JP7470239B2 - Coil device - Google Patents

Description

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

For example, the coil device shown in Patent Document 1 is known as a coil device used in transformers and the like. The coil device shown in Patent Document 1 has a case for housing a core and a coil wound around the core (middle leg), and the inside of the case is filled with a heat dissipating resin. It is possible to dissipate heat generated by the core and coil via this heat dissipating resin.

However, when a large terminal block is provided above the case, as in the coil device shown in Patent Document 1, it is inappropriate to use a tall case, and most of the core, coil, etc. housed inside the case may be exposed to the outside of the case. In this case, the upper part of the core, which is prone to high temperatures, and the coil, which generates a large amount of heat, cannot be sufficiently immersed in the heat dissipation resin, making it impossible to obtain high heat dissipation performance.

JP 2014-036194 A

The present invention was made in consideration of these circumstances, and its purpose is to provide a coil device with excellent heat dissipation properties.

In order to achieve the above object, a coil device according to the present invention comprises:
A bobbin on which the coil is attached;
a terminal to which a lead portion of the coil is connected;
and a case in which the bobbin is housed.
The terminal has a case side piece that straddles the upper opening edge of the case, and a downward extension piece that is connected to the case side piece and extends downward from the case side piece on the outside of the case.

In the coil device according to the present invention, the terminal has a side piece of the case that straddles the upper opening edge of the case, and a downward extension piece that is connected to the side piece of the case and extends downward from the side piece of the case around the outside of the case. Therefore, the terminal extends to the side of the case (in the direction along which the side piece of the case extends) rather than above the case, and there is no need to provide a terminal block above the case to fix the terminal. Therefore, it is possible to use a tall case and house most of the coil, etc. inside the case, and by filling the case with heat dissipation resin, most of the coil, etc. can be immersed in the heat dissipation resin, and the heat generated by the coil, etc. can be sufficiently dissipated through the heat dissipation resin.

In addition, as described above, the coil device according to the present invention does not require a terminal block above the case, so the height of the coil device can be reduced, allowing the coil device to be made low-profile.

In addition, in the coil device according to the present invention, since the terminals are provided with downward extension pieces, it is not necessary to draw the terminals outwardly and downwardly of the case, for example by providing a notch or the like below the case. Therefore, when the case is filled with heat dissipation resin, the heat dissipation resin does not leak out from the notch or the like, and a sufficient amount of heat dissipation resin can be filled into the case, allowing the heat generated by the coil, etc. to be efficiently dissipated through the heat dissipation resin.

Preferably, the terminal has an outward protruding piece that is connected to the downward extending piece and extends away from the case. With this configuration, the outward protruding piece can be used as a user terminal.

Preferably, the terminal further has an insulating protection part, at least a part of which is interposed between the terminal and the case and insulates the terminal from the case. With this configuration, the terminal can be pulled out to the side of the case while preventing short circuits between the terminal and the case through the insulating protection part.

Preferably, the insulating protection part has a case crossing part that straddles the upper opening edge of the case, and an outer extension part that is connected to the case crossing part and extends along the outer wall surface of the case. With this configuration, the terminal can be insulated from the upper opening edge of the case via the case crossing part, and the terminal can be insulated from the outer wall surface of the case via the outer extension part.

The coil device may further include a terminal block to which the terminal is fixed, and the insulating protection part may be formed integrally with the terminal block. With this configuration, it is possible to omit the process of separately attaching the insulating protection part to the case during the manufacturing process of the coil device, making it easier to manufacture the coil device.

Preferably, the insulating protection part is formed integrally with the terminal. For example, by integrally molding the terminal with the insulating protection part by insert molding or the like, the coil device can be easily manufactured.

The terminal may further include a terminal block to which the terminal is fixed, and the insulating protection part may be formed separately from the terminal block. With this configuration, it is possible to simplify the configuration of the terminal block or the insulating protection part, and the terminal block or the insulating protection part can be easily formed.

Preferably, the terminal block is formed separately from the bobbin. With this configuration, if there is a change in the specifications of the terminal block, a terminal block corresponding to the change in specifications can be prepared and attached to the bobbin, allowing for flexible response to changes in specifications.

FIG. 1A is a perspective view of a coil device according to a first embodiment of the present invention. FIG. 1B is a perspective view of a coil device according to a second embodiment of the present invention. FIG. 2A is an exploded perspective view of the coil device shown in FIG. FIG. 2B is an exploded perspective view of the coil device shown in FIG. 2A with the members attached to the bobbin removed. FIG. 2C is an exploded perspective view of the coil device shown in FIG. 2B with the members attached to the bobbin removed. FIG. 2D is a perspective view showing the lead portion of the outer coil shown in FIG. 2B and its surrounding structure. FIG. 2E is an exploded perspective view of the coil device shown in FIG. 2A with a lead drawing block attached to the bobbin removed. FIG. 3 is a cross-sectional view of the coil device taken along line III-III shown in FIG. 1A. FIG. 4A is a perspective view showing the lead portion of the outer coil and its surrounding structure in the coil device shown in FIG. 1A. FIG. 4B is a perspective view showing the lead portion of the outer coil and its surrounding structure in the coil device shown in FIG. 1B. FIG. 5A is a perspective view showing the insulating protection portion shown in FIG. 1A. FIG. 5B is a perspective view showing the insulating protection portion shown in FIG. 1B.

The present invention will now be described with reference to the embodiments shown in the drawings.

2A and 2C, a coil device 10 according to a first embodiment of the present invention shown in Fig. 1A has four cores 12, a bobbin 40, a bobbin cover 50, two core covers 60, a lead pull-out cover 70, a heat dissipation plate 80, an insulating protection section 100, an insulating plate 200, and a case 300. In this embodiment, the X-axis, Y-axis, and Z-axis are mutually perpendicular in the figure, the Z-axis is the direction perpendicular to the mounting surface of the coil device 10, and the X-axis is the direction in which a pair of lead pull-out sections 49 formed on the bobbin 40 are located on opposite sides to each other.

The case 300 has an outer surface 310, an inner surface 320, an upper opening edge 330, a bottom plate 340, and recessed corners 350. The recessed corners 350 are formed at the four corners of the case 300 and are recessed toward the inside of the case 300. Examples of materials that make up the case 300 include metals with good thermal conductivity such as aluminum, copper, and stainless steel.

The bobbin 40 and other components are housed inside the case 300, which is filled with a heat dissipation resin (not shown). As shown in FIG. 1A, in this embodiment, the height of the case 300 in the Z-axis direction is such that most of the bobbin 40, core 12, and other components fit inside the case 300. Of the various components that make up the case 300, the bottom plate 340 is configured as a separate body from these various components.

As shown in Figures 2A to 2C, the four cores 12 are assembled to form a magnetic path through which the magnetic flux generated by the coil described below passes. These cores 12 have a symmetrical shape and are connected to each other so as to sandwich the bobbin cover 50 and the bobbin 40 from above and below (the Z-axis direction in the figures).

