JP7439708B2 - coil device - Google Patents

Description

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

For example, a coil device described in Patent Document 1 is known as a coil device used in a transformer or the like. The coil device described in Patent Document 1 includes a bobbin, a wire wound around the outer periphery of the bobbin, and a terminal to which a lead portion of the wire is connected. A terminal block is formed on the bobbin, and a terminal can be fitted and fixed to the terminal block.

In this type of coil device, there is a demand for connecting the terminal directly to the circuit board when connecting the coil device to the circuit board. However, this type of connection is not easy due to the necessity of aligning the mounting position of the circuit board and the position of the terminal with high precision.

Japanese Patent Application Publication No. 2014-36194

The present invention was made in view of the above circumstances, and an object thereof is to provide a coil device that can be easily positioned with respect to a substrate such as a circuit board.

In order to achieve the above object, the coil device according to the present invention includes:
a bobbin having a winding part around which a wire is wound;
a terminal to which the lead portion of the wire is connected;
a terminal block to which the terminal is attached and is movably attached to the bobbin in both a first axial direction and a second axial direction of the bobbin;
The terminal block includes a guide portion that guides the lead portion so as to form a predetermined gap between the end portion of the terminal block in the first axial direction and the lead portion.

The coil device according to the present invention includes a terminal block to which a terminal is attached and which is attached to the bobbin so as to be movable in both the first axial direction and the second axial direction of the bobbin. Therefore, after roughly positioning a board such as a circuit board and the coil device, the terminals of the terminal block and the board can be accurately positioned and connected by simply moving the terminal block relative to the bobbin.

In addition, in the coil device according to the present invention, it is no longer necessary to accurately align the terminals of the terminal block with the mounting positions of the board at the manufacturing stage of the coil device, and each component constituting the coil device This makes manufacturing and assembly easier, contributing to lower manufacturing costs.

In particular, the coil device according to the present invention includes a guide portion that guides the lead portion so as to form a predetermined gap between the end portion of the terminal block in the first axial direction and the lead portion. By providing the guide portion in this manner, the terminal block can be smoothly moved in the first axis direction, as described below.

When the lead part is connected to the terminal by thermocompression bonding, etc., the lead part may harden and become difficult to bend at the part where the thermocompression bonding etc. was applied due to the influence of heat. It may become difficult to move the connected terminal blocks in the first axis direction. Therefore, by providing a guide part in the coil device and routing the lead part toward the terminal along the path guided by the guide part, it is possible to provide the lead part with a sufficient wire length, and the heat When the lead portion is connected to the terminal by crimping or the like, the proportion of the portion that hardens due to the influence of heat can be reduced, and the flexibility of the lead portion can be maintained sufficiently. Therefore, movement of the terminal block in the first axis direction is prevented from being inhibited by the hardened portion of the lead part, and smooth movement of the terminal block in the first axis direction is realized, and the terminals of the terminal block and the board are prevented from being obstructed. The accuracy of positioning can be greatly improved.

In addition, since the terminal block can freely move within the range of the above-mentioned gap without being hindered by the guide part or the lead part guided by the guide part, when moving in the first axis direction, the first It is possible to prevent the axial end portion from coming into contact with the guide portion or the lead portion guided by the guide portion. Therefore, also in this respect, smooth movement of the terminal block in the first axis direction is realized, and the above-mentioned effects can be obtained.

Preferably, the guide portion is provided at a position spaced apart from an end of the terminal block in the first axial direction by a distance equal to or greater than a movable distance of the terminal block in the first axial direction. With this configuration, the guide part is placed outside the movable range of the terminal block in the first axis direction, so it is effective for the terminal block to come into contact with the guide part or the lead part guided by the guide part. This makes it possible to effectively prevent the terminal block from moving in the first axis direction.

Preferably, the guide part has a pair of protrusions that protrude outward, and a lead insertion passage through which the lead part is inserted is formed between each of the pair of protrusions. By inserting the lead part into the lead insertion path, each of the pair of protrusions restricts the positional shift of the lead part in the first axis direction, and the lead part is inserted into the inside of the movement path of the terminal block in the first axis direction. It is possible to prevent the lead portion from entering and effectively realize smooth movement of the terminal block in the first axis direction.

Preferably, the bobbin has a flange formed on the outer periphery of the winding portion, and the guide portion is arranged in the first axial direction of the terminal block at an end of the flange in the second axial direction. It is formed outside the range of motion. By integrally forming the guide part with the flange part, it is possible to prevent the coil device from increasing in size due to the formation of the guide part. In addition, by forming the guide part in the above area, it becomes possible to pull out the lead part toward the terminal so as to bypass the end of the terminal block in the first axis direction, so that the lead part has a sufficient length of wire. It is possible to increase the lead length, reduce the proportion of the portion that hardens under the influence of heat due to thermocompression bonding, etc., and maintain sufficient flexibility of the lead portion.

Preferably, the wire includes a first wire and a second wire, and the bobbin includes a first coil portion formed by winding the first wire and a second coil portion formed by winding the second wire. is formed. With such a configuration, it becomes possible to use the transformer as a transformer in which either the first coil portion or the second coil is a primary coil and the other is a secondary coil.

Preferably, each of the first coil part and the second coil part is arranged adjacent to each other along the winding axis direction. With this configuration, the number of parts can be reduced compared to, for example, arranging the first coil part around the outer periphery of the bobbin and the second coil part outside of the first coil part, and the number of parts of the coil device can be reduced. It is possible to achieve compactness.

Preferably, one of the first coil part and the second coil part, and the first coil part and the second coil part drawn out from the end of the bobbin in the second axial direction toward the terminal. An insulating cover is attached to the end of the bobbin in the second axial direction, and the guide part is provided on the insulating cover. With such a configuration, good insulation between the first coil part and the second coil part can be achieved. Further, by integrally forming the guide portion with the insulating cover, it is possible to prevent the coil device from increasing in size due to the formation of the guide portion.

Preferably, the diameter of one of the first wire and the second wire is larger than the diameter of the other wire, and the lead portion of the wire with the larger diameter is guided by the guide portion. Wires with a larger diameter are inherently more rigid and less likely to bend, so if the lead portion of the wire with a larger diameter hardens due to the influence of heat from thermocompression bonding or the like, the flexibility of the lead portion is particularly likely to be impaired. Therefore, by routing the lead part of the wire with a larger diameter along the path guided by the guide part, it is possible to reduce the proportion of the hardened part of the lead part and maintain the flexibility as much as possible. It is possible to effectively avoid the problem that the movement in the first axis direction is obstructed.

FIG. 1 is a perspective view of a coil device according to an embodiment of the present invention. FIG. 2 is an exploded perspective view of the coil device shown in FIG. 1. FIG. 3A is an exploded perspective view showing the structure of the bobbin shown in FIG. 2 and various members attached thereto. FIG. 3B is an exploded perspective view showing the configuration of FIG. 3A when viewed from another angle. FIG. 4 is an exploded perspective view showing the configuration of the bobbin shown in FIG. 2 and each terminal block attached to one side and the other side of the bobbin in the X-axis direction. FIG. 5A is an exploded perspective view showing the structure of various members respectively attached to the bobbin shown in FIG. 4 and the terminal block on one side in the X-axis direction. FIG. 5B is an exploded perspective view showing the configuration of various members respectively attached to the bobbin shown in FIG. 4 and the terminal block on the other side in the X-axis direction. FIG. 6A is a cross-sectional view of the coil device shown in FIG. 1 taken along line VIA-VIA. FIG. 6B is a cross-sectional view of the coil device shown in FIG. 1 taken along line VIB-VIB. FIG. 7 is an enlarged perspective view showing the structure of the bobbin shown in FIG. 4 and a terminal block attached to one end of the bobbin in the X-axis direction.

The present invention will be described below based on embodiments shown in the drawings.

As shown in FIG. 1, a coil device 10 according to an embodiment of the present invention is used, for example, as a transformer, and is attached to a substrate such as a circuit board 300. In the drawings, the X axis corresponds to the long axis direction of the bobbin 40 (see FIG. 2) having a substantially elliptical shape, the Y axis corresponds to the short axis direction of the bobbin 40, and the Z axis corresponds to the height direction of the bobbin 40. do.

