring core 31a, the first lead wires 41a, 41b, 41c, and 41d extend in the ring core 31a so that they intersect with adjacent first lead wires 41a, 41b, 41c, and 41d at the center of the ring core 31a. In the ring core 31a, the first lead wires 41a and 41c face each other. The first lead wires 41b and 41d face each other. The first lead wires 41a, 41b, 41c, and 41d and the opposing first lead wires 41a, 41b, 41c, and 41d preferably extend on a straight line passing through the center of the ring core 31a. For example, the first lead wires 41a and 41c preferably extend on a straight line passing through the center of the ring core 31a. The first lead wire 41a is adjacent to the first lead wires 41b and 41d. The angles formed by the intersection of the first lead wires 41a, 41b, 41c, and 41d with the adjacent first lead wires 41a, 41b, 41c, and 41d are preferably right angles. For example, the angles formed by the intersection of the first lead wire 41a with the adjacent first lead wires 41b and 41d are preferably right angles. For example, it is preferable that the angle formed by the intersection of the first lead wire 41a and the adjacent first lead wires 41b and 41d is a right angle. By winding the first lead wires 41a, 41b, 41c, and 41d in this manner, it is possible to prevent the first lead wires 41a to 41d from crossing each other and to provide a distance between the adjacent first lead wires 41a to 41d. This ensures mutual insulation between the first lead wires 41a to 41d.

[0037] Similarly, the coil 32 includes a ring core 32a. When viewed from the main surface of the substrate 2 facing the ring core 32a, the second lead wires 42a, 42b, 42c, and 42d are each wound around one ring core 32a so that they extend in a cross shape from the center of the ring core 32a. When viewed from the main surface of the substrate 2 facing the ring core 32a, the second lead wires 42a, 42b, 42c, and 42d extend in the ring core 32a so that they intersect with adjacent second lead wires 42a, 42b, 42c, and 42d at the center of the ring core 32a. In the ring core 32a, the second lead wires 42a and 42c face each other. The second lead wires 42b and 42d face each other. The second lead wires 42a, 42b, 42c, and 42d and the opposing second lead wires 42a, 42b, 42c, and 42d preferably extend on a straight line passing through the center of the ring core 32a. For example, the second lead wires 42a and 42c preferably extend on a straight line passing through the center of the ring core 32a. The second lead wire 42a is adjacent to the second lead wires 42b and 42d. The angles formed by the intersection of the second lead wires 42a, 42b, 42c, and 42d with the adjacent second lead wires 42a, 42b, 42c, and 42d are preferably right angles. For example, the angles formed by the intersection of the second lead wire 42a with the adjacent second lead wires 42b and 42d are preferably right angles. For example, the angle formed by the intersection of the second lead wire 42a and the adjacent second lead wires 42b and 42d may be a right angle. By winding the second lead wires 42a, 42b, 42c, and 42d in this manner, the second lead wires 42a to 42d can be prevented from crossing each other and a distance can be created between the adjacent second lead wires 42a to 42d. This ensures mutual insulation between the second lead wires 42a to 42d.

[0038] Fig. 7 is a perspective view showing the terminal block and its periphery in one configuration example of the noise filter shown in Fig. 3. Note that in Fig. 7, the coil 31, the first lead wires 41a, 41b, 41c, and 41d, the electronic component 5, and the lid 72 are not shown.