Each core 12 has a generally E-shaped longitudinal section (a cut surface including the Y-axis and Z-axis). Each core 12 is made of a soft magnetic material such as ferrite or a magnetic metal, and has a flat base 13 extending in the Y-axis direction, a pair of side legs 16, 16 protruding in the Z-axis direction from both ends of each base 13 in the Y-axis direction, and a center leg 14 protruding in the Z-axis direction from the middle of each base 13 in the Y-axis direction.

In this embodiment, the middle leg 14 of each core 12 fits into the first through hole 44a formed in the first hollow cylinder 44 of the bobbin 40. A separation protrusion 44b formed on the inner peripheral wall of the first hollow cylinder 44 creates a gap between adjacent cores 12, 12 in the X-axis direction. A heat dissipating resin such as a potting resin (described later) fills this gap, improving the dissipation of heat generated inside the coil device 10.

The gap formed by the separating protrusion 44b corresponds to the thickness of the separating protrusion 44b in the X-axis direction. The separating protrusion 44b is formed inside the through hole 44a, at the center in the X-axis direction, on both sides in the Y-axis direction, along the Z-axis. The thickness of the separating protrusion 44b in the X-axis direction is not particularly limited, but is preferably 0.05 to 5 mm, and more preferably 0.1 to 3 mm.

The bobbin 40 has a substantially elliptical, flat bobbin base plate 42 at its lower end in the Z-axis direction. Legs 42a are formed at each end of the bobbin base plate 42 in the X-axis direction, and a first hollow cylinder portion 44 is integrally formed at approximately the center of the bobbin base plate 42 so as to extend upward in the Z-axis direction.

A bobbin upper flange 48 is integrally formed at the top of the first hollow cylinder 44 in the Z-axis direction so as to protrude radially from the first hollow cylinder 44 in the Y-axis-X-axis plane. Lead pull-out portions 49 are provided at both ends of the bobbin upper flange 48 in the X-axis direction.

As shown in FIG. 2E, the lead pull-out section 49 is composed of a lead pull-out block (terminal block) 490 and a lead pull-out block 491, and the lead pull-out block 490 is provided with terminals 91 and 92. The terminals 91 and 92 are embedded and fixed (integrated) into the lead pull-out block 490 by insert molding or the like.

As shown in Figures 4A and 5A, the terminals 91, 92 have lead connection pieces 91a, 92a. The lead connection pieces 91a, 92a are connected to the lead portions 22a, 22a of the inner coil 20 (first wire 22) or the lead portions 32a, 32a of the outer coil 30 (second wire 32) shown in Figure 2C. The lead connection pieces 91a, 92a are roughly C-shaped and, as shown in Figure 2E, clamp the lead portions 22a, 22a or the lead portions 32a, 32a drawn outward in the Y-axis direction.

As shown in Figures 4A and 5A, the lateral extension pieces 91b, 92b are integrally connected to the ends of the lead connection pieces 91a, 92a in the X-axis direction. When viewed from the lead connection pieces 91a, 92a, the lateral extension pieces 91b, 92b extend outward in the Y-axis direction (away from the bobbin 40), and the extension direction is approximately the same as the extension direction of the lead portions 22a, 22a or the lead portions 32a, 32a, as shown in Figure 2E.

As shown in Figures 4A and 5A, the upper extension pieces 91c, 92c are integrally connected to the inner ends of the lateral extension pieces 91b, 92b in the Y-axis direction (opposite the side where the lead connection pieces 91a, 92a are arranged). The upper extension pieces 91c, 92c extend upward in the Z-axis direction and extend above the upper opening edge 330 of the case 320 shown in Figure 2A. In other words, a portion of the upper extension pieces 91c, 92c extends above the upper opening edge 330, and the upper extension pieces 91c, 92c extend across the upper and lower edges of the upper opening edge 330 of the case 300 along the Z-axis direction.

The case side pieces 91d, 92d are integrally connected to the upper ends of the upper extension pieces 91c, 92c in the Z-axis direction. The case side pieces 91d, 92d extend toward the center of the bobbin 40 along the X-axis direction. A step is formed between the case side pieces 91d, 92d and the side extension pieces 91b, 92b according to the height of the upper extension pieces 91c, 92c. As shown in FIG. 3, the case side pieces 91d, 92d extend along the Y-axis direction, straddling the inside and outside of the case 300, and extend above the upper opening edge 330 of the case 300 from the outside (inside) to the inside (outside) while straddling (crossing or climbing over) the upper opening edge 330. The case side pieces 91d, 92d have a flat plate shape parallel to the X-Y plane, but may have a bent structure, for example.

As shown in Figures 4A and 5A, the outer ends of the case horizontal pieces 91d, 92d in the X-axis direction are integrally connected to downward extension pieces 91e, 92e. The downward extension pieces 91e, 92e have a flat plate shape parallel to the YZ plane and extend downward in the Z-axis direction. The downward extension pieces 91e, 92e have a shape longer in the Z-axis direction than the upper extension pieces 91c, 92c,
As shown in FIG. 3, the outer side of the case 300 extends downward from the case side pieces 91d and 92d.

The downward extension pieces 91e, 92e extend along the outer surface 310 of the case 300 shown in FIG. 2A, and extend above and below the upper opening edge 330 of the case 300 along the Z-axis direction.

As shown in Figures 4A and 5B, the outward protruding pieces 91f, 92f are integrally connected to the lower ends of the downward extending pieces 91e, 92e in the Z-axis direction, on the inside in the Y-axis direction. The outward protruding pieces 91f, 92f have a flat plate shape parallel to the X-Z plane and extend toward the X-axis direction. As shown in Figure 3, the outward protruding pieces 91f, 92f extend in a direction away from the outer surface 310 of the case 300. The height of the outward protruding pieces 91f, 92f relative to the bottom plate 340 of the case 300 is determined according to the length of the downward extending pieces 91e, 92e in the Z-axis direction, but this height is not limited to the example shown in the figure and may be further lower.

As shown in FIG. 2E, the lead pull-out base 491 is formed integrally with the bobbin 40 and is disposed at each end of the bobbin upper flange 48 of the bobbin 40 in the X-axis direction. An insulating wall 491e is formed between the lead pull-out base 491 and the bobbin upper flange 48. The insulating wall 491e has a flat plate shape parallel to the YZ plane and abuts against the insulating plate portion 66 of the core cover 60. The position of the upper end of the insulating wall 491e is approximately the same as the position of the upper end of the insulating plate portion 66. The insulating wall 491e is provided to insulate the core 12 and the lead portion 32a of the outer coil 30 when the core 12 shown in FIG. 2A is attached to the bobbin 40.

The insulating wall 491e is formed with a fixing recess 491f that is recessed toward the center of the bobbin 40. The fixing recess 491f is disposed between each of a pair of insulating plate portions 66 of the core cover 60, and the fixing recess 491f and the insulating plate portions 66 are disposed so as to be substantially flush with each other.