As shown in FIG. 2, the coil device 10 includes four cores 12, a first coil section 20 (FIG. 6A), a second coil section 30 (FIG. 6A), a bobbin 40, an insulating cover 50, and a pair of core covers 60, 60, and a pair of terminal blocks 70_1, 70_2.

The four cores 12 are assembled to form a magnetic path through which the magnetic flux generated by the coils described below passes. These cores 12 have a symmetrical shape and are connected to each other so as to sandwich the core covers 60, 60 and the bobbin 40 from above and below (Z-axis direction in the figure).

Each core 12 has a substantially E-shaped longitudinal section (a cut surface including the Y-axis and the Z-axis). Each core 12 is made of a soft magnetic material such as ferrite or a magnetic metal material, and includes a flat base 13 extending in the Y-axis direction, and a pair of bases 13 that protrude in the Z-axis direction from both ends of each base 13 in the Y-axis direction. It has side legs 16, 16, and a middle leg 14 that protrudes in the Z-axis direction from an intermediate position of each base 13 in the Y-axis direction.

The middle leg 14 of each core 12 enters the inside of the through hole 44a formed in the hollow cylindrical portion 44 of the bobbin 40. Due to the separation convex portion 44b formed on the inner peripheral wall of the hollow cylinder portion 44, a gap is formed between the cores 12, 12 adjacent to each other in the X-axis direction. By entering a highly thermally conductive resin such as a potting resin into this gap, the heat dissipation of heat generated inside the coil device 10 is improved.

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

The bobbin 40 has a hollow cylindrical portion 44 . The hollow cylindrical portion 44 has a cylindrical shape extending in the Z-axis direction. As shown in FIG. 3A, a bobbin lower flange 47 is integrally molded at the lower part of the hollow cylindrical portion 44 in the Z-axis direction so as to protrude from the hollow cylindrical portion 44 in the radial direction on the XY-axis plane. Further, a bobbin upper flange 48 is integrally formed at the upper part of the hollow cylindrical part 44 in the Z-axis direction so as to protrude from the hollow cylindrical part 44 in the radial direction on the XY-axis plane. A step portion 48a is formed on the upper surface of the bobbin upper flange portion 48, and a positioning recess 48b recessed toward the center of the bobbin 40 is formed in the step portion 48a. An engagement protrusion 48c is formed inside the positioning recess 48b, and can be engaged with the inside of an opening 64b formed in the mounting edge 64 of the core cover 60 shown in FIG.

A winding portion 45 is formed on the outer periphery of the hollow cylinder portion 44 . In the winding part 45, a plurality of winding partition flanges 46 are formed integrally with the hollow cylinder part 44, substantially parallel to the bobbin lower collar part 47 and the bobbin upper collar part 48. The plurality of winding partition walls 46 have an elliptical ring shape, and each of the winding axes (Z-axis ) to separate adjacent wire windings from each other.

For example, the first wire 22 serving as a primary coil and the second wire 32 serving as a secondary coil are each wound α (or aligned) in the winding portion 45 . The α winding will be described later. Note that aligned winding is a normal winding method in which the wire is wound from one end of the winding shaft to the other end.

As shown in FIGS. 6A and 6B, the wound partition flange 46 is arranged in the X- It is formed in a plane substantially parallel to the Y axis. The winding section S1 is a winding section formed between the bobbin upper flange 48 and the winding partition flange 46 at the uppermost position, and the winding section S2 is a winding section formed between the winding partition flange 46 at the uppermost position and the winding partition flange 46 at the center position. The winding section S3 is a winding section formed between the winding partition collar 46 at the center position and the winding partition wall collar 46 at the lowest position. The winding section S4 is a winding section formed between the winding partition flange 46 at the lowest position and the bobbin lower flange 47. In this embodiment, a plurality of winding partition rib flanges 46 are formed substantially parallel to each other at predetermined intervals along the Z-axis direction, but the number is not particularly limited. The area where these winding partition flanges 46 are formed becomes the winding portion 45.

The winding division width along the winding axis (Z-axis) in each of the winding divisions S1 to S4 separated by the winding partition flange 46 is such that only one first wire 22 (or second wire 32) can enter therein. It is set to width. That is, the winding section width w1 (not shown) preferably satisfies d1<w1<(2×d1) with respect to the wire diameter d1 (not shown) of the first wire 22 (or second wire 32). Preferably, the relationship is d1<w1<(1.2×d1). If the winding section width w1 is too wide with respect to the wire diameter d1, the winding is likely to be disordered, and this goes against the request for making the coil device more compact.

Note that in each of the winding sections S1 to S4, the winding section widths are preferably all the same, but may be slightly different. In this embodiment, the total number of turns scheduled to be wound in each of the winding sections S1 to S4 is not particularly limited.

As shown in FIG. 2, the hollow cylindrical portion 44, the winding partition flange 46, the bobbin lower flange 47, and the bobbin upper flange 48 of the bobbin 40 are preferably integrally molded by injection molding or the like.

The middle leg 14 of the core 12 enters the through hole 44a from above and below in the Z-axis direction, and the tips of the middle legs 14 abut against each other at a substantially central portion of the through hole 44a in the Z-axis direction. Note that in the approximate center of the through hole 44a in the Z-axis direction, the tips of the middle legs 14 inserted from above and below the Z-axis may not contact each other, but gaps may be formed at predetermined intervals (FIGS. 6A and 6B). reference).

A pair of core covers 60, 60 are attached to the outer periphery of the bobbin 40 from both sides in the Y-axis direction. The core cover 60 is made of an insulating member such as synthetic resin, and has a cover main body 62, the outer circumferential surface of which serves as a guide surface for guiding the side legs 16 in the core 12, and the inner circumferential surface of which has a first A coil section 20 and a second coil section 30 are located therein.

Attachment edges 64, 64 are integrally formed at both ends of the cover body 62 in the Z-axis direction. The mounting edge 64 on the upper side of the Z-axis engages with the upper surface of the bobbin upper flange 48 , and the mounting edge 64 on the lower side of the Z-axis engages with the lower surface of the bobbin lower flange 47 . More specifically, a protruding piece 64a is formed at approximately the center of the mounting edges 64, 64 in the Y-axis direction, and the bobbin upper flange 48 is inserted into the opening 64b formed in the protruding piece 64a. By engaging the engagement convex portion 48c (FIG. 3A) formed on the stepped portion 48a, it is possible to engage the mounting edges 64, 64 and the bobbin upper collar portions 48, 48.

The cover main body 62 has an inner peripheral surface shape corresponding to the outer peripheral surface shape of the bobbin 40, and insulating plate portions 66 are integrally formed at both ends of the cover main body 62 in the X-axis direction. At the top and bottom of the insulating plate portion 66 in the Z-axis direction, engaging convex portions 66a that protrude inward in the Y-axis direction are formed. As shown in FIG. 1, the engagement convex portion 66a on the upper side of the Z-axis engages with the inner surface of the insulating wall 410 of the first terminal block installation part 41 or the insulating wall 420 of the second terminal block installation part 42 of the bobbin 40. However, the engagement convex portion 66a on the lower side of the Z-axis engages with the lower surface of the bobbin lower flange 47 at both ends of the bobbin lower flange 47 shown in FIG. 2 along the X-axis.

As a result, the insulating plate part 66 of the core cover 60 is combined with the insulating walls 410 and 420 and the bobbin lower collar part 47 to improve insulation between the core 12 and the first coil part 20 and the second coil part 30. 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 matching the outer shape of the core 12 .

As shown in FIGS. 6A and 6B, the first wire 22 may be composed of a single wire or a twisted wire, and is preferably composed of an insulated conductive wire. The outer diameter d1 (not shown) of the first wire 22 is not particularly limited, but is preferably φ1.0 to φ3.0 mm, for example, when a large current is to flow. The second wire 32 may be the same as the first wire 22, or may be different.

In this embodiment, the wire diameter of the second wire 32 is larger than the wire diameter of the first wire 22. However, the relationship between the wire diameters of the wires 22 and 32 is not limited to this, and the wire diameter of the second wire 32 may be smaller than or equal to the wire diameter of the first wire 22. Moreover, the materials of the first wire 22 and the second wire 32 may be the same or different. Alternatively, the first coil section 20 may be used as a secondary coil, and the second coil section 30 may be used as a primary coil.