[0039] As shown in FIG. 7 , the terminal block 6 and the circuit board 2 are stacked on an end 71 a of the bottom plate 71. The terminal block 6 includes a terminal holding portion 6 a, a flange 6 b, and a groove 6 c. The terminal block 6 includes at least one terminal holding portion 6 a, which holds a terminal fitting 1. Note that a large current may flow through the coil 31 and the first lead wires 41 a, 41 b, 41 c, and 41 d shown in FIG. 4 . Therefore, it is preferable that the coil 31 and the first lead wires 41 a, 41 b, 41 c, and 41 d are thick and resistant to deformation. Therefore, it is preferable to align the height of the terminal holding portion 6 a with the positions of the coil connection portion 12 and the first lead wires 41 a, 41 b, 41 c, and 41 d, because this facilitates electrical connection between the coil connection portion 12, the first lead wires 41 a, 41 b, 41 c, and 41 d, and the coil 31. The flange 6b extends from the bottom of the terminal block 6. The flange 6b of the terminal block 6, the circuit board 2, and the end 71a of the bottom plate 71 are fastened together with bolts 6d. The bottom plate 71, the circuit board 2, and the terminal block 6 are stacked in this order. The groove 6c may have a shape that can fit into the opening of the lid 72 of the metal case 7. A transparent cover 61 is provided above the terminal holding portion 6a of the terminal block 6.

[0040] (Terminal Fittings) Next, the terminal fittings will be described with reference to Figs. 8 to 12. Fig. 8 is an exploded perspective view of the terminal fitting shown in Fig. 7. Fig. 9 is a top view showing the terminal fitting and its periphery shown in Fig. 4, and is an enlarged view of area A9. Fig. 10 is a bottom view showing the board-side terminal of the terminal fitting shown in Fig. 8 and its periphery. In other words, Fig. 10 is a view of the terminal fitting and its periphery shown in Fig. 9 as viewed from below the board 2. Fig. 11 is a view showing the expanded shape of the terminal fitting shown in Fig. 8. Fig. 12 is a view showing the expanded shape of the terminal fitting shown in Fig. 8 in a plate material.

[0041] As shown in Fig. 8, the terminal fitting 1 includes an external terminal 11, a coil connection portion 12, and a board connection portion 13. An example of a portion of the external terminal 11, the coil connection portion 12, and the board connection portion 13 shown in Fig. 8 is formed integrally by molding a single plate-like body.

[0042] An example of the terminal fitting 1 shown in FIG. 8 extends in a generally L-shape, upside down and left to right, on the front surface (here, the ZX plane) of the noise filter 100 shown in FIG. 7 . The external terminal 11 is electrically connectable to an external device. The coil connection portion 12 is electrically connected to the coil 31 via the first lead wire 41 shown in FIG. 3 . The board connection portion 13 is electrically connected to the board 2. The external terminal 11 is located in the terminal holding portion 6a of the terminal block 6 shown in FIG. 7 . The coil connection portion 12 is located on the coil 31 side of the terminal block 6 (here, in the positive X-axis direction). The coil connection portion 12 extends from an end 11d in the axial direction of the first lead wire 41 (here, in the X-axis direction) from the external terminal 11 toward the coil 31 side. The board connection portion 13 bends from an end 12d of the coil connection portion 12 in the axial direction of the first lead wire 41 toward the board 2 (here, in the negative Z-axis direction). This eliminates the need to arrange components such as the board connection portion 13 below the coil connection portion 12 on the board 2. Therefore, a space SP1 extending in the axial direction of the first lead wire 41 can be secured below the coil connection portion 12 on the board 2. The space SP1 is longer in the axial direction of the first lead wire 41 than the space SP9 shown in FIG. 22 and other figures. Therefore, the terminal fitting 1 can secure a longer space in the axial direction of the first lead wire 41 below the coil connection portion 12 on the board 2 than the terminal fitting 91. One specific example of the board 2 shown in FIG. 16 has a wiring pattern P1. The wiring pattern P1 includes a wiring pattern P1a and a wiring pattern P1b. The wiring pattern P1b may be able to cross the space SP1 between the terminal block 6 and the board-side terminals 13b and 13c (described later) of the board connection portion 13.

[0043] The external terminal 11 has a hole 11c. The hole 11c has a female thread portion. The external terminal 11 is provided with a male screw 11a and a washer 11b. The male screw 11a passes through the washer 11b and fastens to the female thread portion of the hole 11c. The washer 11b is supported by a spring (not shown). When the male screw 11a is loosened, the washer 11b is pushed upward by the spring (not shown), and the male screw 11a moves upward due to the pressure of the washer 11b. A washer such as a spring washer or a flat washer may be provided between the male screw 11a and the washer 11b. A connection wire (not shown) is sandwiched between the washer 11b and the external terminal 11, and the male screw 11a is fastened to the washer 11b. The external terminal 11 can then be electrically connected to an external device (not shown) via the connection wire. The external device is, for example, a power supply.