A pedestal center portion 491a and two pedestal side portions 491b, 491b are formed at each end of the bobbin upper flange portion 48 in the X-axis direction. The pedestal center portion 491a and the pedestal side portions 491b have a shape that extends the bobbin upper flange portion 48 outward in the X-axis direction, and have a generally flat plate shape parallel to the XY plane. The pedestal center portion 491a is disposed between each of the two pedestal side portions 491b, 491b.

A pedestal pull-out groove 491c is formed between one of the pedestal side parts 491b and the pedestal central part 491a. Similarly, a pedestal pull-out groove 491c is formed between the other pedestal side part 491b and the pedestal central part 491a. The lead part 32a of the outer coil 30 can be inserted into the pedestal pull-out groove 491c. The pedestal pull-out groove 491c extends along the X-axis direction.

A side thin plate portion 491d is formed at the outer end of the base side portion 491b in the Y-axis direction. The side thin plate portion 491d extends along the X-axis direction, and the thickness of the side thin plate portion 491d is thinner than the thickness of the base side portion 491b. The side thin plate portion 491d engages with a recessed groove 490i of the lead pull-out block 490, which will be described later.

The lead pull-out block 490 functions as a terminal block for fixing the terminals 91 and 92, and is formed separately from the bobbin 40 (lead pull-out block 491). Examples of materials that make up the lead pull-out block 490 include resin materials such as PET, PBK, or PPS.

As shown in FIG. 5A, the lead extraction block 490 has a base 490a.
An engaging protrusion 490g is formed at approximately the center of the seat 490a in the Y-axis direction. The engaging protrusion 490g protrudes from the inner end of the seat 490a in the X-axis direction toward the center of the bobbin 40.

Two front wall portions 490b, 490b are formed on the inner end surface of the base 490a in the X-axis direction, sandwiching the engagement protrusion 490g between them. One front wall portion 490b is disposed on one side of the base 490a in the Y-axis direction, and the other front wall portion 490b is disposed on the other side of the base 490a in the Y-axis direction. The front wall portion 490b has a wall surface parallel to the Y-Z plane, and as shown in FIG. 2E, the front surface of the front wall portion 490b abuts against the insulating wall 491e.

A fixing protrusion 490h is formed on the inner end surface of the front wall portion 490b. The fixing protrusion 490h is located on the side of the inner end surface of the front wall portion 490b where the engagement protrusion 490g is located. The inner end surface of each fixing protrusion 490h formed on each front wall portion 490b abuts each end of the fixing recess 491f formed on the insulating wall 491e of the lead drawer table 491 in the Y-axis direction. This makes it possible to prevent the lead drawer block 490 from being misaligned in the Y-axis direction relative to the lead drawer table 491 when the lead drawer block 490 is attached to the lead drawer table 491.

A vertical pull-out groove 490e is formed between the engagement protrusion 490g and one of the front wall portions 490b. Similarly, a vertical pull-out groove 490e is formed between the engagement protrusion 490g and the other of the front wall portions 490b. The vertical pull-out groove 490e extends in the Z-axis direction, and the lead portion 32a of the outer coil 30 can be inserted along the vertical pull-out groove 490e. The lead portion 32a is pulled out upward in the Z-axis direction through the inside of the vertical pull-out groove 490e. In other words, the vertical pull-out groove 490e serves as a guide groove that guides the lead portion 32a upward in the Z-axis direction.

At the rear end of the base 490a in the X-axis direction, a rear wall portion 490c is formed, which extends from one side to the other side in the Y-axis direction. As shown in FIG. 5A, two terminal holes 490j are formed in the rear wall portion 490c at a predetermined interval in the Y-axis direction. Case side pieces 91d, 92d of terminals 91, 92 are pulled out through each terminal hole 490j.

A horizontal pull-out groove 490f is formed between the rear wall portion 490c and the front wall portion 490b. The horizontal pull-out groove 490f extends outward in the Y-axis direction, and the lead portion 32a of the outer coil 30 can be inserted along the horizontal pull-out groove 490f. More specifically, the lead portion 32a pulled out toward the upper side in the Z-axis direction along the vertical pull-out groove 490e bends toward the Y-axis direction and is pulled outward in the Y-axis direction along the horizontal pull-out groove 490f. That is, the horizontal pull-out groove 490f serves as a guide groove that guides the lead portion 32a outward in the Y-axis direction.

A side wall portion 490d is formed at each end of the base 490a in the Y-axis direction. The side wall portion 490d has a wall surface parallel to the X-Z plane and extends downward in the Z-axis direction. The aforementioned terminal hole 490j is connected to the side wall portion 490d, and the lateral extension pieces 91b, 92b of the terminals 91, 92 are pulled out through this terminal hole 490j.

A groove 490i is formed in the side wall portion 490d. The groove 490i is formed on the inside of the side wall portion 490d in the Y-axis direction and extends along the X-axis direction. A side thin plate portion 491d (see FIG. 2E) of the lead pull-out base 491 is inserted into the groove 490i while sliding, and the groove 490i and the side thin plate portion 491d engage with each other. This allows the lead pull-out base 491 to engage with the lead pull-out block 490, making it possible to fix the lead pull-out block 490 to the lead pull-out base 491. The side wall portion 490d is formed in the case 300.
Alternatively, the lead block 490 may be formed so as to extend below the upper surface of the highly thermally conductive resin (the portion indicated by the two-dot chain line in FIG. 3) that fills the interior of the case 300. In that case, the lead block 490 comes into contact with the highly thermally conductive resin that fills the interior of the case 300, enabling heat dissipation.

The insulating protection part 100 has an inner extension part 110, a case crossing part 120, and an outer extension part 130. The insulating protection part 100 is interposed between the terminals 91, 92 and the case 300, and insulates the terminals 91, 92 from the case 300 (see FIG. 3). In this embodiment, the insulating protection part 100 is formed separately from the lead pull-out block 490, and is held in a freely detachable manner relative to the case 300.

The insulating protection part 100 is made of an insulating material. Examples of materials that can be used to make up the insulating protection part 100 include polyimide resins, silicone resins, epoxy resins, acrylic resins, polyether ether ketone resins, polyether sulfone resins, polyacetal resins, and aromatic polyamide resins. In addition, resins that are heat resistant or elastic in addition to insulating properties may also be used.

The insulating protection part 100 has a thin plate (flat plate) shape and is approximately C-shaped. As shown in FIG. 1A, the insulating protection part 100 is attached to the case 300 so as to straddle the outer surface 310, the inner surface 320, and the upper opening edge 330 of the case 300. The thickness of the insulating protection part 100 is preferably 0.5 to 1.0 mm. However, the thickness of the insulating protection part 100 is not limited to the above thickness, and can be appropriately determined within a range that can effectively ensure insulation between the terminals 91, 92 arranged on the front surface and the case 300 arranged on the back surface. The width of the insulating protection part 100 in the Y-axis direction is greater than the distance between the terminals 91, 92 in the Y-axis direction.

