JP6424910B2 - Coil device - Google Patents

Description

  The present invention relates to a coil device that can be suitably used, for example, as a transformer such as a leakage transformer.

  Coil devices are used in a variety of electrical products and in a variety of applications. For example, in a DC / DC converter that steps down high voltage supplied from high voltage battery of electric car or hybrid car to low voltage and supplies it to other electric devices, coil system is used, transformer such as leakage transformer It is commonly used as

  As an example of a coil device, for example, a coil device shown in Patent Document 1 below can be mentioned. The coil device shown in Patent Document 1 has a primary coil and a pair of secondary coils (bus bars) that sandwich the primary coil at the top and bottom. In this coil device, the primary side bobbin around which the primary coil is wound is sandwiched by the secondary side bobbin on which the secondary coil is insert-molded.

  In the coil device configured in this way, the distance in the winding axis direction between the primary coil and the secondary coil is determined by the sum of the thickness of the flange of the primary side bobbin and the insert molding thickness of the secondary side bobbin It is determined. Therefore, it is difficult to set the distance in the winding axis direction between the primary coil and the secondary coil to a constant thickness, and it is difficult to stabilize the leakage characteristics.

  Further, in this coil device, the secondary side bobbin is provided with an arc-shaped side wall portion, the housing portion is provided inside the side wall portion, and the primary side bobbin is housed in the housing portion. There is also a problem that the outside diameter of the lens is large, and the miniaturization is difficult.

JP, 2013-89787, A

  The present invention has been made in view of such a situation, and an object thereof is to provide a coil device which can be miniaturized and which has stable leakage characteristics.

In order to achieve the above object, a coil device according to the present invention is:
With a bobbin,
A first coil portion made of a plate-like conductor;
A second coil portion which is located separately from the first coil portion and made of a plate-like conductor;
A coil device having an intermediate coil portion located between the first coil portion and the second coil portion, the coil device comprising:
The bobbin is
An intermediate cylinder portion having the intermediate coil portion wound thereon, wherein an intermediate first end portion and a second intermediate end portion are formed on each of the first end and the second end in the axial direction of the intermediate end portion. With a bobbin,
A first bobbin having a first tubular portion combined with the first end, and a first end flange portion being formed on the first tubular portion;
And a second bobbin having a second cylindrical portion combined with the second end, and a second end collar portion formed on the second cylindrical portion,
The intermediate coil portion is wound around the intermediate cylindrical portion so as to be in contact (preferably in close contact) with the first intermediate collar portion and the second intermediate collar portion.
The second tubular portion is combined with the second end of the intermediate tubular portion so that the second intermediate flange portion abuts on the opposite surface of the second coil portion abutting on the second end flange portion.

  The bobbin in the present invention is configured by integrally combining a first bobbin, an intermediate bobbin, and a second bobbin. Moreover, instead of accommodating the intermediate bobbin inside the second bobbin, the second coil in which the second cylindrical portion is combined with the second end of the intermediate cylindrical portion and abuts (preferably adheres to) the second end flange portion The second intermediate collar portion is in contact (preferably in close contact) with the opposite surface of the portion.

  Since the intermediate coil portion is wound on the intermediate bobbin so as to contact the second intermediate collar portion, the intermediate coil portion wound on the intermediate bobbin and the second coil portion disposed on the second bobbin Are spaced apart at a distance corresponding to the thickness of the second intermediate ridge. The thickness of the second intermediate collar portion can be relatively accurately controlled and molded when molding the intermediate bobbin.

  Further, if the second bobbin is disposed on the lower side in the direction of gravity, and the intermediate bobbin and the first bobbin are combined thereon, the first coil portion is disposed on the first intermediate collar portion, The lower surface of the first coil portion abuts (preferably adheres to) the upper surface of the first intermediate collar portion by the gravity of the first coil portion. Further, the intermediate coil portion is wound around the intermediate bobbin so as to abut (preferably adhere) to the lower surface of the first intermediate collar portion.

  Therefore, the intermediate coil portion wound around the intermediate bobbin and the first coil portion arranged on the first bobbin can be spaced apart at a distance corresponding to the thickness of the first intermediate collar portion. The thickness of the first intermediate collar portion can be relatively accurately controlled and molded when molding the intermediate bobbin.

  After combining the first bobbin, the intermediate bobbin and the second bobbin in this manner, these bobbins may be fixed, for example, by a fixing means such as an adhesive, whereby the first coil portion, the intermediate coil portion and the second coil portion The distance in the winding axis direction is kept constant, corresponding to the thickness of each ridge. Therefore, it is easy to enhance the coupling between these coil portions, and a coil device having stable leakage characteristics can be realized.

  Moreover, since it is not necessary to perform insert molding etc., the height in the winding axis direction of the bobbin can be reduced. Furthermore, since the second tubular portion is combined with the second end of the intermediate tubular portion instead of accommodating the intermediate bobbin inside the second bobbin, the radial size of the second bobbin is reduced. be able to. The same applies to the first bobbin as to the second bobbin.

  Furthermore, since the first coil portion and the second coil portion are formed of plate-like conductors, a large current can flow through the first coil portion and the second coil portion.

  The second coil portion may have a substantially ring plate shape. In addition, at the intersection of the inner surface of the second end flange and the outer peripheral surface of the second cylindrical portion, a positioning portion may be formed to be in contact with the inner peripheral side surface of the second coil portion. With such a configuration, the inner peripheral side surface of the second coil portion abuts on the positioning portion, and it is possible to prevent the second coil portion from being displaced in the radial direction.

  Preferably, the positioning portion is formed on an outer peripheral side surface of the stepped portion, and the second intermediate flange portion abuts on the stepped surface of the stepped portion. Preferably, the axial length of the step portion is equal to or less than the thickness of the second coil portion. By adopting such a configuration, the second intermediate collar portion securely adheres to the second coil portion.

  Preferably, on the second end side of the inner peripheral side surface of the intermediate cylindrical portion, an intermediate notch portion notched to a predetermined depth is formed, and on the first end side of the second cylindrical portion, The engagement convex portion is formed so as to form an engagement convex portion engaged with the intermediate cutout portion, and a gap is formed between a tip end surface of the engagement convex portion and a bottom surface of the intermediate cutout portion. Engage with the intermediate notch. By adopting such a configuration, the second intermediate collar portion securely adheres to the second coil portion.

  Preferably, the engagement convex portion engages with the intermediate notch so that the inner peripheral side surface of the intermediate cylindrical portion and the outer peripheral side surface of the engagement convex portion face each other. With such a configuration, the outer peripheral side surface of the engagement convex portion functions as a positioning surface, and it is possible to prevent the intermediate cylindrical portion from being displaced in the radial direction.