[0044] The coil connection portion 12 includes a lead wire holding portion 12a and crimping pieces 14, 15. The crimping pieces 14, 15 crimp the first lead wire 41. Here, the direction perpendicular to the axial direction of the first lead wire 41 and parallel to the substrate 2 is defined as the width direction (here, the Y-axis direction). The crimping piece 14 is provided at one end 12b of the coil connection portion 12 in the width direction. The crimping piece 15 is provided at the other end 12c of the coil connection portion 12 in the width direction. While the lead wire holding portion 12a holds one end of the first lead wire 41, the crimping pieces 14, 15 are bent toward the lead wire holding portion 12a.

[0045] The crimping piece 14 includes a main body 14a and a tip 14b. The main body 14a extends from one end 12b of the coil connection portion 12 in the width direction in the axial direction of the first lead wire 41 of the coil connection portion 12 (here, the positive direction of the X-axis) and bends in a direction away from the substrate 2 (here, the positive direction of the Z-axis). The tip 14b extends from the main body 14a in a direction away from the substrate 2 and bends toward the first lead wire 41 in the width direction (here, the positive direction of the Y-axis). The lead wire holding portion 12a and the crimping piece 14 fasten the first lead wire 41 to fix it. Because the main body 14a and the tip 14b bend in different directions, the base of the crimping piece 14 twists. This reduces the bending radius of the crimping piece 14, making it difficult for the crimping piece 14 to separate from the lead wire holding portion 12a. As a result, the crimping piece 14 can firmly fix the first lead wire 41 to the lead wire holding portion 12a.

[0046] Similarly, the crimping piece 15 has a main body 15a and a tip 15b. The main body 15a extends from the other end 12c of the coil connection portion 12 in the width direction in the axial direction of the first lead wire 41 of the coil connection portion 12 and bends in a direction away from the substrate 2. The tip 15b extends from the main body 15a in a direction away from the substrate 2 and bends toward the first lead wire 41 in the width direction (here, in the negative Y-axis direction). The lead wire holding portion 12a and the crimping piece 15 fasten the first lead wire 41 to fix it. Because the main body 15a and the tip 15b bend in different directions, the base of the crimping piece 15 twists. This reduces the bending radius of the crimping piece 15, making it difficult for the crimping piece 15 to separate from the lead wire holding portion 12a. As a result, the crimping piece 15 can firmly fix the first lead wire 41 to the lead wire holding portion 12a.

[0047] The board connection portion 13 includes a wall portion 13a and board-side terminals 13b and 13c. The board connection portion 13 may include a plurality of board-side terminals. The board-side terminals 13b and 13c are electrically connected to the board 2. The board-side terminals 13b and 13c are aligned in the width direction (here, the Y-axis direction). The maximum width direction length W13 of the board connection portion 13 is shorter than the maximum width direction length W45 of the coil connection portion 12. The board connection portion 13 may be soldered to the board 2 shown in FIG. 7. Specifically, the board-side terminals 13b and 13c protrude downward (here, in the negative Z-axis direction) from the wall portion 13a. The board-side terminals 13b and 13c pass through holes in the board 2 and are soldered to the board 2.

[0048] 9, terminal fittings 1a and 1b are arranged on substrate 2 with a distance W11 therebetween. Terminal fittings 1a and 1b each have a width W45. Width W45 is the length of terminal fittings 1a and 1b in the width direction.