As shown in Figures 3 and 5A, the inner extension portion 110 has a flat plate shape parallel to the YZ plane and extends along the inner side surface 320 of the case 300. The inner extension portion 110 abuts against the inner side surface 320 of the case 300. The length of the inner extension portion 110 in the Z-axis direction is appropriately determined within a range that allows the insulating protection portion 100 to be securely held (hooked) on the upper opening edge 330 of the case 300. The inner extension portion 110 is preferably formed so as to extend below the upper surface of the highly thermally conductive resin filled inside the case 300 (the portion indicated by the two-dot chain line in Figure 3).

The case crossing portion 120 is integrally connected to the upper end of the inner extension portion 110 in the Z-axis direction. The case crossing portion 120 extends along the X-axis direction in a direction away from the bobbin 40 (to the outside of the bobbin 40). The case crossing portion 120 extends along the X-axis direction so as to straddle the inside and outside of the case 300, and extends from the inside to the outside of the case 300 along the upper surface of the upper opening edge 330 while straddling (crossing or climbing over) the upper opening edge 330 of the case 300.

The case crossing portion 120 has a flat plate shape parallel to the XY plane and abuts against the upper opening edge 330 of the case 300. The case crossing portion 120 faces the case crossing pieces 91d, 92d of the terminals 91, 92. The length of the case crossing portion 120 in the X-axis direction is approximately equal to the length of the upper opening edge 330 of the case 300 in the X-axis direction. In the example shown in FIG. 3, a predetermined gap is formed between the case crossing portion 120 and the case crossing pieces 91d, 92d of the terminals 91, 92, but they may be in contact with each other.

An outer extension portion 130 is integrally connected to the outer end of the case crossing portion 120 in the X-axis direction. The outer extension portion 130 has a flat plate shape parallel to the YZ plane and extends downward in the Z-axis direction. The outer extension portion 130 abuts against the outer side surface 310 of the case 300. The outer extension portion 130 has a shape that is longer in the Z-axis direction than the inner extension portion 110, and extends downward from the case crossing portion 120 along the outer side surface 310 of the case 300.

The outer extension 130 and the downward extension pieces 91e, 92e of the terminals 91, 92 face each other. In the example shown in FIG. 3, a predetermined gap is formed between the outer extension 130 and the downward extension pieces 91e, 92e, but they may be in contact with each other.

As shown in FIG. 1A, the lower end of the outer extension 130 in the Z-axis direction is positioned lower than the lower ends of the downward extension pieces 91e, 92e of the terminals 91, 92 in the Z-axis direction. This ensures insulation between the downward extension pieces 91e, 92e and the outer surface 310 of the case 300 via the outer extension 130.

In this embodiment, the upper portion of the case 300 where the terminals 91, 92 are exposed from the lead pull-out portion 49 (lead pull-out block 490) is covered with the case crossing portion 120 and the outer extension portion 130, making it possible to form an insulating region in that portion.

As shown in FIG. 3, a first winding section 45 is formed on the outer periphery of the first hollow cylinder section 44 located between the bobbin upper flange section 48 and the bobbin base plate 42. In the first winding section 45, a plurality of winding partition flanges 46 that separate adjacent wire winding portions along the winding axis (Z-axis) of the inner coil 20 are formed integrally with the first hollow cylinder section 44 at predetermined intervals along the winding axis and approximately parallel to the bobbin base plate 42 (and the bobbin upper flange section 48). Details of the winding partition flanges 46 and the winding method of the first wire 22 will be described later.

In this embodiment, an elliptical ring-shaped wound partition flange 46 is formed on a plane approximately parallel to the X-Y axes so that wound sections 47 are formed at predetermined intervals along the Z-axis direction on the outer periphery of the first hollow cylinder portion 44, which has an approximately elliptical cylindrical shape as shown in FIG. 2B. In this embodiment, a plurality of wound partition flanges 46 are formed approximately parallel to the Z-axis direction at predetermined intervals, but the number is not particularly limited. The area where these wound partition flanges 46 are formed becomes the first wound section 45.

The winding section width along the winding axis (Z-axis) in each winding section 47 separated by the winding partition flange 46 is set to a width that allows only one wire 22 to enter. In other words, the winding section width w1 preferably has a relationship with the wire diameter d1 of the wire 22 such that d1 < w1 < (2 x d1), and more preferably d1 < w1 < (1.2 x d1). If the winding section width w1 is too wide relative to the wire diameter d1, winding irregularities are likely to occur and this is contrary to the demand for a compact coil device.

In addition, it is preferable that the winding section widths in each winding section 47 are all the same, but they may be slightly different. In addition, the winding section width between the bobbin upper flange 48 and the winding partition flange 46 at the uppermost position may be larger than the winding section width between the winding partition flanges 46. Similarly, the winding section width between the bobbin substrate 42 and the winding partition flange 46 at the lowermost position may be larger than the winding section width between the winding partition flanges 46. In this embodiment, the total number of turns to be wound in each winding section 47 is not particularly limited.

As shown in FIG. 2C, in this embodiment, a positioning protrusion 46d is formed in one of the winding partition flanges 46 in a circumferential portion for contacting and positioning the inner peripheral surface of the bobbin cover 50. A flow gap 46e through which the heat dissipating resin can flow is formed between the outer peripheral surface of the winding partition flange 46 and the inner peripheral surface of the bobbin cover 50 other than the positioning protrusion 46d.

The positioning protrusion 46d preferably protrudes from the outer circumferential surface of the winding partition flange 46 at a position that contacts the inside of the split connection portion 53 of the bobbin cover 50. The protruding height (radial height) of the positioning protrusion 46d defines the radial width of the flow gap 46e, and is preferably about 0.5 to 1 mm. This is to facilitate the flow of the heat dissipating resin and to improve the bond between the coils 20, 30.

The upper surface of the bobbin upper flange 48 is formed with a stepped portion 48a that is lower along the Z axis than the other portions. The stepped portion 48a is formed with a positioning recess 48b that is recessed toward the center of the bobbin 40. An engaging protrusion 48c is formed on the inside of the positioning recess 48b, which can be engaged with an opening 64b formed in the mounting edge 64 of the bobbin cover 60 described below.

The bobbin substrate 42, the first hollow cylinder portion 44, the bobbin upper flange portion 48, the lead pull-out base 491, and the winding partition flange 46 in the bobbin 40 are preferably integrally molded by injection molding or the like.