  The first cylindrical portion is combined with the first end of the intermediate cylindrical portion so that a space in which the first coil portion can be disposed is formed between the first end collar portion and the first intermediate collar portion. It may be configured to

  In addition, the first end of the intermediate tubular portion may contact the first end of the intermediate tubular portion so that the first end flange abuts (preferably adheres) to the opposite surface of the first coil portion that abuts the first intermediate ridge. One tube portion may be combined.

  The first coil portion and the second coil portion constitute either one of a primary coil or a secondary coil, and the intermediate coil portion constitutes any one of a primary coil or a secondary coil. May be

FIG. 1A is a perspective view of a transformer as a coil device according to an embodiment of the present invention. FIG. 1B is a perspective view when the case and the bottom plate are removed from the transformer shown in FIG. 1A. FIG. 2 is an exploded perspective view of the transformer shown in FIG. 1A. FIG. 3 is a cross-sectional view of an essential part of the transformer taken along the line III-III shown in FIG. 1A. FIG. 4 is a cross-sectional view of an essential part of the bobbin taken along line IV-IV shown in FIG. 1A. FIG. 5A is a perspective view of a bobbin in the transformer shown in FIG. 1A. FIG. 5B is an exploded perspective view of the bobbin shown in FIG. 5A. FIG. 5C is a cross-sectional view of an essential part of the bobbin shown in FIG. 5A. FIG. 5D is a cross-sectional view of main parts of a modification of the bobbin shown in FIG. 5A. FIG. 5E is a detailed cross-sectional view of the bobbin shown in FIG. 5A. FIG. 5F is a perspective view when the insulating cover or the like is attached to the bobbin shown in FIG. 5A. FIG. 6A is a perspective view of a coil portion in the transformer shown in FIG. 1A. 6B is an exploded perspective view of the coil portion shown in FIG. 6A. FIG. 6C is a perspective view of a modification of the first coil portion and the second coil portion in the coil portion shown in FIG. 6A. FIG. 7 is a circuit diagram showing an equivalent circuit of the transformer shown in FIG. 1A.

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

  The transformer 10 as a coil device according to the present embodiment shown in FIG. 1A reduces the high voltage supplied from the high voltage battery of an electric vehicle or a hybrid vehicle to a low voltage and supplies it to other electric devices. It is used for DC converter etc.

  As shown in FIG. 2, the transformer 10 includes a bobbin 20, magnetic cores 40a and 40b, a cover 50, a lead wire cover 60, a terminal 80, a case 90 for housing them inside, and a bottom plate 91. Have. In the drawings, the X axis, the Y axis, and the Z axis are perpendicular to one another, and the Z axis corresponds to the height (thickness) of the transformer 10. In the present embodiment, the lower side in the Z-axis direction of the transformer 10 is the installation surface of the transformer. The Y axis coincides with the longitudinal direction of the base portions 44a and 44b of the magnetic cores 40a and 40b. Furthermore, the X-axis coincides with the longitudinal direction of the bobbin 20.

  In the present embodiment, the bottom plate 91 is attached to the bottom opening of the case 90 by caulking, adhesion, or the like to form a case 90 having an open top. The bottom plate 91 is preferably made of a metal such as aluminum copper or iron excellent in heat dissipation, but may be made of PPS, PET, PBT or the like. Since the lower end surface of the magnetic core 40 described later in the Z-axis direction is in contact with the bottom plate 91, the bottom plate 91 is preferably made of a material excellent in heat dissipation. Below the case 90, a cooling device such as a cooling pipe or a cooling fin may be attached via the bottom plate 91 or directly.

  At the four corners of the bottom plate 91, bosses 92 are formed. In the boss portion 92, for example, a bolt hole is formed. The case 90 itself is made of metal, but may be made of synthetic resin or the like. The bottom plate 91 and the case 90 may be integrally formed by die-casting of aluminum or the like. Heat dissipation can be further enhanced by forming the entire case with metal.

  As shown in FIG. 3, the inside of the case 90 is filled with a heat dissipation resin 100. Although it does not specifically limit as resin for thermal radiation, For example, thermal conductivity is 0.5-5, Preferably resin which was excellent in the heat dissipation which is 1-3 W / m * K is preferable. Examples of the resin excellent in heat dissipation include silicone resins, urethane resins and epoxy resins. Among them, silicone resins and urethane resins are preferable. Moreover, in order to improve heat dissipation, the resin may be filled with a filler having high thermal conductivity.

  The resin for heat dissipation of this embodiment preferably has a Shore A hardness of 100 or less, preferably 60 or less. Even if the magnetic cores 40a and 40b and the bobbin 20 are deformed by heat, the deformation is absorbed to prevent excessive stress from being generated in the magnetic cores 40a and 40b. A potting resin is illustrated as such resin.

  As shown in FIGS. 3 and 4, the coil 30 mounted on the bobbin 20 includes a first coil portion 31 and a second coil portion 32 along the central axis (Z-axis direction) of the bobbin 20. And an intermediate coil portion 33 located between the first coil portion 31 and the second coil portion 32. That is, the coil portions 31 to 33 are arranged along the central axis so as to sandwich the third coil portion 33 between the first coil portion 31 and the second coil portion 32.

  The intermediate coil portion 33 is constituted by an intermediate wire 37, and the first coil portion 31 and the second coil portion 32 are plate-shaped conductors (in the present embodiment, bus bars) 38 and 39 each having conductivity. It is configured. By forming each of the coil portions 31 and 32 with a bus bar, a large current can be supplied to each of the coil portions 31 and 32.

  In the present embodiment, the intermediate wire 37 constitutes a primary coil, and the bus bars 38 and 39 constitute a secondary coil. That is, as shown in FIG. 7A, the first coil portion 31 and the second coil portion 32 constituted by the bus bars 38 and 39 are formed by the intermediate coil portion 33 constituted by the intermediate wire 37 on the primary side As a result, a transformer is formed between the two.

  In the present embodiment, a high voltage acts on the primary coil as compared to the secondary coil, and a relatively low voltage acts on the secondary coil. The range of the voltage acting on the primary coil is, for example, 300 to 500 V, and the range of the voltage acting on the secondary coil is 12 to 14 V.

  The intermediate wire 37 may be constituted by a single wire or may be constituted by a stranded wire, preferably by a litz wire or the like. The outer diameter of the intermediate wire 37 is not particularly limited, but is preferably in the range of 1 to 3 mm. Moreover, it is preferable that the intermediate wire 37 be provided with an insulating film.

  The lead portions 37a and 37b shown in FIG. 1A are both ends of the intermediate wire 37 shown in FIGS. As shown in FIG. 1A, a terminal 80 made of, for example, a metal terminal is connected by soldering or the like to each end of the lead portions 37a and 37b, and both ends of the wire 37 are electrically connected to the terminal 80. is there.