As shown in FIGS. 3A and 5B, in the bobbin 40 of the present embodiment, an end in the X-axis direction of the winding partition collar 46 at the uppermost position and an end in the X-axis direction of the winding partition collar 46 at the lowermost position. A communication groove 49 is formed in each portion. The winding portion 45 is formed by winding each of the first wire 22 and the second wire 32 in α windings. More specifically, the center part of the first wire 22 is arranged so as to pass through the communication groove 49 formed in the winding partition collar 46 at the uppermost position, and one side of the first wire 22 is arranged so as to pass through the communication groove 49 formed in the winding partition collar 46 at the uppermost position. The first wire 22 is wound in a winding section S1 shown in FIG. 6A, and the other side of the first wire 22 from the center thereof is wound, for example, in a winding section S2.

Similarly, the center part of the second wire 32 is arranged so as to pass through the communication groove 49 formed in the winding partition collar 46 at the lowest position, and one side of the second wire 32 is wound, for example. The second wire 32 is wound around the partition wall S3, and the other side of the second wire 32 from the center thereof is wound around the winding section S4, for example. Thereby, each of the 2nd coil part 20 and the 2nd coil part 30 is arranged adjacently along the winding axis direction.

One first lead part 22a of the first wire 22 wound around the winding section S1 is pulled out from one side in the Y-axis direction of the winding section S1 toward the first terminal block 70_1, and It is connected to a terminal fitting 92 fixed to one side of 70_1 in the Y-axis direction. The other first lead portion 22a of the first wire 22 wound around the winding section S2 is pulled out from the other side in the Y-axis direction of the winding section S2 toward the first terminal block 70_1, and It is connected to a terminal fitting 91 fixed to the other side of 70_1 in the Y-axis direction.

As shown in FIGS. 3B and 6A, one second lead portion 32a of the second wire 32 wound around the winding section S3 is directed toward the second terminal block 70_2 in the Y-axis direction of the winding section S3. It is pulled out from one side and connected to a terminal fitting 93 fixed to one side of the second terminal block 70_2 in the Y-axis direction. The other second lead portion 32a of the second wire 32 wound around the winding section S4 is pulled out from the other side in the Y-axis direction of the winding section S4 toward the second terminal block 70_2, and It is connected to a terminal fitting 94 fixed to the other side of 70_2 in the Y-axis direction.

As shown in FIG. 4, a first terminal block installation part 41 and a second terminal block installation part 42 are integrally molded at both ends of the bobbin upper collar part 48 in the X-axis direction. A first terminal block 70_1 is installed in the first terminal block installation part 41, and a second terminal block 70_2 is installed in the second terminal block installation part 42. In this embodiment, the terminal blocks 70_1 and 70_2 are attached to the terminal block installation parts 41 and 42 so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin 40.

The first terminal block installation section 41 has a bottom section 414 having a substantially flat plate shape that is substantially parallel to the XY axis. The bottom portion 414 is formed on an extension line of the bobbin upper collar portion 48 in the X-axis direction, and constitutes a base in the first terminal block installation portion 41 .

An insulating wall 410 is formed at the inner end of the bottom portion 414 in the X-axis direction. The insulating wall 410 extends upward on the Z-axis, and includes the core 12 (base 13) shown in FIG. , 22a. In this embodiment, the "outside" is the side that is away from the central axis of the bobbin 40, and the "inside" is the side that is close to the central axis of the bobbin 40.

On the outer surface of the insulating wall 410 in the X-axis direction, a loose fitting convex portion 411 is formed that projects outward in the X-axis direction from a substantially central portion of the insulating wall 410 in the Y-axis direction. The loose fitting convex portion 411 has a main convex portion 412, a pair of sub convex portions 413a1, 413a1, and a pair of auxiliary sub convex portions 413a2, 413a2. The main convex portion 412 has a substantially flat plate shape parallel to the XZ axis, and protrudes outward in the X-axis direction from a substantially central portion of the insulating wall 410 in the Y-axis direction. The main convex portion 412 is formed approximately at the center of the Z-axis of the insulating wall 410, and has a predetermined length in the Z-axis direction.

The sub-convex portions 413a1, 413a1 and the auxiliary sub-convex portions 413a2, 413a2 are formed on both sides of the main convex portion 412 in the Y-axis direction, and are spaced apart from the bottom portion 414 by a predetermined height in the Z-axis direction. It is located. The sub-convex parts 413a1, 413a1 and the auxiliary sub-convex parts 413a2, 413a2 mainly have a function of limiting the movement width of the first terminal block 70_1 to one side and the movement width to the other side in the X-axis direction, Acts as a stopper. Note that the main convex portion 412 also plays a similar role.

One of the sub-convex portions 413a1 protrudes from the surface of the main convex portion 412 on one side in the Y-axis direction in the normal direction thereof, and extends toward the one side in the Y-axis direction. The other sub-convex portion 413a1 protrudes from the surface of the main convex portion 412 on the other side in the Y-axis direction in the normal direction thereof, and extends toward the other side in the Y-axis direction. Each sub-convex portion 413a1, 413a1 extends toward opposite sides in the Y-axis direction.

One auxiliary sub-convex part 413a2 is integrally formed at one end of one sub-convex part 413a1 in the Y-axis direction, and extends inward in the X-axis direction. An inner end in the X-axis direction of one of the auxiliary sub-convex portions 413a2 is connected to an outer surface of the insulating wall 410 in the X-axis direction. The other auxiliary sub-convex part 413a2 is integrally formed at the other end of the other sub-convex part 413a1 in the Y-axis direction, and is oriented substantially parallel to the one auxiliary sub-convex part 413a2. , extending inward in the X-axis direction. The inner end of the other auxiliary sub-convex portion 413a2 in the X-axis direction is connected to the outer surface of the insulating wall 410 in the X-axis direction.

On both sides of the main convex portion 412 in the Y-axis direction, a pair of retaining holes 419, 419, each consisting of a through hole, are formed. One of the retaining holes 419 is formed in a region surrounded by the main convex portion 412, one of the sub-convex portions 413a1, one of the auxiliary sub-convex portions 413a2, and the insulating wall 410. The other retaining hole 419 is formed in a region surrounded by the main convex portion 412, the other sub-convex portion 413a1, the other auxiliary sub-convex portion 413a2, and the insulating wall 410. Stopper protrusions 72c2, 72c2 of the first terminal block 70_1, which will be described later, are movably engaged with the retaining holes 419, 419, thereby preventing the first terminal block 70_1 from coming off from the first terminal block installation part 41. It is possible to prevent this.

A pair of restriction walls 415, 415 are formed at both ends of the bottom portion 414 in the Y-axis direction. The restricting walls 415, 415 are formed on both sides of the loose fitting convex portion 411 in the Y-axis direction, respectively. One of the limiting walls 415 protrudes upward from the bottom 414 along the Z-axis at one end of the bottom 414 in the Y-axis direction, and has a predetermined length toward one side in the Y-axis direction. The other limiting wall portion 415 protrudes from the bottom portion 414 in the Z-axis direction at the other end of the bottom portion 414 in the Y-axis direction, and has a predetermined length on the other side in the Y-axis direction. The limiting walls 415, 415 each have a function of limiting the movement width of the first terminal block 70_1 to one side and the movement width to the other side in the X-axis direction, and serve as a stopper.

Step portions 416, 416 are formed on the outer surfaces of the limiting walls 415, 415 in the X-axis direction. The step portion 416 formed in one of the limiting wall portions 415 is formed in a region on one side in the Y-axis direction from the approximate center in the Y-axis direction, and forms a step recessed inward in the X-axis direction. ing. The step portion 416 formed in the other limiting wall portion 415 is formed in a region on the other side in the Y-axis direction from the approximate center portion in the Y-axis direction, and forms a step recessed inward in the X-axis direction. ing. A predetermined gap is formed between the restriction wall portion 415 and the loose fitting convex portion 411 (the sub-convex portion 413a1 and the auxiliary sub-convex portion 413a2), and the Y-axis direction width of this gap is equal to the width of the first terminal block 41. This corresponds to the width of movement of the y-axis to one side or the other side in the Y-axis direction.