As shown in FIG. 2B, a first through hole 44a is formed inside the first hollow cylinder 44 in the bobbin substrate 42, penetrating in the Z-axis direction. The middle leg 14 of the core 12 shown in FIG. 2A enters the first through hole 44a from above and below in the Z-axis direction, and the tips of the middle leg 14 are butted together at approximately the center of the through hole 44a in the Z-axis direction. Note that at approximately the center of the through hole 44a in the Z-axis direction, the tips of the middle leg 14 inserted from above and below the Z axis may not come into contact, forming a gap at a predetermined distance.

As shown in FIG. 2C, the bobbin cover 50 is composed of a pair of halves 50a, 50b that can be split into two in the X-axis direction and are combined at a split connection part 53 that is parallel to the winding axis (Z-axis). In the combined state, a second winding part 55 is formed on the outer periphery of the cover 50. After the first wire 22 is wound around the first winding part 45 (see FIG. 3) of the bobbin 40 to form the inner coil 20, the bobbin cover 50 is attached to the outer periphery of the bobbin 40 and combined at the split connection part 53.

The bobbin cover 50 has a second winding portion 55 that covers the inner coil 20 from the outside, and a cover lower flange portion 52 and a cover upper flange portion 58 are formed around the outer periphery of the second winding portion 55 along the circumferential direction at a predetermined interval in the Z-axis direction. The lower flange portion 52 and the upper flange portion 58 are arranged parallel to the plane of the X-Y axes and extend parallel to the installation surface.

The area between the lower flange 52 and the upper flange 58 forms the second winding section 55, and the second wire 32 that constitutes the outer coil 30, which is the secondary coil, is wound in an aligned manner (or α-winding) around this second winding section 55. Aligned winding is a normal winding method in which the wire is wound from one end of the winding axis to the other end. α-winding will be described later.

At the split connection portion 53 of the bobbin cover 50, the outer connection piece 53b of one half body 50b is inserted into the radially outer side of the inner connection piece 53a of the other half body 50a, and the half bodies 50a and 50b are connected to form the bobbin cover 50.

The cover upper flange 58 located at the connection part 53a of one half-split body 50a is formed with a stepped connection upper flange 58a that is higher along the Z axis than the other parts. The cover upper flange 58 located at the connection part 53b of the other half-split body 50b is formed with a connection upper flange 58b that is located lower along the Z axis than the connection upper flange 58a and can be inserted under the connection upper flange 58a for connection.

The cover upper flange 58 located at the connection portion 53b of the other half body 50b is provided with a stopper protrusion 58i against which the connection tip of the connection upper flange 58a can come into contact.
The stopper protrusions 58i protrude upward along the Z-axis from the upper surface of most of the cover upper flange 58. The protruding height of the stopper protrusions 58i from the upper surface of most of the cover upper flange 58 is preferably approximately the same as the protruding height of the connection upper flange 58a along the Z-axis. The upper surfaces of these stopper protrusions 58i and the upper surface of the connection upper flange 58a contact the lower surface of the bobbin upper flange 48 of the bobbin 40, and form an air outlet gap between the upper surface of most of the cover upper flange 58 other than the split connection portion 53 and the lower surface of the bobbin upper flange 48.

The cover upper flange 58 on the opposite side to the connection upper flange 58a along the X-axis of one half-body 50a is provided with an engagement protrusion 58c that protrudes upward along the Z-axis from the upper surface of the cover upper flange 58. An engagement surface 58e is formed on the upper surface of the engagement protrusion 58c, and the protruding height of the engagement surface 58e along the Z-axis relative to the upper surface of the cover upper flange 58 is approximately the same as the step height of the connection flange 58a. The engagement surface 58e contacts the lower surfaces of the pedestal center portion 491a and the pedestal side portion 491b of the lead pull-out base 491. The lower surfaces of the pedestal center portion 491a and the pedestal side portion 491b are approximately the same height as the lower surface of the bobbin upper flange 48 along the Z-axis. In addition, the engagement protrusion 58c has notches formed that correspond to the two base pull-out grooves 491c, 491c formed in the lead pull-out base 491.

The cover upper flange 58 on the opposite side of the connection upper flange 58b along the X-axis of the other half body 50b is provided with an engagement protrusion 58d that protrudes upward along the Z-axis from the upper surface of the cover upper flange 58. An engagement surface 58f is formed on the upper surface of the engagement protrusion 58d, and the protruding height of the engagement surface 58f along the Z-axis from the upper surface of the cover upper flange 58 is approximately the same as the protruding height of the stopper protrusion 58i. The engagement surface 58f contacts the lower surfaces of the pedestal center portion 491a and the pedestal side portion 491b of the lead pull-out base 491. The lower surfaces of the pedestal center portion 491a and the pedestal side portion 491b are approximately the same height as the lower surface of the bobbin upper flange 48 along the Z-axis.

As shown in Figures 2A and 2B, a pair of core covers 60 are attached to both sides in the Y-axis direction around the outer periphery of the second winding portion 55 (see Figure 2C) of the bobbin cover 50 on which the outer coil 30 is attached. The core cover 60 is made of an insulating material such as synthetic resin, and has a cover body 62, the outer periphery of which serves as a guide surface for guiding the side legs 16 of the core 12, and the outer coil 30 is located on the inner periphery of which.

Attachment edges 64, 64 are integrally formed on both ends of the cover body 62 in the Z-axis direction. A protruding piece 64a that protrudes toward the center of the bobbin 40 is formed on the attachment edge 64, and an opening 64b is formed inside the protruding piece 64a. The engaging protrusion 48c (see FIG. 2C) of the bobbin upper flange 48 engages with the opening 64b, and the protruding piece 64a is combined with the positioning recess 48b (see FIG. 2C) of the bobbin upper flange 48, so that the attachment edge 64 engages with the upper surface of the bobbin upper flange 48 and the core cover 60 is attached to the bobbin 40. Although not shown in detail, the attachment edge 64 on the lower side of the Z-axis engages with the lower surface of the bobbin base plate 42.

The cover body 62 has an inner peripheral shape that corresponds to the outer peripheral shape of the core cover 60, and insulating plate portions 66 are integrally formed at both ends in the X-axis direction. As shown in FIG. 1A, the insulating plate portion 66 of the core cover 60 improves insulation between the core 12 and the lead portion 32a of the outer coil 30 (see FIG. 2B). The inner surface of the insulating plate portion 66 (the center side of the coil device 10) may be in contact with the core 12, or may have a shape that matches the outer shape of the core 12.

The lead pull-out cover 70 is attached to cover the top and sides of the lead pull-out block 490 in the manner shown in FIG. 1A. As shown in FIG. 2B, the lead pull-out cover 70 has a top plate portion 71, a side wall portion 72, a rear wall portion 73, and a recessed portion 74.

The top plate 71 has a flat plate shape that is long in the Y-axis direction, and has a recess 7 at its outer end in the X-axis direction.
2E and the rear wall 490c of the lead pull-out block 490 (see FIG. 1A), and protects the lead pull-out block 490 from above. The recess 74 is recessed toward the center of the bobbin 40 and has a predetermined width in the Y-axis direction.