  As shown in FIGS. 6A and 6B, the bus bars 38 and 39 have a substantially ring plate shape (generally C-shaped plate shape) having openings 383 and 393 in a substantially elliptical shape at the center. The bus bars 38 and 39 are manufactured by bending and processing each portion after punching a flat plate made of a conductive material such as a copper plate. The shape of the bus bars 38 and 39 is not limited to a substantially ring plate shape (substantially C-shaped plate shape), and may be another shape such as an elliptical shape or a square shape, for example. Moreover, in this embodiment, although the bus bars 38 and 39 are each comprised by one turn, you may be comprised by two or more turns.

  A first terminal portion 381a is formed at one end of the bus bar 38, and a second terminal portion 381b is formed at the other end. Further, a first terminal portion 391a is formed at one end of the bus bar 39, and a second terminal portion 391b is formed at the other end. As shown in FIG. 6A, the first terminal portion 381a of the bus bar 38 is connected to the second terminal portion 391a of the bus bar 39 so as to overlap in the Z-axis direction, and the second terminal portion 381 b of the bus bar 38 The two terminal portions 391 b are connected so as to overlap in the Z-axis direction. Thereby, the bus bars 38 and 39 are connected and overlap coaxially so that the openings 383 and 393 communicate. Moreover, as shown to Fig.7 (a), the 1st coil part 31 and the 2nd coil part 32 are connected in parallel.

  As shown to FIG. 5B, the 1st terminal block 24 and the 2nd terminal block 25 are integrally shape | molded on the upper surface of the X-axis direction both ends of the 1st bobbin 21 (1st end collar part 210). Each terminal block 24, 25 has a side wall portion 241, 251. The side wall portions 241 and 251 are formed so as to surround the peripheral edges of the terminal blocks 24 and 25 except for the sides from which the lead portions 37a and 37b and the terminal portions 381a, 381b, 391a and 391b of the bus bars 38 and 39 are drawn out. . The first terminal block 24 is provided with positioning surfaces 242 which abut the plate-like upper portions 384a and 384b of the bus bar 38 to position them.

  In each positioning surface 242, the first plate-like upper portions 384a and 394a raised in the Z-axis direction and the second plate-like upper lead portions 384b and 394b are guided to the first end side in a state where they are close to each other. In the second terminal block 25, engaging projections 253 are formed on both outer end walls of the side wall 251 in the Y-axis direction. The function of the engagement protrusion 253 will be described later.

  Further, a pair of locking portions 252 is formed on the second terminal block 25. As shown in FIG. 5F, in the pair of locking portions 252, the first lead portions 37a and 37b raised in the Z-axis direction by the lead rising portions 371a and 371b are wound from the inside to the outside in the Y-axis direction. , Is guided outside in the X-axis direction.

  By locking the lead portions 37a and 37b to the pair of locking portions 252, the intermediate coil portion 33 composed of the intermediate wire 37 positioned between the lead portions 37a and 37b shown in FIGS. 6A and 6B is not loosened. It is locked to prevent unwinding. In this state, the lead portions 37a and 37b can be pulled away from the coil 30.

  As shown in FIG. 1B, a leader wire cover 60 is mounted above the terminal block 25 in the Z-axis direction so as to cover it. More specifically, holes 61 are formed on the side surfaces at both ends in the Y-axis direction of the lead-out wire cover 60, and the holes 61 are engaged with the engaging projections 253 formed on the terminal block 25. The lead wire cover 60 can be attached to the terminal block 25. As a result, it is possible to prevent the lead portions 37 a and 37 b from protruding unnecessarily above the terminal block 25.

  As shown in FIG. 2, the magnetic cores 40 a and 40 b have the same shape in the present embodiment, have an E-shaped cross section in the Z-Y cross section, and constitute a so-called E-shaped core. The mode of the magnetic cores 40a and 40b is not limited to the mode shown in FIG. 2, and the magnetic cores 40a and 40b may be parallel to the XZ plane along the dashed dotted line (substantially central position in the Y-axis direction) in the figure. It may be a split core formed by cutting. Alternatively, the magnetic core may be a split core formed by cutting the magnetic cores 40a and 40b in parallel to the YZ plane along a straight line (substantially central position in the X-axis direction) intersecting the dashed dotted line in the drawing.

  The magnetic core 40a disposed on the upper side in the Z-axis direction includes a base portion 44a extending in the Y-axis direction, a pair of side leg portions 48a projecting in the Z-axis direction from both ends in the Y-axis direction of the base portion 44a, Between the side legs 48a and the middle leg 46a protruding in the Z axis direction from the center in the Y axis direction. The magnetic core 40b disposed on the lower side in the Z-axis direction includes a base portion 44b extending in the Y-axis direction, and a pair of side leg portions 48b projecting in the Z-axis direction from both ends in the Y-axis direction of the base portion 44b. Between the side legs 48b, there is a middle leg 46b projecting in the Z-axis direction from the center in the Y-axis direction.

  The middle leg portion 46 a is inserted into the core leg through hole 21 a of the bobbin 20 from the upper side in the Z-axis direction. Similarly, the middle leg portions 46b are inserted into the core leg through holes 21a of the bobbin 20 from the lower side in the Z-axis direction, and the tips of the middle leg portions 46a are formed in the core leg through holes 21a. It is configured to contact the tip.

  The tip of the middle leg 46b may face the tip of the middle leg 46a across the predetermined gap in the core leg through hole 21a. Thus, by forming the gap, it is possible to adjust the leakage characteristics according to the width of the gap.

  The middle leg portion 46a and the middle leg portion 46b have a substantially elliptic cylindrical shape so as to conform to the inner peripheral surface shape of the core leg through hole 21a, but the shapes are not particularly limited, and the core leg You may change according to the shape of the through-hole 21a. The side legs 48a and 48b have an inner concave curved shape that matches the outer peripheral surface of the bobbin main body 21, and the outer surface has a flat surface parallel to the XZ plane. In the present embodiment, the material of each of the cores 40a and 40b may be a soft magnetic material such as metal or ferrite, but is not particularly limited.

  A cover 50 is disposed between the inner peripheral surfaces of the side legs 48a and 48b and the outer peripheral surfaces of the bobbins 20 (the bobbins 21, 22, 23). The cover body 52 of the cover 50 is shaped to cover the outer periphery of the bobbin 20 located between the terminal blocks 24 and 25 of the bobbin 20. At both ends in the Z-axis direction of the cover main body 52, locking pieces 54 bent in a substantially vertical direction from the cover main body 52 toward the bobbin 20 are integrally molded. As shown in FIG. 3, the pair of locking pieces 54 formed on both sides in the Z-axis direction of the cover main body 52 is the upper surface in the Z-axis direction of the first end flange portion 210 of the first bobbin 21 and the second The bobbin is attached so as to sandwich the lower surface in the Z-axis direction of the second end flange portion 220 of the bobbin.