Bobbin-side guide portions 417, 417 are integrally formed on the outer surfaces of the limiting walls 415, 415 in the X-axis direction. The bobbin side guide parts 417, 417 are arranged in the first lead part so as to form a predetermined gap between the ends E1, E1 in the Y-axis direction of the first terminal block 70_1 and the first lead parts 22a, 22a, respectively. 22a, 22a are guided toward the terminal fitting 91 (92).

Each bobbin-side guide portion 417 has a pair of protrusions 417a1 and 417a2 that protrude outward in the X-axis direction. The protrusions 417a1 and 417a2 are arranged adjacent to each other at a predetermined interval in the Y-axis direction. The protruding portion 417a1 is formed at a position close to the loose fitting convex portion 411, and the protruding portion 417a2 is disposed at a position of the limiting wall portion 415 where the stepped portion 416 is formed. The protrusions 417a1 and 417a2 have a predetermined thickness in the Z-axis direction, and the thickness of the protrusion 417a1 in the Z-axis direction is greater than the thickness of the protrusion 417a2 in the Z-axis direction, and the thickness of the limiting wall 415 in the Z-axis direction. It's smaller. Furthermore, the width of the protrusion 417a2 that protrudes outward in the X-axis direction is smaller than the width of the protrusion 417a1 that protrudes outward in the X-axis direction.

A lead insertion passage 418 through which the first lead portion 22a is inserted is formed between each of the pair of protrusions 417a1 and 417a2. By inserting the first lead part 22a into the lead insertion passage 418, the first lead part 22a can be guided toward the terminal fitting 91 (92) by the bobbin side guide part 417 (see FIG. (See 3A).

Lead insertion passage 418 extends in the Z-axis direction and has a predetermined depth in the X-axis direction. The width of the lead insertion passage 418 in the Y-axis direction is equal to or greater than the diameter of the first lead portion 22a. The depth of the lead insertion passage 418 in the X-axis direction is such that the first lead part 22a inserted therein does not come out to the outside of the lead insertion passage 418, and is preferably equal to the diameter of the first lead part 22a. It is the same or better.

As shown in FIG. 7, the first lead portion 22a is pulled out of the lead insertion passage 418 in the Z-axis direction. The first lead part 22a is drawn out diagonally from the winding part of the first coil part 20 toward the terminal 91 (or 92), but rather 41 (near the end in the Y-axis direction), it is raised substantially vertically upward from the Z-axis, and is pulled out to the outside in the Y-axis direction in a bent state from the Z-axis direction toward the Y-axis direction.

Predetermined gaps G1, G1 are formed between the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction and the first lead parts 22a, 22a. In this embodiment, the bobbin side guide parts 417, 417 are provided at positions spaced apart from the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction so that gaps G1, G1 are formed. Therefore, when the first lead parts 22a, 22a are inserted into the lead insertion passages 418, 418, the first lead parts 22a, 22a are forcibly inserted from the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction. It is possible to place them in separate positions. The length (distance) W1 of the gaps G1, G1 is equal to or greater than the movable distance of the first terminal block 70_1 in the Y-axis direction. Alternatively, the distance between the gaps G1 and G1 is equal to or greater than the wire diameter of the first wire 22.

The bobbin-side guide portions 417, 417 are formed at one end of the bobbin upper collar portion 48 in the X-axis direction, outside the movable range A1 of the first terminal block 70_1 in the Y-axis direction in the Y-axis direction. Therefore, when the first terminal block 70_1 moves toward one side or the other side in the Y-axis direction, a part of the end E1 of the first terminal block 70_1 in the Y-axis direction (in particular, the first terminal block 70_1 The lower end portions) do not come into contact with the bobbin side guide portions 417, 417 (particularly the protruding portions 417a1, 417a1) or the first lead portions 22a, 22a inserted through the lead insertion passages 418, 418. Therefore, the first terminal block 70_1 can move in the Y-axis direction without being interfered with by the bobbin side guide parts 417, 417 or the first lead parts 22a, 22a. Note that the movable range A1 of the first terminal block 70_1 in the Y-axis direction corresponds to the range between the maximum movement position of the first terminal block 70_1 in the Y-axis direction on one side and the maximum movement position on the other side. do.

As shown in FIG. 5B, the configuration of the second terminal block installation part 42 is partially common to the configuration of the first terminal block installation part 41, including an insulating wall 420, a loose fitting convex part 421, a main convex part 422, and a sub-convex part. The structure of the portions 423a1, 423a1, the auxiliary sub-convex portions 423a2, 423a2, the bottom portion 424, the limiting wall portions 425, 425, the step portions 426, 426, and the retaining holes 429, 429 are the same as the above-mentioned insulating wall 410, loose fitting convex portion. 411, main convex portion 412, sub convex portions 413a1, 413a1, auxiliary sub convex portions 413a2, 413a2, bottom portion 414, restriction wall portions 415, 415, step portions 416, 416, and retaining holes 429, 429. , a detailed explanation thereof will be omitted.

Further, the insulating wall 420, the sub-convex parts 423a1, 423a1, the auxiliary sub-convex parts 423a2, 423a2, the limiting walls 425, 425, and the retaining holes 429, 429 are connected to the insulating wall 410, the sub-convex parts 413a1, 413a1, and the auxiliary sub-convex parts, respectively. The convex portions 413a2, 413a2, the limiting walls 415, 415, and the retaining holes 419, 419 perform the same function for the second terminal block 70_2 as they do for the first terminal block 70_1.

Insertion parts 427, 427 are formed on the outer surfaces of the limiting walls 425, 425 in the X-axis direction. Insertion holes 427a, 427a having a predetermined depth in the X-axis direction are formed in the insertion portions 427, 427. Insert pieces 52, 52 of an insulating cover 50, which will be described later, are inserted into the insertion holes 427a, 427a, thereby making it possible to fix the insulating cover 50 to the second terminal block installation part 42.

As shown in FIG. 5A, terminal fittings (terminals) 91 and 92 are attached to the first terminal block 70_1. Further, as shown in FIG. 5B, the terminal fittings (terminals) 93 and 94 are attached to the second terminal block 70_2. The terminal fittings 91 and 92 have shapes that are line symmetrical to each other about the X-axis and the Z-axis, and the terminal fittings 93 and 94 have shapes that are line-symmetrical to each other about the X-axis and the Z-axis. The terminal fittings 91 and 93 have similar shapes, and the terminal fittings 92 and 94 have similar shapes. Each of the terminal fittings 91 to 94 can be formed by pressing a conductive plate material such as a metal plate.

As shown in FIG. 5A, the terminal fittings 91 and 92 have wire connection parts 91a and 92a for sandwiching and joining the lead part 22a of the first wire 22, respectively. Further, the terminal fittings 91 and 92 have hook portions 91b and 92b formed at positions different from the wire connection portions 91a and 92a, respectively. The hook parts 91b and 92b are inserted into terminal grooves 74 and 74 formed in the first terminal block 70_1, respectively, so as to be movable in the Z-axis direction.

The hook portions 91b, 92b are formed to protrude downward in the Z-axis direction from the end portions in the Y-axis direction of the planar attachment portions 91c, 92c, respectively, and the lower end tips of the hook portions 91b, 92b are It is shaped like a hook. Insertion holes 91d and 92d are formed in the center portions of the mounting portions 91c and 92c, respectively. The insertion holes 91d and 92d are roughly aligned with the bolt holes of the nuts 306 installed in the mounting holes 76 provided in the first terminal block 70_1, so that the respective terminal fittings 91 and 92 are connected to the first terminal block 70_1. can be attached to. Fasteners such as bolts or screws 304 shown in FIG. 1 are attached to these insertion holes 91d and 92d, and the terminal fittings 91 and 92 can be positioned and attached to the circuit board 300 via the fasteners.

The attachment parts 91c, 92c and the wire connection parts 91a, 92a are integrally connected by connecting parts 91e, 92e, respectively. The connecting portions 91e and 92e have a portion that is flush with the plane of the attachment portions 91c and 92c, and a stepped bent portion that is bent downward substantially perpendicularly to the portion. The width of the connecting portions 91e and 92e in the X-axis direction is narrower than the width of the attachment portions 91c and 92c in the X-axis direction.