A side wall portion 72 is formed at each end of the top plate portion 71 in the Y-axis direction. The side wall portion 72 has a flat plate shape parallel to the X-Z plane and is approximately square in shape. The side wall portion 72 is disposed to the side of the lead pull-out block 490, and protects the lead pull-out block 490 from the sides in the Y-axis direction.

Two rear walls 73, 73 are formed on the outer end of the top plate 71 in the X-axis direction. The rear wall 73 has a flat plate shape parallel to the Y-Z plane and is approximately square. One rear wall 73 is disposed on one side of the top plate 71 in the Y-axis direction and is connected to the adjacent side wall 72. The other rear wall 73 is disposed on the other side of the top plate 71 in the Y-axis direction and is connected to the adjacent side wall 72. The rear wall 73 is disposed on the outer side of the lead pull-out block 490 in the X-axis direction and protects the lead pull-out block 490 from behind.

The first wire 22 shown in FIG. 2C may be a solid wire or a twisted wire, and is preferably an insulated conductor. The outer diameter d1 of the first wire 22 is not particularly limited, but when a large current is to be passed through it, for example, a diameter of φ1.0 to φ3.0 mm is preferable. The second wire 32 may be the same as the first wire 22, or may be different.

In this embodiment, the inner coil 20 made of the first wire 22 shown in FIG. 2C constitutes the primary coil of the transformer, and the outer coil 30 made of the second wire 32 wound around the bobbin cover 50 constitutes the secondary coil. Alternatively, the inner coil 20 may constitute the secondary coil, and the outer coil 30 may constitute the primary coil.

In this embodiment, the first wire 22 is wound, for example, α-wound from the center of the first winding portion 45 (see FIG. 3) in the Z-axis direction. Therefore, in this embodiment, the wire diameter of the second wire 32 constituting the outer coil 30 is made thicker than that of the first wire 22, but the wire diameter is not particularly limited and may be the same or different. In addition, the materials of the first wire 22 and the second wire 32 may be the same or different.

The lead portion 22a from the lower winding portion of the first wire 22 after α winding is lifted to the upper portion in the Z-axis direction, passes through the inside of the base pull-out groove 491c of the lead pull-out base 491 shown in FIG. 2E, and is further guided to the vertical pull-out groove 490e of the lead pull-out block 490.

As shown in FIG. 2D, in this embodiment, an insulating plate 200 is attached to one end of the bobbin 40 in the X-axis direction so that the lead portion 22a drawn upward in the Z-axis direction does not come into contact with the outer coil 30. Note that the insulating plate 200 is not attached to the other end of the bobbin 40 in the X-axis direction.

As shown in Figures 2C and 2D, the insulating plate 200 has a plate main body portion 210, a plate top plate portion 220, a plate outward protrusion portion 230, and a lead passage 240. The plate main body portion 210 has a flat plate shape parallel to the YZ plane, and the plate top plate portion 220 is formed at its upper end. The plate top plate portion 220 extends inward in the X-axis direction, and is fixed to the underside of the pedestal center portion 491a and pedestal side portion 491b of the lead pull-out base 491.

Two plate outward protrusions 230, 230 that protrude outward in the X-axis direction of the bobbin 40 are formed on the surface of the plate main body 210. Each of the two plate outward protrusions 230, 230 is disposed at a predetermined interval in the Y-axis direction and extends along the Z-axis direction. The interval between each of the two plate outward protrusions 230, 230 is approximately equal to or greater than the diameter of the first wire 22.

Between each of the two plate outer protrusions 230, 230, a lead passage 240 is formed extending along the Z-axis direction. The lead portion 22a (the lead portion 22a from the lower winding portion of the first wire 22) that is pulled out upward in the Z-axis direction can be inserted inside the lead passage 240. The lead portion 22a is pulled out upward in the Z-axis direction while passing through the inside of the lead passage 240, so that it is possible to prevent a short circuit from occurring between the lead portion 22a and the outer coil 30.

The lead portion 22a from the upper winding portion of the first wire 22 after α winding is directly guided to the base pull-out groove 491c of the lead pull-out base 491 and the vertical pull-out groove 490e of the lead pull-out block 490, and is pulled out toward the outside in the Y-axis direction while passing through the inside of the horizontal pull-out groove 490f. Note that the pair of lead portions 22a of the inner coil 20 are each pulled out toward opposite sides in the Y-axis direction along the horizontal pull-out groove 490f.

In contrast, as shown in Figures 2B and 2C, the second wire 32 constituting the outer coil 30, which becomes the secondary coil, is wound in order around the second winding section 55 of the bobbin cover 50. Aligned winding is a method of winding in which the wire 32 is wound around the outer circumferential surface of the winding section 55 in sequence from one end to the other end in the Z-axis direction, and in this embodiment, the wire 32 is wound in order in only one layer. If two layers are used for aligned winding, the first layer is wound completely before the second layer is wound on top of it.

Below, an example of a method for manufacturing the coil device 10 will be described with reference to Figures 2A to 2C, 2E, etc. In manufacturing the coil device 10, first, the bobbin 40 is prepared. The material of the bobbin 40 is not particularly limited, but the bobbin 40 is formed from an insulating material such as resin.

Next, the first wire 22 is wound around the outer circumference of the first hollow cylinder portion 44 of the bobbin 40 to form the inner coil 20. The first wire 22 used to form the inner coil 20 is not particularly limited, but a Litz wire or the like is preferably used.

Next, the bobbin cover 50 is attached to the bobbin 40 on which the inner coil 20 is formed. The second wire 32 that constitutes the outer coil 30 is wound around the outer circumference of the second winding portion 55 of the bobbin cover 50.

Next, the lead pull-out block 490 to which the terminals 91 and 92 are attached is slid toward the lead pull-out base 491, and the side thin plate portion 491d of the lead pull-out base 491 is engaged with the recessed groove 490i of the lead pull-out block 490, and the lead pull-out block 490 is attached to the lead pull-out base 491.

Next, an insulating plate 200 is attached to one end of the bobbin 40 in the X-axis direction, and the lead portion 22a from the lower winding portion of the inner coil 20 is pulled out upward in the Z-axis direction while being inserted inside the lead passage 240 of the insulating plate 200. Then, the lead portion 22a is inserted inside one of the vertical pull-out grooves 490e of the lead pull-out block 490 and pulled out upward in the Z-axis direction, and is inserted inside one of the horizontal pull-out grooves 490f and pulled out to the outside in the Y-axis direction.

The lead portion 22a from the upper winding portion of the inner coil 20 is directly inserted through the other vertical lead-out groove 490e of the lead draw block 490 and drawn upward in the Z-axis direction, and also through the other horizontal lead-out groove 490f and drawn outward in the Y-axis direction. Note that the pair of lead portions 32a, 32a of the outer coil 30 are both directly inserted through the vertical lead-out grooves 490e of the lead draw block 490 and drawn upward in the Z-axis direction, and also through the horizontal lead-out grooves 490f and drawn outward in the Y-axis direction.