  Further, as shown in FIG. 2, side leg guide pieces 56 extending in the Z-axis direction are integrally formed on both outer surfaces of the cover main body 52 in the X-axis direction. The inner surfaces of the side legs 48a and 48b contact the outer surface of the cover main body 52 located between the pair of side leg guide pieces 56, and movement of the side legs 48a and 48b in the X-axis direction is the pair of side legs It is limited by the guide piece 56. The covers 50 are made of an insulating member such as plastic similar to the bobbin 20 or metal.

  As shown in FIG. 5F, the hook-shaped engaging portion 58 formed on the inner side of the upper locking piece 54 of the cover 50 is a hook-shaped cover engaging portion formed on the upper surface of the first bobbin 21. 211 is detachably fitted.

  As shown in FIG. 5B, the bobbin 20 in the present embodiment is divided into three into a first bobbin 21, an intermediate bobbin 23, and a second bobbin 22. These respective bobbins 21, 22, 23 are integrated. It is configured by combining them.

  Each of these bobbins 21, 22, 23 is made of, for example, a plastic such as PPS, PET, PBT, LCP, nylon or the like, but may be made of other insulating members. However, in the present embodiment, the bobbins 21, 22, and 23 are preferably made of, for example, a plastic having a high thermal conductivity of 1 W / m · K or more, and may be made of, for example, PPS or nylon.

  The intermediate bobbin 23 has an intermediate cylindrical portion 236 around which the intermediate coil portion 33 is wound. At each of the first end (in the embodiment, the upper end in the Z-axis direction) and the second end (the lower end in the Z-axis direction) of the intermediate cylindrical portion 236 in the axial direction, the first intermediate flange portion 231 and the first end A second intermediate collar portion 232 is integrally formed substantially parallel to the XY plane at a predetermined interval in the Z-axis direction so as to extend radially outward.

  In addition, the third intermediate collar portion 233 protrudes radially outward on the outer peripheral surface of the intermediate cylindrical portion 236 located between the first intermediate collar portion 231 and the second intermediate collar portion 232 in the Z-axis direction. It is formed. In the present embodiment, each collar portion 231, 232, 233 is configured such that the thickness in the Z-axis direction of each collar portion 231, 232, 233 is equal. The first coil portion 31 is disposed on the top surface of the first middle collar portion 231.

  As shown in FIG. 5C, due to the third middle collar portion 233 formed between the first middle collar portion 231 and the second middle collar portion 232, as shown in FIG. , Sections S1 and S2 are formed. An intermediate wire 37 is wound around the sections S1 and S2. In addition, the number of middle collar part 233 and division S1 and S2 is not specifically limited.

  As shown in FIG. 4, in the present embodiment, the intermediate wire portion 33 is wound continuously in a plurality of turns such as five turns in the sections S1 and S2 to form an intermediate coil portion 33. In the present embodiment, the third intermediate collar portion 233 serves to divide the intermediate coil portion 33 wound on the first end side and the intermediate coil portion 33 wound on the second end side in the Z-axis direction. .

  As shown in FIG. 5C, the section width T3 along the Z axis in the sections S1 and S2 in which the intermediate wire 37 forming the intermediate coil portion 33 is wound is such that one intermediate wire 37 can enter in the Z axis direction. It is preferable that the width is set. It is because it is easy to wind α. However, the section width T3 may be set to a width in which two or more intermediate wires 37 can enter in the Z-axis direction. Further, in the present embodiment, the section widths T3 in the sections S1 and S2 are preferably all the same, but may be slightly different.

  Further, the radial length H1 of each flange portion 231 to 233 is set to a height at which one or more (one or more layers) of intermediate wires 37 can enter, and in the present embodiment, preferably three to eight layers. The height of the wire can be wound. The lengths H1 of the flanges 231 to 233 are preferably all the same, but may be different.

  In this embodiment, the winding method of the intermediate wire 37 wound in the sections S1 and S2 is α winding, and the intermediate wire is connected to the sections S1 and S2 shown in FIG. 5C from the inter-coil connection portion 372 shown in FIG. 37 are passed through to start winding, and are drawn out to the lead portions 37a and 37b shown in FIG. 5F.

  Here, the alpha winding will be described. For example, to α-wind the intermediate wire 37 on the bobbin 20 shown in FIG. 5A, first, the inter-coil connection portion 372 of the intermediate wire 37 shown in FIG. 6B is inserted for the wire insertion of the third intermediate flange portion 233 shown in FIG. Pass through notch 233b.

  Then, as shown in FIG. 4, the upper half of the intermediate wire 37 in the Z-axis direction is wound around the outer periphery of the intermediate bobbin 23 in a plurality of layers (five layers in the drawing) inside the section S1. At the same time, the lower half of the intermediate wire 37 is wound around the outer periphery of the intermediate bobbin 20 in the direction opposite to the winding direction in the section S1 (or may be the same direction) in the section S2. Note that these operations may be performed using an automatic winding machine.

  As shown in FIG. 5E, on the first end side of the inner peripheral side surface of the intermediate cylindrical portion 236, there is formed a first intermediate cutout 237a cut out toward the second end at a predetermined depth, On the second end side of the inner peripheral side surface of the intermediate cylindrical portion 236, a second intermediate cutout 237b cut to a first end at a predetermined depth is formed. The middle notches 237 a and 237 b are formed along the inner circumferential side surface of the winding cylinder 236.

  As shown in FIG. 5B, in the vicinity of both ends in the X-axis direction of each of the intermediate notches 237a and 237b, the first intermediate convex portion 238a and the first intermediate convex portion 238a and the other in the Z-axis direction depth of the notches. A second intermediate convex portion 238b is formed. In the example shown in FIG. 5B, the circumferential widths of the first intermediate convex portion 238a and the second intermediate convex portion 238b are different from each other, but may be equal.

  As shown in FIG. 5E, the length L1 in the Z-axis direction (the length from the upper surface of the middle positioning portion 239 described later) LC1a of the middle cutout 237a is preferably 1 of the length of the middle cylindrical portion 236 in the Z-axis direction. / 10 to 4/10, more preferably around 1/3. In addition, the length L1 in the Z-axis direction (the length from the lower surface of the second middle collar portion 232) LC1a of the intermediate notch portion 237b is 1/10 to 4/10 of the length in the Z-axis direction of the intermediate cylindrical portion 236. Preferably it is around 1/3.

  An intermediate positioning portion 239 in contact with the inner peripheral side surface of the first coil portion 31 is formed along the outer periphery of the intermediate cylindrical portion 236 at the intersection of the upper surface of the first intermediate collar portion 231 with the intermediate cylindrical portion 236. is there. The intermediate positioning portion 239 has an intermediate stepped portion 239 a which rises substantially perpendicularly to the upper surface of the first intermediate collar portion 231. With such a configuration, when the first coil portion 31 is disposed on the upper surface of the first intermediate collar portion 231, the inner circumferential side surface of the first coil portion 31 has an intermediate stepped portion 239a (and a first step described later) By abutting on the portion 219a), it is possible to prevent the first coil portion 31 from being displaced in the radial direction.