Insertion projections 91f, 92f protruding downward in the Z-axis direction from the plane of the mounting parts 91c, 92c are formed at the ends of the mounting parts 91c, 92c opposite to the hook parts 91b, 92b. be. The insertion protrusions 91f and 92f are respectively inserted into fitting grooves 75 and 75 formed on the upper surface of both ends in the Y-axis direction of the first terminal block 70_1.

The configuration of the terminal fittings 93, 94 is the same as that of the terminal fittings 91, 92, and includes wire connecting portions 93a, 94a, hook portions 93b, 94b, mounting portions 93c, 94c, insertion holes 93d, 94d, and connecting portions 93e, 94e. The configuration of the insertion holes 93f, 94f is as follows: the wire connection parts 91a, 92a, the hook parts 91b, 92b, the attachment parts 91c, 92c, the insertion holes 91d, 92d, the connecting parts 91e, 92e, and the insertion holes 91f, 92f. It is similar to the configuration. Lead portions 32a and 32a of the second wire 32 are connected to the terminal fittings 93 and 94, respectively.

In this embodiment, the first terminal block 70_1 and the second terminal block 70_2 are formed separately from the bobbin 40. The configuration of the second terminal block 70_2 is similar to the configuration of the first terminal block 70_1, so detailed description thereof will be omitted. As the material constituting the first terminal block 70_1 and the second terminal block 70_2, a resin different from that of the bobbin 40 can be selected, for example, a resin with better moldability than the bobbin 40, or a resin with better heat dissipation. can be selected. Specifically, resin materials such as PET, PBK, or PPS may be used.

As shown in FIGS. 4 and 5A, the first terminal block 70_1 has a main body 71. As shown in FIGS. A through hole 72 is formed in the base body 71, and the through hole 72 passes through the base body 71 in the X-axis direction. Terminal mounting portions 73, 73 are integrally formed on both sides of the base body 71 in the Y-axis direction. Attachment holes 76, 76 are formed in substantially central portions of the upper surfaces of the terminal attachment portions 73, 73, respectively, and a nut 306 can be attached to each attachment hole 76, respectively.

Terminal grooves 74, 74 are formed at the boundaries between the terminal mounting parts 73, 73 and the stand main body 71, respectively, and the hook parts 91b, 92b of the terminal fittings 91, 92 are respectively formed in the terminal grooves 74, 74. It is inserted movably in the Z-axis direction. In addition, fitting grooves 75, 75 are formed on the upper surfaces of the ends of the terminal mounting parts 73, 73 in the Y-axis direction, into which the insertion convex parts 91f, 92f of the terminal fittings 91, 92 are inserted, respectively. . As a result, the terminal fittings 91, 92 are restricted from moving in the X-axis and Y-axis directions with respect to the first terminal block 70_1, and the terminal fittings 91, 92 are restricted in movement in the Z-axis direction with respect to the first terminal block 70_1. Only directional movement is allowed.

The wire connection parts 91a, 92a of the terminal fittings 91, 92 are located outside along the Y-axis direction from both ends of the first terminal block 70_1 in the Y-axis direction, and the upper surface of the wire connection parts 91a, 92a is the mounting part 91c. , 92c is located below the Z-axis.

On the side of the through hole 72 formed in the base body 71 facing the bobbin 40, a loose fitting recess 72a into which the loose fitting convex portion 411 formed in the first terminal block installation part 41 is inserted is formed. . In this embodiment, a part of the inner wall constituting the loose fitting recess 72 is constituted by an elastically deformable support piece 72c1 that can widen the width of the opening entrance of the loose fitting recess 72 in the Z-axis direction. be. A pair of stopper protrusions 72c2, 72c2 are formed on the tip side of the support piece 72c1. The stopper protrusions 72c2, 72c2 engage with the pair of retaining holes 419, 419, and have a function as a retainer. The stopper protrusions 72c2, 72c2 are formed at a predetermined interval in the Y-axis direction. In order to elastically deform the support piece 72c1 into a cantilever shape, slits are formed on both sides of the support piece 72c1 in the Y-axis direction.

When the stopper convex portions 72c2, 72c2 are engaged with the retaining holes 419, 419, gaps are formed in the X-axis direction and the Y-axis direction between each retaining hole 419 and each stopper convex portion 72c2, respectively. ing. Therefore, the first terminal block 70_1 can freely slide (slide) in each of the X-axis direction and the Y-axis direction within the range of this gap with respect to the first terminal block installation part 41. It has become.

The loose fitting recess 72a has a main recess 72a1, a sub recess 72a2, and an auxiliary sub recess 72a3. These recesses have an approximately T-shape as a whole when viewed from the X-axis direction, the main recess 72a1 constitutes a portion extending in the Z-axis direction, and the sub-recess 72a2 and the auxiliary sub-general portion 72a3 extend in the Y-axis direction. It constitutes the existing part. The sub-recess 72a2 and the auxiliary sub-recess 72a3 are each connected in the X-axis direction, and the auxiliary sub-recess 72a3 is located inside the sub-recess 72a2 in the X-axis direction. The sub-recess 72a2 and the auxiliary sub-recess 72a3 are each connected to the lower end of the main recess 72a1 in the Z-axis direction, and extend to one side and the other side of the main recess 72a1 in the Y-axis direction. The auxiliary sub-recess 72a3 is formed to be wider in the Y-axis direction than the sub-recess 72a2.

The main convex portion 412 (more specifically, the portion of the main convex portion 412 located above the upper surface of each of the sub-convex portions 413a1, 413a1 and the auxiliary sub-convex portions 413a2, 413a2) is inserted into the main concave portion 72a1. be done. Since the width of the main recess 72a1 in the Y-axis direction is larger than the width of the main projection 412 in the Y-axis direction (see FIG. 7), there is a gap in the Y-axis direction between the main recess 72a1 and the main projection 412. It is formed. Therefore, the main convex portion 412 is fitted into the main recess 72a1 within the range of this gap so as to be movable in the Y-axis direction, and accordingly, the first terminal block 70_1 is fitted into the first terminal block installation portion 41. It is possible to slide in the Y-axis direction within this gap. Note that the length corresponding to the difference between the width of the main recess 72a1 in the Y-axis direction and the width of the main convex portion 412 in the Y-axis direction (for example, half the length of the difference) is the width of the first terminal block 70_1 in the Y-axis direction. It is a movable distance.

A pair of sub-convex portions 413a1, 413a1 are inserted into the sub-concave portion 72a2. When the sub-convex parts 413a1, 413a1 are inserted into the sub-concave part 72a2, there is a gap between one end of the sub-convex part 413a1 in the Y-axis direction and one side of the sub-concave part 72a2 in the Y-axis direction. is formed. Further, a gap is formed between the end of the other sub-convex portion 413a1 on the other side in the Y-axis direction and the other side of the sub-recessed portion 72a2 in the Y-axis direction. Therefore, the sub-convex portions 413a1, 413a1 fit into the sub-concave portion 72a2 so as to be movable in the Y-axis direction within the range of these gaps. It is possible to slide in the Y-axis direction within the range of these gaps.

A pair of auxiliary sub-convex portions 413a2, 413a2 are inserted into the auxiliary sub-concave portion 72a3. When the auxiliary sub-convex parts 413a3, 413a2 are inserted into the auxiliary sub-concave part 72a3, the end of one auxiliary sub-convex part 413a2 on one side in the Y-axis direction and the one side of the auxiliary sub-concave part 72a3 in the Y-axis direction A gap is formed between them. Further, a gap is formed between the other end of the other auxiliary sub-convex portion 413a2 in the Y-axis direction and the other side of the auxiliary sub-concave portion 72a3 in the Y-axis direction. Therefore, the auxiliary sub-convex parts 413a2, 413a2 fit into the auxiliary sub-concave part 72a3 so as to be movable in the Y-axis direction within the range of these gaps, and accordingly, the first terminal block 70_1 is installed in the first terminal block. It is possible to slide in the Y-axis direction with respect to the portion 41 within the range of these gaps.

A mounting recess 72b is formed on the side of the through hole 72 opposite to the side facing the bobbin 40. The attachment recess 72b is connected to the outside of the sub-recess 72a2 in the X-axis direction. An inner cover 78 is attached to the attachment recess 72b.