[0049] As shown in FIG. 10 , a solder layer 8a is formed on the board-side terminals 13b and 13c of the terminal fitting 1a on the lower surface 2a of the substrate 2. A solder layer 8b is also formed on the board-side terminals 13b and 13c of the terminal fitting 1b. The widthwise length W8 of the solder layers 8a and 8b is shorter than the width W45 between the terminal fittings 1a and 1b. Therefore, the distance W88 between the solder layers 8a and 8b is longer than the distance W11 between the terminal fittings 1a and 1b. Therefore, the distance W11 between the terminal fittings 1a and 1b can be shortened while ensuring insulation between the terminal fittings 1a and 1b. This increases the density of the components of the noise filter 100, thereby enabling the noise filter 100 to be made more compact.

[0050] The unfolded shape E1 shown in FIG. 11 is the shape of the terminal fitting 1 shown in FIG. 8 unfolded in a predetermined plane (here, the XY plane). The unfolded shape E1 is encompassed by a substantially rectangular shape. In the unfolded shape E1, the external terminal 11, the coil connection portion 12, and the board connection portion 13 extend along the longitudinal direction of the substantially rectangular shape (here, the X-axis direction). The workpiece WK1 shown in FIG. 12 is a substantially rectangular plate having a width WW and a length LL, and is the same size as the workpiece WK9 shown in FIG. 26. The workpiece WK1 is made of the same type of metal material as the metal material constituting the terminal fitting 1. The workpiece WK1 may be an original metal plate. The unfolded shape E1 is encompassed by the main surface of the workpiece WK1. The external terminal 11, the coil connection portion 12, and the board connection portion 13 extend along the short-side direction of the workpiece WK1 (here, the X-axis direction). Furthermore, it is preferable that a plurality of developed shapes E1 are arranged side by side on the main surface of the workpiece WK1 in the longitudinal direction of the workpiece WK1 (here, the Y-axis direction). In the example shown in Fig. 12, ten developed shapes E1 can be arranged on the workpiece WK1. In other words, ten terminal fittings 1 can be obtained from one workpiece WK1. This may be preferable because more terminal fittings can be obtained from one workpiece than in the examples shown in Figs. 25 and 26. In other words, it is possible to reduce waste in the workpiece and increase yield.

[0051] (Relay Terminal) Next, the relay terminal will be described with reference to Figs. 13 to 16. Fig. 13 is a perspective view showing the relay terminal shown in Fig. 4. Fig. 14 is a top view showing the relay terminal and its periphery shown in Fig. 4, and is an enlarged view of area A14. Fig. 15 is a bottom view showing the relay board connection portion of the relay terminal shown in Fig. 13 and its periphery. In other words, Fig. 15 is a view of the terminal fitting and its periphery shown in Fig. 14, viewed from the underside of the board 2. Fig. 16 is a bottom view showing the wiring pattern of the board of the noise filter according to embodiment 1.

[0052] 13, the relay terminal 21 includes a lead wire relay portion 211, a first relay board connecting portion 212, and a second relay board connecting portion 213. An example of the lead wire relay portion 211, the first relay board connecting portion 212, and the second relay board connecting portion 213 shown in FIG. 13 is formed integrally by molding a single plate-like body.

[0053] 13 extends in a generally upside-down U-shape on the front surface (here, the ZX plane) of the noise filter 100 shown in FIG. 3. The first relay board connecting portion 212 extends from one end 211b of the lead wire relay portion 211 in the axial direction of the first lead wire 41 (here, the X-axis direction) and bends toward the board 2 (here, the negative Z-axis direction). The second relay board connecting portion 213 extends from the other end 211c of the lead wire relay portion 211 in the axial direction of the first lead wire 41 and bends toward the board 2.

[0054] The lead wire relay portion 211 relays the electrical connection between the first lead wire 41 and the second lead wire 42. An example of the lead wire relay portion 211 shown in FIG. 13 includes a lead wire holding portion 211a, a first relay crimping piece 214, and a second relay crimping piece 215. The first relay crimping piece 214 and the second relay crimping piece 215 crimp the first lead wire 41 and the second lead wire 42 together. The other end of the first lead wire 41 and the other end of the second lead wire 42 may be soldered as appropriate. The first relay crimping piece 214 is provided at one end 211d of the lead wire relay portion 211 in the width direction (here, the Y-axis direction). The second relay crimping piece 215 is provided at the other end 211e of the lead wire relay portion 211 in the width direction. While the lead wire holding portion 211a holds the other end of the first lead wire 41 and the other end of the second lead wire 42, the first relay crimping piece 214 and the second relay crimping piece 215 are bent toward the lead wire holding portion 211a.