  As shown in FIG. 5B, a first lead locking notch 231a is formed on the second terminal block 25 side (X-axis negative direction side) of the first middle collar portion 231, and the third middle collar portion 233 is formed. A second lead locking notch 233a and a wire insertion notch 233b are formed on the second terminal block 25 side (X-axis negative direction side). Lead standing portions 371a and 371b of the lead portions 37a and 37b shown in FIG. 5F are engaged with the lead locking notches 231a and 233a, respectively, to facilitate formation of the lead standing portions 371a and 371b. The wire insertion notch 233b shown in FIG. 5B is, as shown in FIG. 4, when the intermediate wire 37 is wound (.alpha.-wound) around the outer periphery of the intermediate cylindrical portion 236, the inter-coil connection portion 372 shown in FIG. (The central portion of the intermediate wire 37 located substantially at the center between the lead portions 37a and 37b) is to be inserted.

  As shown in FIG. 5E, the first bobbin 21 has a first cylindrical portion 216 combined with the first end of the intermediate cylindrical portion 236. In the first cylindrical portion 216, the first end flange portion 210 is integrally formed substantially in parallel with the XY plane so as to extend outward in the radial direction. On the second end side of the inner circumferential side surface of the first cylindrical portion 216, a first engagement convex portion 217 that engages with the middle notch portion 237a is formed. The first engagement convex portion 217 is configured by an engagement piece that protrudes to the second end side.

  As shown in FIG. 5B, the first engagement convex portion 217 is formed along the outer periphery of the first cylindrical portion 216. In the vicinity of both ends in the X-axis direction of the first engagement convex portion 217, first concave portions 218 are formed such that the width in the Z-axis direction protruding toward the second end side is smaller than that in other portions. The first concave portion 218 engages with the first intermediate convex portion 238a, and the portion of the first engagement convex portion 217 other than the first concave portion 218 is the portion other than the first intermediate convex portion 238a in the intermediate cutout 237a. Engage in the part. Thus, the first cylindrical portion 216 is combined with the first end of the intermediate cylindrical portion 236, and the first end shown in FIG. 5C is formed between the lower surface of the first end collar portion 210 and the upper surface of the first intermediate collar portion 231. Space A1 which can arrange coil part 31 is formed. In the present embodiment, the distance (shortest distance) between the first coil portion 31 and the intermediate coil portion 33 is equal to the thickness of the first intermediate collar portion 231 that divides these.

  As shown in FIG. 5E, at the intersection of the lower surface of the first end flange portion 210 with the first cylindrical portion 216, the first positioning portion 219 that contacts the inner circumferential side surface of the first coil portion 31 forms the first cylinder. It is formed along the outer periphery of the portion 216. The first positioning portion 219 has a first step portion 219 a that falls substantially perpendicularly to the lower surface of the first end flange portion 210. With such a configuration, when the first coil portion 31 is disposed on the upper surface of the first intermediate collar portion 231, the inner circumferential side surface of the first coil portion 31 is the first step portion 219a (and the above-described intermediate step Since it abuts on the portion 239a), it is possible to prevent the first coil portion 31 from being displaced in the radial direction.

  In the present embodiment, the Z-axis direction length (height from the upper surface of the middle positioning portion 239) LE1 of the first engagement convex portion 217 is smaller than the Z-axis direction length LC1a of the middle cutout portion 237a. Therefore, when the first cylindrical portion 216 is combined with the first end of the intermediate cylindrical portion 236, the lower surface of the first positioning portion 219 abuts on the upper surface of the intermediate positioning portion 239, and the tip of the first engagement convex portion 217 A gap G1 is formed between the surface F1 and the bottom surface F3a of the middle notch portion 237a.

  As a result, the section width T1 along the Z axis in the space A1 is equal to the sum (LP1 + LP3) of the Z axis direction length LP1 of the first step portion 219a and the Z axis direction length LP3 of the intermediate step portion 239a. . In the present embodiment, the sum (LP1 + LP3), that is, the section width T1 along the Z axis in the space A1 is equal to or larger than the thickness TH1 of the first coil portion 31. Therefore, a gap LG10 may be formed between the upper surface of the first coil portion 31 and the lower surface of the first end flange portion 210.

  The length LP1 of the first step portion 219a and the length LP3 of the middle step portion 239a may be adjusted, and the value of the sum (LP1 + LP3) of these may be changed as appropriate. For example, the sum LP1 + LP3 may be equal to or less than the thickness TH1 of the first coil portion 31. In this case, the lower surface of the first end flange portion 210 abuts on the upper surface of the first coil portion 31. That is, the first coil portion 31 is sandwiched between the lower surface of the first end collar portion 210 and the upper surface of the first middle collar portion 231, and the section width T1 becomes equal to the thickness TH1 of the first coil portion 31. In that case, the gap LG10 between the upper surface of the first coil portion 31 and the lower surface of the first end flange portion 210 can be omitted.

  In the present embodiment, the length LE1 of the first engagement convex portion 217, the length LP1 of the first intermediate step portion 219a, the length LP3 of the intermediate step portion 239a, or the length LC1a of the first intermediate notch portion 237a By adjusting, the gap G1 can be formed, and it is possible to appropriately adjust the section width T1 along the Z-axis direction in the space A1.

  In the present embodiment, when the first engagement convex portion 217 engages with the first intermediate cutout 237a, the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the first engagement convex portion 217 face each other. Further, the outer peripheral side surface of the first engagement convex portion 217 abuts on the first end side of the inner peripheral side surface of the intermediate cylindrical portion 236. Therefore, the outer peripheral side surface of the first engagement convex portion 217 functions as a positioning surface, and the intermediate cylindrical portion 236 can be prevented from being displaced in the radial direction. Note that a slight gap may be formed between the inner circumferential side surface of the intermediate cylindrical portion 236 and the outer circumferential side surface of the first engagement convex portion 217 in manufacturing.

  As shown in FIG. 5B, the second bobbin 22 has a second cylindrical portion 226 combined with the second end of the intermediate cylindrical portion 236. The second cylindrical portion 226 is integrally formed substantially parallel to the XY plane so that the second end flange portion 220 extends outward in the radial direction.

  As shown in FIG. 5E, at the intersection of the upper surface of the second end flange portion 220 with the second cylindrical portion 226, the second positioning portion 229 that abuts on the inner circumferential side surface of the second coil portion 32 It is formed along the outer periphery of the portion 226. The second positioning portion 229 has a second step portion 229 a that rises substantially perpendicularly to the upper surface of the second end flange portion 220. In the present embodiment, the height LP2 of the second step portion 229a is equal to or smaller than the thickness TH2 of the second coil portion 32.