The inner cover 78 is attached to the mounting recess 72b of the first terminal block 70_1 after the hook parts 91b, 92b of the terminal fittings 91, 92 are inserted into the terminal grooves 74, 74 of the first terminal block 70_1, respectively. This makes it possible to prevent the terminal fittings 91, 92 from slipping out of the first terminal block 70_1, and to limit the Z-axis movement range of the terminal fittings 91, 92 with respect to the first terminal block 70_1.

An outer cover 79 shown in FIGS. 3A and 3B is attached to the outside of the inner cover 78. The outer cover 79 covers the first terminal block 70_1 to which the inner cover 78 is attached, together with the terminal fittings 91 and 92, from the outside of the X-axis and the Y-axis. The outer cover 79 also covers the lower part of the Z-axis of the first terminal block 70_1, but does not cover the upper part of the Z-axis. In a state where the outer cover 79 is attached to the first terminal block 70_1, the outer cover 79 is movable relative to the bobbin 40 in the same direction so as to follow the relative movement of the first terminal block 70_1 in the X-axis and Y-axis directions. It is composed of

As shown in FIG. 5B, the insulating cover 50 includes a cover body 51, a pair of insertion pieces 52, 52, a lower fixing piece 53, and a pair of cover side guide parts 54, 54. The insulating cover 50 is detachably attached to the end of the bobbin 40 in the X-axis direction (the side where the second terminal block installation part 42 is arranged), and is attached to the first coil wound around the winding part 45 of the bobbin 40. It has a function of insulating the second lead portions 32a, 32a of the second coil portion 30 drawn out from the ends of the bobbin 40 in the X-axis direction toward the terminals 93, 94.

The cover main body 51 has a shape corresponding to the curved shape at the end of the bobbin 40 in the X-axis direction, and is arranged outside the first coil section 20 formed in the winding section 45 . The pair of insertion pieces 52, 52 are integrally formed at the upper end portion of the cover body 51, and are respectively formed at both ends of the cover body 51 in the Y-axis direction. The insertion pieces 52, 52 have a substantially flat plate shape parallel to the XY axis and protrude inward in the X axis direction. The insertion pieces 52, 52 are inserted into the insertion holes 427a, 427a of the second terminal block installation part 42.

The lower fixing piece 53 is integrally formed at the lower end of the cover body 51 and has a substantially flat plate shape parallel to the XY axis. The lower fixing piece 53 is arranged substantially parallel to the insertion pieces 52, 52. The lower fixing piece 53 protrudes inward in the X-axis direction and is fixed to the lower surface of the winding partition collar 46 located between the winding section S2 and the winding section S3 shown in FIG. 6A.

The cover-side guide portions 54, 54 are integrally formed on the outer surface of the cover body 51 in the X-axis direction, and are arranged at both ends of the cover body 51 in the Y-axis direction. The cover side guide parts 54, 54 have the same function as the bobbin side guide parts 417, 417, and as shown in FIG. 3B, the end E2 of the second terminal block 70_2 in the Y-axis direction and the second lead part 32a. The second lead portion 32a is guided toward the terminal fitting 93 (94) so as to form a predetermined gap G2 between the two leads. In this embodiment, bobbin side guide parts 417, 417 are integrally formed with the bobbin 40 at one end in the X-axis direction of the bobbin 40 (the side where the first terminal block 70_1 is arranged), and the bobbin At the other end in the X-axis direction of 40 (the side where the second terminal block 70_2 is arranged), cover-side guide parts 54, 54 are integrally formed with the insulating cover 50, which is configured separately from the bobbin 40. has been done.

As shown in FIGS. 3B and 5B, the cover side guide parts 54, 54 each have a pair of protrusions 54a1, 54a2 that protrude outward in the X-axis direction. The protrusions 54a1 and 54a2 are arranged adjacent to each other with a predetermined interval in the Y-axis direction. The protrusions 54a1 and 54a2 have a predetermined length in the Z-axis direction, and the protrusion length of the protrusion 54a2 in the X-axis direction is greater than the protrusion length of the protrusion 54a1 in the X-axis direction.

A lead insertion passage 55 through which the second lead portion 32a is inserted is formed between each of the pair of protrusions 54a1 and 54a2. By inserting the second lead portion 32a into the lead insertion passage 55, the second lead portion 32a can be guided toward the terminal fitting 93 (94) by the cover side guide portion 54.

The lead insertion passage 55 extends in the Z-axis direction and has a predetermined depth in the X-axis direction. The width of the lead insertion passage 55 in the Y-axis direction is equal to or longer than the diameter of the second lead portion 32a. The depth of the lead insertion passage 55 in the X-axis direction is such that the second lead part 32a inserted therein does not come out to the outside of the lead insertion passage 55, and is preferably equal to the diameter of the second lead part 32a. It is the same or better.

The second lead portion 32a is pulled out inside the lead insertion passage 55 in the Z-axis direction. The second lead part 32a is drawn out diagonally from the winding part of the second coil part 30 toward the terminal 93 (or 94), but rather 42 (near the end in the Y-axis direction), it is raised substantially vertically upward in the Z-axis direction, and is pulled out to the outside in the Y-axis direction in a bent state from the Z-axis direction toward the Y-axis direction.

Predetermined gaps G2, G2 are formed between the ends E2, E2 of the second terminal block 70_2 in the Y-axis direction and the second lead parts 32a, 32a. In this embodiment, the cover-side guide parts 54, 54 are provided at positions spaced apart from the ends E2, E2 of the second terminal block 70_2 in the Y-axis direction so that gaps G2, G2 are formed. Therefore, when the second lead parts 32a, 32a are inserted into the lead insertion passages 55, 55, the second lead parts 32a, 32a are forcibly inserted from the ends E2, E2 of the second terminal block 70_2 in the Y-axis direction. It is possible to place them in separate positions. The length (distance) of the gaps G2, G2 is equal to or greater than the movable distance of the second terminal block 70_2 in the Y-axis direction. Alternatively, the distance between the gaps G2 and G2 is equal to or greater than the wire diameter of the second wire 32.

The cover-side guide parts 54, 54 are formed outside the movable range of the second terminal block 70_2 in the Y-axis direction at the other end of the bobbin upper collar part 48 in the X-axis direction. Therefore, when the second terminal block 70_2 moves toward one side or the other side in the Y-axis direction, a part of the end E2 of the second terminal block 70_2 in the Y-axis direction (in particular, the second terminal block 70_2 The lower end portions) do not come into contact with the cover-side guide portions 54, 54 (particularly the protruding portion 54a1) or the second lead portions 32a, 32a that are inserted through the lead insertion passage 55. Therefore, the second terminal block 70_2 can move in the Y-axis direction without being interfered with by the cover-side guide parts 54, 34 or the second lead part 32a. Note that the movable range of the second terminal block 70_2 in the Y-axis direction is similar to the movable range A1 (FIG. 7) of the first terminal block 70_1 in the Y-axis direction.

In this embodiment, the diameter of the second wire 32 is larger than the diameter of the first wire 22, and at the other end of the bobbin 40 in the The lead portion 32a is guided toward the terminal 93 (94) by the cover side guide portions 54, 54.

An example of a method for manufacturing the coil device 10 will be described below. In manufacturing the coil device 10, first, a bobbin 40 shown in FIG. 2 is prepared. The material of the bobbin 40 is not particularly limited, but may include insulating materials such as resin.

Next, the first wire 22 is wound around the outer periphery of the hollow cylinder part 44 to form the first coil part 20 at the positions of the winding sections S1 and S2 of the bobbin 40 shown in FIG. 6A. Further, the second wire 32 is wound around the outer periphery of the hollow cylinder part 44 at the positions of the winding sections S3 and S4 of the bobbin 40 to form the second coil part 30. After forming the first coil section 20 and the second coil section 30, an insulating cover 50 is attached to the outer periphery of the bobbin 40 at the end of the bobbin 40 in the X-axis direction. The first wire 22 is not particularly limited, but a Litz wire or the like is preferably used. The same applies to the second wire 32.

Next, the first lead parts 22a, 22a are pulled out from the winding sections S1, S2 to mutually opposite sides in the Y-axis direction, and as shown in FIG. 5A, raised toward the Z-axis direction, and the bobbin side guide part 417, 417 into the lead insertion passages 418, 418. Thereby, the first lead parts 22a, 22a can be guided toward the terminals 91, 92 via the bobbin side guide parts 417, 417 while being sufficiently routed in the Y-axis direction and the Z-axis direction. It becomes possible. After the first lead parts 22a, 22a are inserted into the lead insertion passages 418, 418, they are bent in the Y-axis direction and pulled out to the outside in the Y-axis direction.