[0055] The first relay crimping piece 214 includes a first base portion 214a, a central portion 214b, and a tip portion 214c. The first base portion 214a is provided at one end portion 211d in the width direction of the lead wire relay portion 211. The central portion 214b extends from the first base portion 214a in the axial direction of the first lead wire 41 (here, the X-axis direction) and bends in a direction away from the substrate 2 (here, the positive Z-axis direction). The tip portion 214c extends from the central portion 214b in a direction away from the substrate 2 and bends toward the first lead wire 41 and the second lead wire 42 in the width direction (here, the positive Y-axis direction). The lead wire holding portion 211a and the first relay crimping piece 214 fasten the first lead wire 41 and the second lead wire 42 to fix them. The central portion 214b and the tip portion 214c bend in different directions, twisting the base of the first intermediate crimping piece 214. This reduces the bending radius of the first intermediate crimping piece 214, making it difficult for the first intermediate crimping piece 214 to separate from the lead wire holding portion 211a. As a result, the first intermediate crimping piece 214 can firmly fix the first lead wire 41 and the second lead wire 42 to the lead wire holding portion 211a.

[0056] Similarly, the second relay crimping piece 215 has a second base portion 215a, a central portion 215b, and a tip portion 215c. The second base portion 215a is provided at the other end portion 211e of the lead wire relay portion 211 in the width direction. The central portion 215b extends from the second base portion 215a in the axial direction of the first lead wire 41 and bends in a direction away from the substrate 2. The tip portion 215c extends from the central portion 215b in a direction away from the substrate 2 and bends toward the first lead wire 41 and the second lead wire 42 in the width direction (here, in the negative Y-axis direction). The lead wire holding portion 211a and the second relay crimping piece 215 fasten the first lead wire 41 and the second lead wire 42 to fix them. The central portion 215b and the distal end portion 215c bend in different directions, twisting the base of the second intermediate crimping piece 215. This reduces the bending radius of the second intermediate crimping piece 215, making it difficult for the second intermediate crimping piece 215 to separate from the lead wire holding portion 211a. As a result, the second intermediate crimping piece 215 can firmly fix the first lead wire 41 and the second lead wire 42 to the lead wire holding portion 211a.

[0057] The first relay board connection portion 212 includes a wall portion 212a and board-side terminals 212b and 212c. The first relay board connection portion 212 may include one or more board-side terminals. The board-side terminals 212b and 212c are electrically connected to the board 2. The board-side terminals 212b and 212c are aligned in the width direction (here, the Y-axis direction). The maximum width direction length W212 of the first relay board connection portion 212 is shorter than the maximum width direction length W245 of the lead wire relay portion 211. The first relay board connection portion 212 may be soldered to the board 2 shown in FIG. 3. Specifically, the board-side terminals 212b and 212c protrude downward (here, in the negative Z-axis direction) from the wall portion 212a. The board-side terminals 212b and 212c pass through holes in the board 2 and are soldered to the board 2.

[0058] Similarly, the second relay board connection portion 213 includes a wall portion 213a and board-side terminals 213b and 213c. The second relay board connection portion 213 may include one or more board-side terminals. The board-side terminals 213b and 213c are electrically connected to the board 2. The board-side terminals 213b and 213c are aligned in the width direction (here, the Y-axis direction). The maximum width direction length W213 of the second relay board connection portion 213 is shorter than the maximum width direction length W245 of the lead wire relay portion 211. The second relay board connection portion 213 may be soldered to the board 2. Specifically, the board-side terminals 213b and 213c protrude downward (here, in the negative Z-axis direction) from the wall portion 213a. The board-side terminals 213b and 213c pass through holes in the board 2 and are soldered to the board 2.