Next, the pair of lead portions 22a, 22a are sandwiched and connected by the lead connection pieces 91a, 92a of the terminals 91, 92. Similarly, the pair of lead portions 32a, 32a are sandwiched and connected by the lead connection pieces 91a, 92a of the terminals 91, 92.

Next, the lead pull-out cover 70 is attached to the lead pull-out block 490 so as to cover the lead pull-out block 490. After that, the core cover 60 is attached to both sides of the bobbin cover 50 in the Y-axis direction, and then the core 12 is attached from above and below in the Z-axis direction. That is, the tips of the middle legs 14, 14 of the core 12 are butted up against each other, and the tips of the side legs 16, 16 are butted up against each other. Note that a gap may be provided between the tips of the middle legs 14, 14.

The material of each core 12 may be soft magnetic material such as metal or ferrite, but is not limited thereto. The core 12 is fixed to the bobbin cover 50 and the bobbin 40 by being adhered with an adhesive or by wrapping a tape-like material around the outer periphery. A heat dissipation plate 80 is attached above the core 12 in the Z-axis direction.

The assembly formed by assembling the above-mentioned components is then housed inside the case 300, which is filled with heat dissipating resin. The resin is filled before housing the coil device 10 inside the case 300. It is preferable to use a case 300 that is tall enough to accommodate the entire inner coil 20 and outer coil 30 inside. There are no particular limitations on the heat dissipating resin, but it is preferable to use a resin with excellent heat dissipation properties, for example, a thermal conductivity of 0.5 to 5, preferably 1 to 3 W/m·K.

Examples of resins with excellent heat dissipation properties include silicone resins, urethane resins, and epoxy resins, with silicone resins and urethane resins being preferred. In order to improve heat dissipation properties, the resin may be filled with a filler with high thermal conductivity.

The heat dissipating resin of this embodiment preferably has a Shore A hardness of 100 or less, and more preferably 60 or less. This is to absorb the deformation even if the core 12 is deformed by heat, and to prevent excessive stress from being generated in the core 12. An example of such a resin is a potting resin.

The amount of heat dissipation resin filled inside the case 300 is preferably such that the entire inner coil 20 arranged around the bobbin 40 and the outer coil 30 arranged around the bobbin cover 50 are soaked in the heat dissipation resin (the upper ends of the inner coil 20 and the outer coil 30, or the lower surface of the bobbin upper flange 48 are soaked).

The insulating protection part 100 is attached to each wall located on both sides of the case 300 in the X-axis direction so as to straddle the outer surface 310, the inner surface 320, and the upper opening edge 330. If necessary, the insulating protection part 100 may be fixed to the case 300 with an adhesive or the like.

A cooling device such as a cooling pipe or cooling fins may be attached to the bottom of the case 300 via a metal plate or directly.

In this embodiment, after the series of assembly steps, a varnish impregnation treatment may be performed on the coil device 10. Through the steps described above, the coil device 10 according to this embodiment can be manufactured.

In the coil device 10 according to this embodiment, the terminals 91 and 92 have case side pieces 91d and 92d and downward extension pieces 91e and 92e. Therefore, the terminals 91 and 92 extend to the side of the case 300 (in the direction along the extension direction of the case side pieces 91d and 92d) rather than above the case 300, and there is no need to provide a terminal block (lead pull-out block 490) for fixing the terminals 91 and 92 above the case 300. Therefore, by using a tall case 300, it is possible to accommodate most of the coils 20 and 30 and the core 12 inside the case 300, and by filling the case 300 with heat dissipation resin, most of the coils 20 and 30 and the core 12 can be immersed in the heat dissipation resin, and the heat generated by the coils 20 and 30 and the core 12 can be sufficiently dissipated through the heat dissipation resin.

In addition, as described above, in the coil device 10 according to this embodiment, there is no need to provide a terminal block (lead pull-out block 490) above the case 300, so it is possible to reduce the height of the coil device 10, and the coil device 10 can be made low-profile.

In addition, in the coil device 10 according to this embodiment, the terminals 91, 92 are provided with downward extension pieces 91e, 92e, so there is no need to draw the terminals 91, 92 outward and downward from the case 300, for example by providing a notch or the like below the case 300. Therefore, when the case 300 is filled with heat dissipation resin, the heat dissipation resin will not leak out from the notch or the like, and a sufficient amount of heat dissipation resin can be filled into the case 300, and the heat generated by the coils 20, 30 and the core 12 can be efficiently dissipated through the heat dissipation resin.

In addition, in this embodiment, the terminals 91 and 92 have outward protruding pieces 91f and 92f. Therefore, the outward protruding pieces 91f and 92f can be used as user terminals.

The coil device 10 according to this embodiment also has an insulating protection section 100. Therefore, the terminals 91 and 92 can be pulled out to the side of the case 300 while preventing short circuits between the terminals 91 and 92 and the case 300 via the insulating protection section 100.

In addition, in this embodiment, the insulating protection part 100 has a case crossing part 120 and an outer extension part 130. Therefore, the terminals 91, 92 can be insulated from the upper opening edge 330 of the case 300 via the case crossing part 120, and the terminals 91, 92 can be insulated from the outer surface 310 of the case 300 via the outer extension part 130.

In addition, in this embodiment, a lead pull-out block 490 is provided, and the insulating protection section 100 is formed separately from the lead pull-out block 490. This makes it possible to simplify the configuration of the lead pull-out block 490 or the insulating protection section 100, and makes it easy to form the lead pull-out block 490 or the insulating protection section 100.

In addition, in this embodiment, the lead pull-out block 490 is formed separately from the bobbin 40. Therefore, if there is a change in the specifications of the lead pull-out block 490, a lead pull-out block 490 that corresponds to the change in specifications can be prepared and attached to the bobbin 40, allowing for flexible response to specification changes.

1B and 5B, the coil device 10A according to the second embodiment has the same configuration as the coil device 10 according to the first embodiment, and exerts the same effects and advantages, except for the following points: In Fig. 1B and 5B, the same reference numerals are used to designate the same members as those in the coil device 10 according to the first embodiment, and some of the descriptions thereof will be omitted.

The coil device 10A in this embodiment has an insulating protection part 100A. As is clear from a comparison between FIG. 5A and FIG. 5B, the insulating protection part 100A in this embodiment differs from the insulating protection part 100 in the first embodiment in that it is integrally formed with the lead pull-out block 490. The insulating protection part 100A and the lead pull-out block 490 are integrally molded by injection molding or the like.

The insulating protection part 100A has a case crossing part 120A and an outer extension part 130A, and has a generally L-shaped shape. On the other hand, the insulating protection part 100A does not have a configuration corresponding to the inner extension part 110 in the first embodiment. In this embodiment, the insulating protection part 100A is integrated with the lead pull-out block 490, so that the rear wall part 490c of the lead pull-out block 490 plays a role similar to that of the inner extension part 110.