  By forming the second positioning portion 229, when the second coil portion 32 is disposed on the upper surface of the second end flange portion 220, the inner peripheral side surface of the second coil portion 32 abuts on the second step portion 229a. The second coil portion 32 can be prevented from being displaced in the radial direction.

  At the first end side of the inner peripheral side surface of the second cylindrical portion 226, an engagement convex portion 227 which engages with the middle cutout portion 237b is formed. The engagement convex part 227 consists of an engagement piece protruded to the 1st end side, and as shown to FIG. 5B, it forms along the outer periphery of the 2nd cylinder part 226. As shown in FIG. Second concave portions 228 are formed in the vicinity of both ends in the X-axis direction of the engagement convex portions 227 so that the width in the Z-axis direction protruding toward the first end side is smaller than that of other portions.

  The second intermediate convex portion 238b is engaged with the second concave portion 228, and the portion other than the second concave portion 228 in the engagement convex portion 227 is a portion other than the second intermediate convex portion 238b in the middle cutout portion 237b. Engage in Thereby, the second end of the intermediate cylindrical portion 236 is combined with the second cylindrical portion 226, and as shown in FIG. 5E, between the upper surface of the second end collar portion 220 and the lower surface of the second intermediate collar portion 232. A space A2 in which the second coil portion 32 can be disposed is formed.

  In the present embodiment, the length (height from the upper surface of the second positioning portion 229) LE2 of the engagement protrusion 227 is the same as or smaller than the length LC1b of the middle cutout 237b. Therefore, when the intermediate cylindrical portion 236 is combined with the second cylindrical portion 226, the lower surface of the second intermediate collar portion 232 abuts on the upper surface of the second positioning portion 229, and the tip surface F2 of the engagement convex portion 227; A gap G2 is formed between the middle notch portion 237b and the bottom surface F3b. As a result, the section width T2 along the Z axis in the space A2 is equal to the length LP2 of the second step 229a.

  In the present embodiment, the second positioning portion 229 is formed such that the length LP2 of the second step portion 229a is equal to or less than the thickness TH2 of the second coil portion 32. Therefore, the lower surface of the second intermediate collar portion 232 also contacts (closely contacts) the upper surface of the second coil portion 32, and the weight of the first coil portion 31 is the second coil portion via the second intermediate collar portion 232. It is transmitted to 32.

  That is, at least at the time of assembly, a force corresponding to the weight of the first coil portion 31 is applied to the second coil portion 32, and the second coil portion 32 is tightly held between the second intermediate collar portion 232 and the second end collar portion 220. . In addition to the weight of the first coil portion 31, the weights of the first bobbin 21, the intermediate bobbin 23, and the intermediate coil portion 33 are also transmitted to the second coil portion 32 through the second middle collar portion 232.

  Thus, in the present embodiment, the distance between the second coil portion 32 and the intermediate coil portion 33 (the shortest distance) is because the lower surface of the second intermediate collar portion 232 and the upper surface of the second coil portion 31 are in close contact. Is equal to the thickness of the second middle collar portion 232 which divides these.

  In the present embodiment, the gap G2 is formed according to the length LE2 of the engagement convex portion 227, the length LP2 of the second intermediate step portion 229a, and the length LC1b of the second intermediate notch portion 237b. The lower surface of the collar portion 232 is in close contact with the upper surface of the second coil portion 32.

  In the present embodiment, when the engagement convex portion 227 engages with the second intermediate cutout 237b, the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the engagement convex portion 227 face each other, and the engagement is performed. The outer peripheral side surface of the convex portion 227 abuts on the second end side of the inner peripheral side surface of the intermediate cylindrical portion 236. Therefore, the outer peripheral side surface of the engagement convex portion 227 functions as a positioning surface, and the intermediate cylindrical portion 236 can be prevented from being displaced in the radial direction. Note that a slight gap may be formed between the inner circumferential side surface of the intermediate cylindrical portion 236 and the outer circumferential side surface of the engagement convex portion 227 in manufacturing.

  As shown in FIG. 5B, bobbin legs 26 are integrally formed on both ends of the second end flange 220 in the X-axis direction. Each bobbin leg 26 is formed so as to protrude downward in the Z-axis direction from both ends in the X-axis direction of the second end flange 220. As shown in FIG. 5C, each bobbin leg 26 accommodates each pedestal 70. In the example shown in FIG. 5C, the height of each pedestal 70 in the Z-axis direction is such that when the pedestals 70 are accommodated in the respective bobbin legs 26, the bottom surface of each pedestal 70 is below the respective bobbin legs 26 in the Z axis. It is set to the height that it protrudes. However, the height in the Z-axis direction of each pedestal 70 is not limited to this, and may be adjusted as appropriate.

  The transformer 10 according to the present embodiment is manufactured by assembling the members shown in FIG. Below, an example of the manufacturing method of the transformer 10 is demonstrated using FIG. 2 etc. FIG. In manufacturing the transformer 10, first, the bobbin 20 is prepared.

  The bobbin 20 in the present embodiment is divided into three into the first bobbin 21, the intermediate bobbin 23, and the second bobbin 22. The bobbin 20 is configured by integrally combining the respective bobbins 21, 22, and 23. . The intermediate wire 37 shown in FIG. 6B is wound around the outer periphery of the intermediate bobbin 23 by α winding to form an intermediate coil portion 33. The intermediate coil portion 33 is preferably formed before assembly of the first bobbin 21, the intermediate bobbin 23 and the second bobbin 22, but may be performed after assembly.

  In addition, as shown to FIG. 5E, when assembling | attaching the 1st coil part 31 and the 2nd coil part 32 to a bobbin, it is preferable to carry out simultaneously with assembly of each bobbin 21,22,23.

  That is, the first coil portion 31 is disposed on the upper surface of the first intermediate collar portion 231 of the intermediate bobbin 23, and the first engagement convex portion 217 of the first cylindrical portion 216 is disposed in the first intermediate cutout 237 a of the intermediate cylindrical portion 236. The first cylindrical portion 216 is assembled to the first end of the intermediate cylindrical portion 216 by engaging.

  At the same time or before and after that, the second coil portion 32 is disposed on the upper surface of the second end flange portion 220 of the second bobbin 22, and the second engagement convex portion 227 of the second cylindrical portion 226 The second end of the intermediate cylindrical portion 236 is combined with the second cylindrical portion 226 by engaging the second intermediate cutout 237b.

  As described above, the first bobbin 21, the second bobbin 22 and the intermediate bobbin 23 are integrally combined to constitute the bobbin 20, and the bobbins 21, 22, 23 are fixed with an adhesive or the like.

  Next, the lead portions 37a and 37b are pulled out from the intermediate coil portion 33 shown in FIG. 6B above the winding axis, and as shown in FIG. 5F, the respective lead portions 37a and 37b are locked to the first locking portion 252. , Pull out in the direction away from the bobbin 20.