[0059] As shown in FIG. 14, on the substrate 2, relay terminals 21a, 21b, 21c, and 21d, which are examples of the relay terminal 21, are arranged in parallel in the width direction (here, the Y-axis direction).

[0060] As shown in FIG. 15 , a solder layer 82 is formed on the board-side terminals 212b and 212c of the relay terminals 21a, 21b, 21c, and 21d on the lower surface 2a of the substrate 2. A solder layer 83 is also formed on the board-side terminals 213b and 213c of the relay terminals 21a, 21b, 21c, and 21d. A space SP2 can be secured between the board-side terminals 212b and 213b. The substrate 2 may have a wiring pattern on the lower surface 2a that crosses the space between the first relay board connection portion 212 and the second relay board connection portion 213. The wiring pattern may be, for example, a copper foil pattern. This increases the degree of freedom in the wiring pattern of the substrate 2. In one specific example of the substrate 2 shown in FIG. 16 , the wiring pattern P1a may cross the space SP2 between the board-side terminals 212b and 213b. The wiring pattern P1a is preferably a neutral line.

[0061] (One Modified Example of Relay Terminal) Next, a modified example of the relay terminal will be described with reference to Fig. 17 to Fig. 19. Fig. 17 is a perspective view showing a modified example of the relay terminal according to embodiment 1. Fig. 18 is a top view showing the modified example of the relay terminal shown in Fig. 17 and its periphery. Fig. 19 is a diagram showing the expanded shape of the modified example of the relay terminal shown in Fig. 17.

[0062] The relay terminal 121 shown in Fig. 17 is a modified example of the relay terminal 21 shown in Fig. 13. The relay terminal 121 has the same configuration as the relay terminal 21 except for a first base 314a and a second base 315a. The first base 314a extends from one end 211d of the lead wire relay portion 211 in the width direction and rises toward the first lead wire 41 and the second lead wire 42 (here, in the positive direction of the Z axis). The second base 315a extends from the other end 211e of the lead wire relay portion 211 in the width direction and rises toward the first lead wire 41 and the second lead wire 42 (here, in the positive direction of the Z axis).

[0063] As shown in FIG. 18, the first base portion 314a and the second base portion 315a face each other across the space between the first lead wire 41 and the second lead wire 42.

[0064] The first base portion 314a has a length L314 in the axial direction of the first lead wire 41. The second base portion 315a has a length L315 in the axial direction of the first lead wire 41. The lengths L314 and L315 are longer than the distance L44 between the first lead wire 41 and the second lead wire 42.

[0065] Molten solder is supplied between the first lead wire 41 and the second lead wire 42. The first base 314a and the second base 315a then block the molten solder, preventing it from spreading in the width direction of the lead wire relay portion 211. The molten solder solidifies and forms a solder layer. The width of the formed solder layer is shorter than the width W245 of the lead wire relay portion 211 shown in FIG. 17 . This allows the distance between adjacent relay terminals 121 to be shortened while ensuring the insulation distance between them. Therefore, the noise filter 100 can be miniaturized while ensuring insulation. Furthermore, to increase the current flowing through the first lead wire 41 and the second lead wire 42, the first lead wire 41 and the second lead wire 42 may have a large cross-sectional area, or the number of wires included in the first lead wire 41 and the second lead wire 42 may be increased. In either case, the amount of molten solder supplied increases. As described above, the first base portion 314a and the second base portion 315a block the molten solder and prevent it from spreading in the width direction of the lead wire relay portion 211. This prevents the molten solder from moving outward in the width direction of the lead wire relay portion 211 and thereby preventing it from not contributing to the electrical connection between the first lead wire 41 and the second lead wire 42. In other words, the molten solder can be reliably supplied between the first lead wire 41 and the second lead wire 42. Therefore, an appropriate amount of molten solder can be supplied to electrically connect the first lead wire 41 and the second lead wire 42.