Further, the second lead parts 32a, 32a are pulled out from the winding sections S3, S4 to mutually opposite sides in the Y-axis direction, and raised toward the Z-axis direction, as shown in FIG. , 54 into the lead insertion passages 55, 55. This makes it possible to guide the second lead parts 32a, 32a toward the terminals 93, 94 via the cover-side guide parts 54, 54 in a state where the second lead parts 32a, 32a are sufficiently routed in the Y-axis direction and the Z-axis direction. It becomes possible. After the second lead parts 32a, 32a are inserted into the lead insertion passages 55, 55, they are bent in the Y-axis direction and pulled out to the outside in the Y-axis direction.

After that, as shown in FIGS. 5A and 5B, the first terminal block 70_1 and the second terminal block 70_2 are attached to the first terminal block installation part 41 and the second terminal block installation part 42 of the bobbin 40, respectively, in the X-axis direction. Move and install from the outside.

More specifically, as shown in FIG. 4, when attaching the first terminal block 70_1, the main concave portion 72a1 is fitted into the main convex portion 412 so as to be movable in the X-axis direction and the Y-axis direction, and the sub-convex portions 413a1, By fitting the sub-recessed part 72a2 into the auxiliary sub-convex part 413a1 so as to be movable in the X-axis direction and the Y-axis direction, and by fitting the auxiliary sub-recessed part 72a3 into the auxiliary sub-convex parts 413a2 and 413a2 so as to be movable in the X-axis direction and the Y-axis direction. conduct.

Further, as shown in FIGS. 4 and 5B, when attaching the second terminal block 70_2, the main concave portion 72a1 is fitted into the main convex portion 422 so as to be movable in the X-axis direction and the Y-axis direction, and the sub-convex portions 423a1, By fitting the sub-recessed part 72a2 into the auxiliary sub-convex part 423a1 so as to be movable in the X-axis direction and the Y-axis direction, and by fitting the auxiliary sub-recessed part 72a3 into the auxiliary sub-convex parts 423a2 and 423a2 so as to be movable in the X-axis direction and the Y-axis direction. conduct.

As shown in FIGS. 5A and 5B, when terminal fittings 91, 92 and terminal fittings 93, 94 are attached to the first terminal block 70_1 and the second terminal block 70_2, respectively, each terminal fitting 91, 94 is attached to the first terminal block 70_1 and the second terminal block 70_2, respectively. The lead portions 22a and 32a are connected to the wire connection portions 91a to 94a. The method for connecting each lead portion 22a, 32a to the wire connection portions 91a to 94a of each terminal fitting 91 to 94 is not particularly limited, and may include soldering, welding, resistance welding, ultrasonic welding, laser welding, Examples include caulking, thermocompression bonding, and heat fusion bonding.

Before attaching the terminal blocks 70_1, 70_2 to the terminal block installation parts 41, 42, each lead part 22a, 32a is connected in advance to the wire connection part 91a to 94a of each terminal fitting 91 to 94, and each terminal The metal fittings 91 to 94 may be attached to the terminal blocks 70_1 and 70_2.

After that, the inner covers 78, 78 are attached to the terminal blocks 70_1, 70_2. Further, before and after that, core covers 60, 60 shown in FIG. 2 are attached to both sides of the bobbin 40 in the Y-axis direction, and then the core 12 is attached from above and below in the Z-axis direction.

As described above, the coil device 10 according to the present embodiment has the terminal blocks 70_1 and 70_2 to which the terminals 91 to 94 are attached and which are attached to the bobbin 40 so as to be movable in both the X-axis direction and the Y-axis direction of the bobbin 40. Therefore, after roughly positioning the positions of each mounting hole 302 of the circuit board 300 and the positions of the terminals 91 to 94 of the coil device 10, the terminal blocks 70_1 and 70_2 are simply moved relative to the bobbin 40. The positions of the terminals 91 to 94 of the terminals 70_1 and 70_2 and each mounting hole 302 of the circuit board 300 can be accurately positioned and connected.

Further, in the coil device 10 according to the present embodiment, the positions of the terminals 91 to 94 of the terminal blocks 70_1 and 70_2 are accurately aligned with each mounting hole 302 of the circuit board 300 at the stage of manufacturing the coil device 10. There is no need for manufacturing, and the manufacturing and assembly of each component constituting the coil device 10 is facilitated, contributing to a reduction in manufacturing costs.

In particular, the coil device 10 according to the present embodiment is configured such that predetermined gaps G1, G1 are formed between the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction and the first lead parts 22a, 22a. It has bobbin side guide parts 417, 417 that guide the first lead parts 22a, 22a. In this way, by providing the bobbin side guide parts 417, 417, the first terminal block 70_1 can be smoothly moved in the Y-axis direction, as shown below.

When the first lead parts 22a, 22a are connected to the terminals 91, 92 by thermocompression bonding, etc., the first lead parts 22a, 22a become hardened and difficult to bend due to the influence of the heat in the areas where the thermocompression bonding etc. were applied. In this case, it may become difficult to move the first terminal block 70_1 connected to the first lead parts 22a, 22a via the terminals 91, 92 in the Y-axis direction. Therefore, by providing the bobbin side guide parts 417, 417 in the coil device 10 and routing the first lead parts 22a, 22a toward the terminals 91, 92 along the route guided by the bobbin side guide parts 417, 417, It becomes possible to provide the first lead parts 22a, 22a with a sufficient wire length, and when the first lead parts 22a, 22a are connected to the terminals 91, 92 by thermocompression bonding etc., It is possible to reduce the proportion of hardened portions and maintain sufficient flexibility of the first lead portions 22a, 22a. Therefore, movement of the first terminal block 70_1 in the Y-axis direction is prevented from being inhibited by the hardened portions of the first lead parts 22a, 22a, and smooth movement in the Y-axis direction by the first terminal block 70_1 is realized. Therefore, the accuracy of positioning the terminals 91, 92 of the first terminal block 70_1 and the circuit board 300 can be significantly improved.

Further, the first terminal block 70_1 can freely move within the range of the gaps G1, G1 without being hindered by the bobbin side guide parts 417, 417 or the first lead parts 22a, 22a guided by the bobbin side guide parts 417, 417. , when moving in the Y-axis direction, the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction come into contact with the bobbin-side guide parts 417, 417 or the first lead parts 22a, 22a guided by the bobbin-side guide parts 417, 417. It is possible to prevent this from happening. Therefore, also in this respect, smooth movement in the Y-axis direction by the first terminal block 70_1 is realized, and the above-mentioned effects can be obtained.

In addition, in the present embodiment, the bobbin side guide parts 417, 417 are arranged at ends E1, 417 of the first terminal block 70_1 in the Y-axis direction at a distance equal to or greater than the movable distance of the first terminal block 70_1 in the Y-axis direction. It is provided at a position spaced apart from E1. As a result, the bobbin side guide parts 417, 417 are arranged outside the movable range of the first terminal block 70_1 in the Y-axis direction, so the terminal block comes into contact with the guide part or the lead part guided by the guide part. It is possible to effectively prevent this from occurring, and it is possible to effectively realize smooth movement of the terminal block in the first axis direction.

Further, in this embodiment, the bobbin side guide parts 417, 417 have a pair of protrusions 417a1, 417a2 that protrude outward in the X-axis direction, and there is a space between each of the pair of protrusions 417a1, 417a2. , lead insertion passages 418, 418 are formed through which the first lead portions 22a, 22a are inserted. By inserting the first lead part 22a into the inside of each lead insertion passage 418, the pair of protrusions 417a1 and 417a2 restrict the positional shift of the first lead part 22a in the Y-axis direction, and the first terminal block The first lead portion 22a is prevented from entering the movement path of the terminal block 70_1 in the Y-axis direction, and smooth movement in the Y-axis direction by the first terminal block 70_1 can be effectively realized.