  Moreover, as shown to FIG. 6B, plate-shaped standing-up part 384a, 384b and terminal part 381a, 381b are formed in the bus-bar 38 which comprises the 1st coil part 31. As shown in FIG. Further, the plate-like upper portions 394 a and 394 b and the terminal portions 391 a and 391 b are formed on the bus bar 39 constituting the second coil portion 32. The heights of the plate-like rising portions 384a, 384b, 394a, 394b in the Z-axis direction are adjusted so that the terminal portions 381a, 381b and the terminal portions 391a, 391b overlap and are connected in the Z-axis direction.

  The plate-like upper portions 384a, 384b, 394a and 394b and the terminal portions 381a, 381b, 391a and 391b are preferably formed in advance in the bus bars 38 and 39, respectively. In that case, as shown in FIG. 5D, the intermediate wire 37 is wound around the intermediate bobbin 23 before the first bobbin 21, the second bobbin 22 and the intermediate bobbin 23 are integrally combined with the bus bars 38 and 39. It is preferable to keep the After the first bobbin 21, the second bobbin 22 and the intermediate bobbin 23 are integrally combined with the bus bars 38 and 39, the winding of the intermediate wire 37 is difficult due to the plate-like rising portions 394a and 394b.

  As shown in FIG. 2, after forming the bobbin 20, the covers 50 are attached to both sides in the Y-axis direction of the bobbin 20, and thereafter, the magnetic cores 40a and 40b are attached from the vertical direction of the Z-axis direction. That is, the tips of the middle legs 46a and 46b of the magnetic cores 40a and 40b and the tips of the side legs 48a and 48b are joined.

  Next, the pedestal 70 shown in FIG. 5D is accommodated inside the bobbin leg 26. A pedestal 70 may be attached to the bobbin leg 26 in advance. Thereafter, the bottom plate 91 shown in FIG. 2 is adhered to the bottom opening of the case 90, and the above assembly is housed in the case 90 whose top is open, and the inside of the case 90 is filled with a heat dissipation resin. The transformer 10 according to the present embodiment can be manufactured by the processes as described above.

  As shown to FIG. 5B, the bobbin 20 in this embodiment is comprised by combining the 1st bobbin 21, the intermediate bobbin 23, and the 2nd bobbin 22 integrally. In addition, instead of accommodating the intermediate bobbin 23 inside the second bobbin 22, the second cylindrical portion 226 is combined with the second end (lower end in the Z-axis direction) of the intermediate cylindrical portion 236. As a result, as shown in FIG. 5E, the second intermediate collar portion 232 is in close contact with the opposite surface of the second coil portion 32 in close contact with the second end collar portion 220.

  As shown in FIG. 4, since the intermediate coil portion 33 is wound around the intermediate bobbin 23 so as to contact the second intermediate collar portion 232, the intermediate coil portion 33 wound around the intermediate bobbin 23, and The second coil portion 32 disposed on the second bobbin 22 is spaced apart by a distance corresponding to the thickness of the second intermediate collar portion 232. The thickness of the second intermediate collar portion 232 can be relatively accurately controlled and molded when molding the intermediate bobbin 23.

  Further, if the second bobbin 22 is disposed on the lower side in the gravity direction (Z-axis direction), and the intermediate bobbin 23 and the first bobbin 21 are combined thereon, the upper surface of the first intermediate flange portion 231 is obtained. The lower surface of the first coil portion 31 is in close contact with the upper surface of the first intermediate collar portion 231 due to the gravity of the first coil portion 31. In addition, the intermediate coil portion 33 is wound around the intermediate bobbin 23 so as to abut (preferably adhere to) the lower surface of the first intermediate collar portion 231.

  Therefore, the intermediate coil portion 33 wound around the intermediate bobbin 23 and the first coil portion 31 disposed on the first bobbin 21 are separated by a distance corresponding to the thickness of the first intermediate collar portion 231. be able to. The thickness of the first intermediate collar portion 231 can be relatively accurately controlled and molded when molding the intermediate bobbin 23.

  After combining the first bobbin 21, the intermediate bobbin 23 and the second bobbin 22 in this manner, the first coil portion 31 and the intermediate coil portion 33 may be fixed, for example, by fixing means such as an adhesive. The distance in the winding axis direction between the second coil portion 32 and the second coil portion 32 is maintained constant, corresponding to the thickness of each of the flange portions 231, 232. Therefore, it is easy to enhance the coupling between the coil portions 31, 33 and 32, and it is possible to realize the transformer 10 which is a coil device having a stable leakage characteristic.

  Further, in the present embodiment, since it is not necessary to perform insert molding or the like, the height in the winding axis direction of the bobbin 20 can be reduced. Furthermore, since the second cylindrical portion 226 is combined with the second end (lower end in the Z-axis direction) of the intermediate cylindrical portion 236 instead of accommodating the intermediate bobbin 23 inside the second bobbin 22, The radial size of the two bobbins 22 can be reduced. The same applies to the first bobbin 21 as to the second bobbin 22.

  Furthermore, in the present embodiment, as shown in FIG. 4, since the first coil portion 31 and the second coil portion 32 are configured by the bus bars 38 and 39 that are plate-like conductors, the first coil portion A large current can be supplied to the coil 31 and the second coil 32.

  Further, in the present embodiment, as shown in FIG. 5E, the second coil portion 32 is formed at the intersection of the inner surface (upper surface in the Z-axis direction) of the second end flange portion 220 and the outer peripheral surface of the second cylindrical portion 226. A second positioning portion 229 is formed in contact with the inner peripheral side surface of the second. With such a configuration, the inner peripheral side surface of the second coil portion 32 abuts on the positioning portion 229, and it is possible to prevent the second coil portion 32 from being displaced in the radial direction.

  Moreover, the positioning portion 229 is formed on the outer peripheral side surface of the stepped portion 229a, and the second intermediate flange portion 232 abuts on the stepped surface (upper surface in the Z-axis direction) of the stepped portion 229a. The length LP2 in the Z-axis direction of the stepped portion 229a is equal to or less than the thickness TH2 of the second coil portion 32. With such a configuration, the second intermediate collar portion 232 is in close contact with the surface of the bus bar 39 constituting the second coil portion 32.

  On the second end (lower end in the Z-axis direction) side of the inner peripheral side surface of the intermediate cylindrical portion 236, a second intermediate cutout 237b cut out at a predetermined depth is formed. At the first end (upper end in the Z-axis direction), a second engagement convex portion 227 engaged with the second intermediate cutout 237b is formed, and the tip of the second engagement convex portion 227 in the Z-axis direction is formed. The engagement convex portion 227 engages with the middle notch portion 237b such that a gap G2 is formed between the face F2 and the bottom surface F3b of the second middle notch portion 237b. With such a configuration, the lower surface of the second intermediate collar portion 232 is in close contact with the upper surface of the bus bar 39 of the second coil portion 32.