[0066] (Expanded Shape) The expanded shape E121 shown in FIG. 19 is the shape of the relay terminal 121 shown in FIG. 17 expanded in a predetermined plane (here, the XY plane). The expanded shape E121 is encompassed by a substantially rectangular shape. In the expanded shape E121, the lead wire relay portion 211, the first relay board connection portion 212, and the second relay board connection portion 213 extend along the longitudinal direction of the substantially rectangular shape (here, the X-axis direction). The expanded shape E121, like the expanded shape E1 shown in FIG. 12, is encompassed by the main surface of the workpiece WK1. Note that the lead wire relay portion 211, the first relay board connection portion 212, and the second relay board connection portion 213 extend along the lateral direction of the workpiece WK1 (here, the X-axis direction). Furthermore, it is preferable that multiple expanded shapes E121 are arranged side by side on the main surface of the workpiece WK1 in the longitudinal direction of the workpiece WK1 (here, the Y-axis direction). That is, it is possible to obtain many relay terminals 121 from one workpiece, which means that waste in the workpiece can be reduced and the yield can be increased.

[0067] (Circuit) As described above, the coils 31, 32, electronic component 5, and resistor 5a are electrically connected via the terminal fitting 1, the printed wiring pattern of the substrate 2, and the relay terminal 21, thereby forming an electric circuit. An example of this formed electric circuit is shown in FIG. 20 . FIG. 20 is a circuit diagram of the noise filter 100 shown in FIG. 1 . FIG. 21 is a top view showing components in the circuit of one configuration example of the noise filter shown in FIG. 20 . Resistors Rx1, Rx2, Rx3, Rx4, Rx5, Rx6, Ry1, and Ry2 shown in FIGS. 20 and 21 are examples of the resistor 5a shown in FIG. 4 . Capacitors Cx1, Cx2, Cx3, Cx4, Cx5, Cx6, Cy1, and Cy2 shown in FIGS. 20 and 21 are examples of the electronic component 5 shown in FIG. 4 .

[0068] The present invention is not limited to the above-described embodiment, and modifications can be made as appropriate without departing from the spirit of the present invention. Furthermore, the present invention may be implemented by appropriately combining the above-described embodiment and examples thereof. For example, while the exemplary configuration of the noise filter 100 shown in FIG. 1 includes terminal fittings 1a to 1h, first lead wires 41a to 41d, and second lead wires 42a to 42d, the noise filter 100 may include at least one terminal fitting, one first lead wire, and one second lead wire.

[0069] This application claims priority based on Japanese Patent Application No. 2024-025074, filed February 22, 2024, the disclosure of which is incorporated herein in its entirety by reference.

[0070] 100 Noise filter 1, 1a to 1h Terminal fitting 11 External terminal 11a Male screw 11b Washer 11c Hole 11d End 12 Coil connection portion 12a Lead wire holding portion 12b One end 12c Other end 12d End 13 Board connection portion 13a Wall portion 13b Board side terminal 14, 15 Crimping piece 14a, 15a Main body 14b, 15b Tip portion 21, 21a to 21d, 121 Relay terminal 211 Lead wire relay portion 211a Lead wire holding portion 211b, 211d One end 211c, 211e Other end 212 First relay board connection portion 213 Second relay board connection portion 212a, 213a Wall portion 212b, 212c, 213b, 213c Board side terminal 214 First relay crimping piece 215 Second relay crimping piece 214a, 314a First base portion 215a, 315a Second base portion 214b, 215b Central portion 214c, 215c Tip portion 2 Board 2a Lower surface 31, 32 Coil 31a, 32a Ring core 41, 41a to 41d First lead wire 42, 42a to 42d Second lead wire 5 Electronic component 5a Resistor 6 Terminal block 6a Terminal holding portion 6b Flange 6c Groove 6d Bolt 61 Transparent cover 7 Metal case 71 Bottom plate 71a End portion 72 Lid 8a, 8b, 82 Solder layer A14 Area Cx1 to Cx6, Cy1 to Cy2 Capacitor E1, E121 Expanded shape L44 Distance P1, P1a, P1b Wiring pattern Rx1 to Rx6, Ry1 to Ry2 Resistor SP1, SP2 Space W11 Distance W45 Width W88 Distance WK1 Work WW Width