Further, in this embodiment, the bobbin 40 has the bobbin upper flange 48, and the bobbin side guide parts 417, 417 are connected to the Y-axis of the first terminal block 70_1 at the end of the bobbin upper flange 48 in the X-axis direction. It is formed outside the movable range A1 in the direction. By integrally forming the bobbin side guide parts 417, 417 with the bobbin upper collar part 48, it is possible to prevent the coil device 10 from increasing in size due to the formation of the bobbin side guide parts 417, 417. Moreover, by forming the bobbin side guide parts 417, 417 in the above region, the first lead part 22a can be directed toward the terminals 91, 92 so as to bypass the ends E1, E1 of the first terminal block 70_1 in the Y-axis direction. , 22a can be pulled out, giving a sufficient wire length to the first lead parts 22a, 22a, reducing the proportion of the portion that hardens due to the influence of heat due to thermocompression bonding, etc. The flexibility of 22a can be maintained sufficiently.

Moreover, in this embodiment, each of the first coil part 20 and the second coil part 30 is arranged adjacent to each other along the winding axis direction. Therefore, compared to, for example, arranging the first coil part 20 on the outer periphery of the bobbin 40 and arranging the second coil part 30 on the outside thereof, it is possible to reduce the number of parts, and the coil device 10 can be made more compact. can be achieved.

Further, in this embodiment, an insulating cover 50 that insulates the first coil part 20 and the second lead part 32 of the second coil part 30 is attached to the end of the bobbin 40 in the X-axis direction, and the insulating cover 50 is provided with cover side guide portions 54, 54. The cover-side guide parts 54, 54 connect the second leads so as to form predetermined gaps G2, G2 between the ends E2, E2 of the second terminal block 70_2 in the Y-axis direction and the second lead parts 32a, 32a. The parts 32a, 32a are guided. Therefore, based on the cover-side guide portions 54, 54, the same effects as those described above regarding the bobbin-side guide portion 417 can be obtained.

Furthermore, the insulation cover 50 can provide good insulation between the first coil section 20 and the second coil section 30. Further, by integrally forming the cover-side guide parts 54, 54 with the insulating cover 50, it is possible to prevent the coil device 10 from increasing in size due to the formation of the cover-side guide parts 54, 54.

Further, in this embodiment, the diameter of the second wire 32 is larger than the diameter of the first wire 22, and the second lead portion 32a of the second wire 32 having the larger diameter is guided by the cover side guide portion 54. . The second wire 32 with a larger diameter is originally highly rigid and difficult to bend, so if the second lead part 32a of the second wire 32 with a larger diameter hardens due to the influence of heat due to thermocompression bonding, etc., the second lead part 32a Flexibility is particularly likely to be impaired. Therefore, by routing the second lead portion 32a of the second wire 32, which has a larger diameter, along the lead insertion path 55 guided by the cover-side guide portion 54, the ratio of the hardened portion of the second lead portion 32a is reduced. This makes it possible to maintain flexibility as much as possible, and it is possible to effectively avoid the problem of inhibiting movement of the second terminal block 70_2 in the Y-axis direction.

The present invention is not limited to the embodiments described above, and can be variously modified within the scope of the present invention. For example, the arrangement of the first coil section 20 and the second coil section 30 shown in FIG. 6A may be reversed. Further, the first coil portion 20 may be used as a secondary coil, and the diameter of the first wire 22 may be made larger than the diameter of the second wire 32.

Furthermore, the method of winding the first wire 22 is not limited to alpha winding, but may also be aligned winding. Even with aligned winding, the effects of the present invention can be expected. The same applies to the second wire 32. Furthermore, the specific shape of the bobbin 40 or the specific shape of the core 12 is not limited to the embodiment described above, and can be modified in various ways.

In the above embodiment, an example of application of the present invention to a transformer is shown, but the present invention may be applied to other coil devices. For example, the coil device of the present invention can also be used for a reactor.

In the above embodiment, the arrangement of the loose fitting protrusions 411, 421 and the loose fitting recess 72a may be reversed. That is, the loose fitting protrusions 411 and 421 may be formed on the first terminal block 70_1 or the second terminal block 70_2, and the loose fitting recess 72a may be formed on the bobbin 40.

Furthermore, the manner in which the first wire 22 and the second wire 32 are wound inside the coil device 10 is not limited to the embodiment described above. For example, the first coil portion 20 may be formed on the outer periphery of the bobbin 40 (the winding portion 45), a bobbin cover may be attached to the outer side of the first coil portion 20, and the second coil portion 30 may be formed on the outer periphery of the bobbin cover. good. In this case, the first coil part 20 is arranged inside and the second coil part 30 is arranged outside, making it possible to arrange the first coil part 20 and the second coil part 30 in a double arrangement. Become.

In the above embodiment, the terminal blocks 70_1 and 70_2 are formed on both sides of the bobbin 40 in the X-axis direction, but one of the terminal blocks 70_1 and 70_2 may be formed only on one side in the X-axis direction.

DESCRIPTION OF SYMBOLS 10... Coil device 20... First coil 22... First wire 22a... First lead part 30... Second coil 32... Second wire 32a... Second lead part 40... Bobbin 41... First terminal block installation part 410... Insulation Wall 411... Loose fitting convex part 412... Main convex part 413a1, 413a1... Sub-convex part 413a2, 413a2... Auxiliary sub-convex part 414... Bottom part 415... Limiting wall part 416... Step part 417... Bobbin side guide part 417a1, 417a2... Projection part 418...Lead insertion path 419...Preventing hole 42...Second terminal block installation part 420...Insulating wall 421...Loose fitting convex part 422...Main convex part 423a1, 423a1...Subconvex part 423a2, 423a2...Auxiliary sub-convex part Part 424... Bottom part 425... Limiting wall part 426... Step part 427... Insertion part 427a... Insertion hole 429... Retaining hole 45... Winding part 50... Insulating cover 51... Cover body 52... Insert piece 53... Lower fixing Piece 54...Cover side guide part 54a1, 54a2...Protrusion part 55...Lead insertion passage 70_1, 70_2...Terminal block 71...Base body 72...Through hole 72a...Loose fitting recess 72a1...Main recess 72a2...Sub-recess 72a3...Auxiliary sub Recessed part 72b...Mounting recessed part 72c1...Support piece 72c2...Stopper convex part 73...Terminal mounting part 74...Terminal groove 75...Fitting groove 76...Mounting hole 91-94...Terminal fitting (terminal)
91a to 94a...Wire connection part 91b to 94b...Hook part 91c to 94c...Mounting part 91d to 94d...Through hole 91e to 94e...Connecting part 91f to 94f...Insertion convex part 300...Circuit board

Claims (8)

a bobbin having a winding part around which a wire is wound;
a terminal to which the lead portion of the wire is connected;
a terminal block to which the terminal is attached and is movably attached to the bobbin in both a first axial direction and a second axial direction of the bobbin;
A coil device comprising: a guide portion that guides the lead portion so as to form a predetermined gap between the end portion of the terminal block in the first axial direction and the lead portion. 2. The guide portion according to claim 1, wherein the guide portion is provided at a position spaced apart from an end of the terminal block in the first axial direction by a distance equal to or greater than a movable distance of the terminal block in the first axial direction. The described coil device. The guide part has a pair of protrusions that protrude outward,
3. The coil device according to claim 1, wherein a lead insertion path through which the lead portion is inserted is formed between each of the pair of protruding portions. The bobbin has a flange formed on the outer periphery of the winding part,
The coil according to any one of claims 1 to 3, wherein the guide portion is formed outside a movable range of the terminal block in the first axial direction at an end portion of the collar portion in the second axial direction. Device. The wire consists of a first wire and a second wire,
5. The bobbin according to claim 1, wherein a first coil part formed by winding the first wire and a second coil part formed by winding the second wire are formed on the bobbin. coil device. The coil device according to claim 5, wherein each of the first coil part and the second coil part is arranged adjacent to each other along a winding axis direction thereof. one of the first coil part and the second coil part; and the other of the first coil part and the second coil part drawn out from the end of the bobbin in the second axial direction toward the terminal. an insulating cover that insulates the lead from the bobbin, and an insulating cover is attached to the end of the bobbin in the second axis direction;
The coil device according to claim 5 or 6, wherein the guide portion is provided on the insulating cover. The diameter of one of the first wire and the second wire is larger than the diameter of the other;
The coil device according to any one of claims 5 to 7, wherein the lead portion of the wire having a larger diameter is guided by the guide portion.

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