The case crossing portion 120A is formed thicker than the case crossing portion 120 in the first embodiment, and houses the case cross pieces 91d, 92d of the terminals 91, 92 inside. That is, in this embodiment, the case cross pieces 91d, 92d are not exposed to the outside, but are embedded inside the case crossing portion 120A. The inner end in the X-axis direction of the case crossing portion 120A is integrally connected to the upper end in the Z-axis direction of the rear wall portion 490c of the lead pull-out block 490. The lower surface of the case crossing portion 120A abuts against the upper opening edge 330 of the case 300.

The outer extension portion 130A is formed thicker than the outer extension portion 130A in the first embodiment, and houses the downward extension pieces 91e, 92e of the terminals 91, 92 inside. That is, in this embodiment, the downward extension pieces 91e, 92e are not exposed to the outside, but are embedded inside the outer extension portion 130A. Two terminal holes 131, 131 are formed at the outer end surface in the X-axis direction of the outer extension portion 130A, each of which is spaced apart by a predetermined distance in the Y-axis direction. The outward protruding pieces 91f, 92f of the terminals 91, 92 are pulled out through the terminal holes 131, 131. The inner end surface in the X-axis direction of the outer extension portion 130A abuts against the outer surface 310 of the case 300.

The insulating protection part 100A is attached to the case 300 by sandwiching the upper end of the case 300 between the outer extension part 130A and the rear wall part 490c of the lead pull-out block 490.

In this embodiment, the same effects as in the first embodiment can be obtained. In addition, in this embodiment, the insulating protection part 100A is formed integrally with the lead pull-out block 490. Therefore, in the manufacturing process of the coil device 10A, it is possible to omit the process of separately attaching the insulating protection part 100A (as a single unit) to the case 300, making it easier to manufacture the coil device 10A.

In addition, in this embodiment, the insulating protection part 100A is formed integrally with the terminals 91 and 92. For example, by integrally molding the terminals 91 and 92 with the insulating protection part 100A by insert molding or the like, the coil device 10A can be easily manufactured.

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

For example, the first wire 22 does not need to be α-wound, and may be aligned. Even with aligned winding, the effects of the present invention can be expected. Furthermore, the specific shape of the bobbin 40 or the specific shape of the core 12 is not limited to the above-described embodiment, and can be modified in various ways. Furthermore, the coil device of the present invention can be used for applications other than transformers, such as reactors.

In each of the above embodiments, the shape of the insulating protection parts 100, 100A may be changed as appropriate. For example, in FIG. 5A, the inner extension part 100 may be omitted from the insulating protection part 100, and the insulating protection part 100 may be configured to be composed of the case crossing part 110 and the outer extension part 130. Also, in FIG. 5B, the insulating protection part 100A and the lead pull-out block 490 may be separated.

In each of the above embodiments, the coil device 10, 10A may be provided with two insulating protection parts 100, 100A, one of the insulating protection parts 100, 100A may insulate the terminal 91 from the case 300, and the other insulating protection part 100, 100A may insulate the terminal 92 from the case 300.

In this case, the shape of the insulating protection parts 100, 100A may be substantially the same as the shapes of the case side pieces 91d, 92d and the downward extension pieces 91e, 92e of the terminals 91, 92.

10, 10A... Coil device 12... Core 13... Base 14... Middle leg 16... Side leg 20... Inner coil 22... First wire 22a... Lead portion 30... Outer coil 32... Second wire 32a... Lead portion 40... Bobbin 42... Bobbin substrate 42a... Leg portion 44... First hollow cylinder portion 44a... First through hole 44b... Separation protrusion 45... First winding portion 46... Winding partition flange 46d... Positioning protrusion 46e... Flow gap 47... Winding section 48... Bobbin upper flange 48a... Step portion 48b... Positioning recess 48c... Engagement protrusion 49... Lead pull-out portion 490... Lead pull-out block (terminal block)
490a...Pedestal 490b...Front wall 490c...Rear wall 490d...Side wall 490e...Vertical pull-out groove 490f...Horizontal pull-out groove 490g...Engagement protrusion 490h...Fixing protrusion 490i...Concave groove 490j...Terminal hole 491...Lead pull-out base 491a...Pedestal center 491b...Pedestal side 491c...Pedestal pull-out groove 491d...Side thin plate 491e...Insulating wall 491f...Fixing recess 50...Bobbin cover 50a, 50b...Half body 52...Cover lower flange 52a...Support portion 53...Split connection portion 53a...Inner connection piece 53b...Outer connection piece 55...Second winding portion 58...Cover upper flange 58a...Connection upper flange 58b...connection lower flange 58c, 58d...engagement portion 58e, 58f...engagement surface 58g, 58h...step surface 58i...stopper protrusion 60...core cover 62...cover body 62a...division piece 64...mounting edge 64a...projection piece 64b...opening 66...insulating plate portion 70...lead pull-out cover 71...top plate portion 72...side wall portion 73...rear wall portion 74...recess 80...heat dissipation plate 91, 92...terminal 91a, 92a...lead connection piece 91b, 92b...side extension piece 91c, 92c...upper extension piece 91d, 92d...case side piece 91e, 92e...lower extension piece 91f, 92f...outer projection piece 100, 100A...insulating protection portion 110...inner extension portion 120, 120A: Case crossing portion 130, 130A: Outer extension portion 131: Terminal hole 200: Insulating plate 210: Plate main body portion 220: Plate top plate portion 230: Plate outward protrusion portion 240: Lead passage 300: Case 310: Outer surface 320: Inner surface 330: Upper opening edge 340: Bottom plate 350: Concave corner portion

Claims (5)

A bobbin on which the coil is attached;
a terminal to which a lead portion of the coil is connected;
and a case in which the bobbin is housed.
the terminal has a case side piece straddling an upper opening edge of the case, and a downward extension piece connected to the case side piece and extending downward from the case side piece to an outside of the case,
The terminal block further includes a terminal block to which the terminal is fixed.
The horizontal piece of the terminal is pulled out from the terminal block through a terminal hole formed in the terminal block so that a gap is formed between the terminal and the upper opening edge of the case, and is exposed to the outside, and is pulled out to the outside of the case . the terminal further includes a lead connection piece to which the lead portion is connected, a side extension piece integrally connected to the lead connection piece, and an upward extension piece connected to the side extension piece and extending above an upper opening edge of the case,
The coil device according to claim 1 , wherein the case horizontal piece is connected to an upper end of the upward extension piece. The coil device according to claim 2 , wherein the upward extension piece extends across the upper opening edge of the case from above to below. 4. The coil device according to claim 1, wherein the terminal is connected to the downward extending piece and has an outward protruding piece extending in a direction away from the case. The coil device according to any one of claims 1 to 4 , wherein the terminal block is formed separately from the bobbin.

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