Claims

1. A noise filter comprising: a terminal fitting; a substrate; and a coil mounted on the substrate, wherein the terminal fitting comprises an external terminal electrically connectable to an external device, a coil connection portion electrically connecting to the coil via a first lead wire, and a substrate connection portion electrically connecting to the substrate, wherein, when a direction perpendicular to the axial direction of the first lead wire and parallel to the substrate is defined as a width direction, the coil connection portion extends from an end of the external terminal in the axial direction of the first lead wire toward the coil, and the substrate connection portion bends from an end of the coil connection portion in the axial direction of the first lead wire toward the substrate, and the terminal fitting comprises a crimping piece provided at an end in the width direction of the coil connection portion, and the crimping piece crimps one end of the first lead wire.

2. The noise filter according to claim 1, wherein the board connection portion comprises a plurality of board-side terminals electrically connected to the board, the plurality of board-side terminals being aligned in the width direction, and the length of the board connection portion in the width direction is shorter than the length of the coil connection portion in the width direction.

3. A noise filter as claimed in claim 1 or 2, wherein the crimping piece comprises a main body and a tip portion, the main body extending from an end of the coil connection part in the width direction in the axial direction of the first lead wire of the coil connection part and bending in a direction away from the substrate, and the tip portion extending from the main body in a direction away from the substrate and bending towards the first lead wire in the width direction.

4. A noise filter according to claim 1 or 2, wherein the expanded shape of the terminal fitting is encompassed by a substantially rectangular shape, and the external terminal, the coil connection portion, and the board connection portion extend along the longitudinal direction of the substantially rectangular shape in the expanded shape of the terminal fitting.

5. The noise filter according to claim 1 or 2, further comprising a relay terminal, wherein the relay terminal comprises a lead wire relay portion that relays the electrical connection between the first lead wire and the second lead wire, and first and second relay board connection portions that are electrically connected to the board, wherein the first relay board connection portion extends from one end of the lead wire relay portion in the axial direction of the first lead wire and bends toward the board, and the second relay board connection portion extends from the other end of the lead wire relay portion in the axial direction of the first lead wire and bends toward the board, and the board has a wiring pattern that traverses the space between the first relay board connection portion and the second relay board connection portion.

6. The noise filter according to claim 5, wherein the wiring pattern includes a neutral line that crosses the space between the first relay board connection portion and the second relay board connection portion.

7. The noise filter according to claim 5, wherein the relay terminal comprises a first relay crimping piece that crimps the other ends of the first and second lead wires, the first relay crimping piece comprising a first base, a central portion, and a tip portion, the first base portion being provided at one end of the lead wire relay portion in the width direction, the central portion extending from the first base portion in the axial direction of the first lead wire and bending in a direction away from the substrate, and the tip portion extending from the central portion in a direction away from the substrate and bending towards the first and second lead wires in the width direction.

8. The noise filter according to claim 7, wherein the relay terminal further comprises a second relay crimping piece that crimps the other ends of the first and second lead wires, the second relay crimping piece comprising a second base provided at the other end in the width direction of the lead wire relay portion, the first base extending from one end in the width direction of the lead wire relay portion and rising toward the first and second lead wires, the second base extending from the other end in the width direction of the lead wire relay portion and rising toward the first and second lead wires, the first and second bases facing each other with a space between the first lead wire and the second lead wire sandwiched therebetween, and the first and second bases being longer in the axial direction of the first lead wire than the distance between the first lead wire and the second lead wire.

9. A noise filter as claimed in claim 1 or 2, comprising four of the first lead wires, the coil comprising one ring core, and the four first lead wires wound around each of the ring cores so that, when viewed from the main surface of the substrate facing the ring core, the four first lead wires extend in a cross shape from the center of the ring core.

Images