  Furthermore, the engagement convex portion 227 engages with the middle notch portion 237b such that the inner peripheral side surface of the intermediate cylindrical portion 236 and the outer peripheral side surface of the engagement convex portion 227 face each other. With such a configuration, the outer peripheral side surface of the engagement convex portion 227 functions as a positioning surface, and the intermediate cylindrical portion 236 can be prevented from being displaced in the radial direction.

  The present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention.

  For example, as shown in FIG. 6C, the second terminal portion 381b of the bus bar 38 may be connected to the first terminal portion 391a of the bus bar 39, and the bus bars 38 and 39 may be connected in series in a predetermined winding direction. In this case, as shown in FIG. 7B, the first coil portion 31 and the second coil portion 32 respectively configured by the bus bars 38 and 39 on the secondary side are connected in series.

  Moreover, in FIG. 5E, the formation of the second positioning portion 229 may be omitted. In addition, either one of the first positioning portion 219 and the middle positioning portion 239 may be omitted. In that case, for example, the function of the intermediate positioning portion 239 can be complemented by setting the length in the Z-axis direction of the first step portion 219a of the first positioning portion 219 to LP1 + LP3. Alternatively, the length of the middle step portion 239a of the middle positioning portion 239 in the Z-axis direction may be LP1 + LP3, in which case the function of the first positioning portion 219 can be substantially complemented.

  Further, the relationship between the primary coil and the secondary coil described above may be reversed. That is, the bus bars 38 and 39 may constitute a primary coil, and the intermediate wire 37 may constitute a secondary coil.

DESCRIPTION OF SYMBOLS 10 ... Transformer 20 ... Bobbin 21 ... 1st bobbin 210 ... 1st end collar part 211 ... Cover engaging part 216 ... 1st cylinder part 217 ... 1st engagement convex part 218 ... 1st engagement concave part 219 ... 1st Positioning portion 219a First step portion 22 Second bobbin 220 Second end flange portion 226 Second cylindrical portion 227 Second engagement convex portion 228 Second engagement concave portion 229 Second positioning portion 229a Second stepped portion 23: Intermediate bobbin 231: First intermediate flange portion 231a: Notch for first lead engagement 232: Second intermediate ridge portion 233: Third intermediate flange portion 233a: Notch for second lead engagement 233b: Wire Insertion notch 236: Intermediate cylindrical portion 237a: First intermediate cutout portion 238a: First intermediate convex portion 237b: Second intermediate cutout portion 238b: Second intermediate convex portion 239: Intermediate positioning portion 239a: Intermediate stepped portion 24 First terminal block 241: first side wall portion 242: positioning surface 25: second terminal block 251: second side wall portion 252: locking portion 253: engagement projection portion 26: bobbin leg 30: coil portion 31: first coil portion 32 ... Second coil portion 33: Intermediate coil portion 37: Intermediate wire 37a, 37b: Lead portion 371a, 371b: Lead upstanding portion 372: Inter-coil connection portion 38, 39: Bus bar 381a, 381b, 391a, 391b: Terminal portion 383, 393 ... Openings 384a, 384b, 394a, 394b ... Plate shaped uprights 40a, 40b ... Magnetic cores 44a, 44b ... Bases 46a, 46b ... Middle legs 48a, 48b ... Side legs 50 ... Cover 52 ... Cover body 54 ... Locking piece 56 ... Side leg guide piece 58 ... Engagement part 60 ... Draw-out wire cover 61 ... Engagement part 70 ... Base 80 ... Terminal 90 ... K Scan 91 ... bottom plate 92 ... boss 100 ... heat radiating resin

Claims (8)

With a bobbin,
A first coil portion made of a plate-like conductor;
Yes apart position from the first coil portion, Ri Do a plate-like conductor, and a second coil portion which is configured separately from the first coil portion,
A coil device having an intermediate coil portion located between the first coil portion and the second coil portion, the coil device comprising:
The bobbin is
An intermediate cylinder portion having the intermediate coil portion wound thereon, wherein an intermediate first end portion and a second intermediate end portion are formed on each of the first end and the second end in the axial direction of the intermediate end portion. With a bobbin,
A first bobbin having a first tubular portion combined with the first end, and a first end flange portion being formed on the first tubular portion;
And a second bobbin having a second cylindrical portion combined with the second end, and a second end collar portion formed on the second cylindrical portion,
The intermediate coil portion is wound around the intermediate cylindrical portion so as to contact the first intermediate collar portion and the second intermediate collar portion,
The first tubular portion is combined with the first end of the intermediate tubular portion so that the first coil portion abuts on the first intermediate flange portion by the weight of the first coil portion,
The second end of the intermediate tubular portion is configured such that the second intermediate flange portion abuts on the opposite surface of the second coil portion that abuts the second end flange portion by the weight of the second coil portion. A coil device in which the second cylindrical portion is combined. The second coil portion has a substantially ring plate shape,
The coil according to claim 1, wherein a positioning portion that contacts the inner peripheral side surface of the second coil portion is formed at the intersection of the inner surface of the second end collar portion and the outer peripheral surface of the second cylindrical portion. apparatus. The positioning portion is formed on the outer peripheral side surface of the stepped portion,
The second intermediate collar portion abuts on the stepped surface of the stepped portion,
The coil device according to claim 2, wherein the axial length of the stepped portion is equal to or less than the thickness of the second coil portion. On the second end side of the inner peripheral side surface of the intermediate cylindrical portion, an intermediate cutout portion cut out at a predetermined depth is formed,
At the first end side of the second cylindrical portion, an engagement convex portion that engages with the intermediate cutout portion is formed,
The said engagement convex part is engaged with the said intermediate notch so that a clearance gap may be formed between the front end surface of the said engagement convex part, and the bottom face of the said intermediate notch. Coil device as described.   The coil device according to claim 4, wherein the engagement convex portion engages with the intermediate notch so that an inner peripheral side surface of the intermediate cylindrical portion and an outer peripheral side surface of the engagement convex portion face each other.   The first cylindrical portion is combined with the first end of the intermediate cylindrical portion so that a space in which the first coil portion can be disposed is formed between the first end collar portion and the first intermediate collar portion. The coil device according to any one of claims 1 to 5.   The first cylindrical portion is combined with the first end of the intermediate cylindrical portion such that the first end collar portion abuts on the opposite surface of the first coil portion abutting on the first intermediate collar portion. The coil device according to 6.   The first coil portion and the second coil portion constitute either one of a primary coil or a secondary coil, and the intermediate coil portion constitutes either the other of the primary coil or the secondary coil. The coil device according to any one of claims 1 to 7, characterized in that:

Images