Coil device

Patent metadata

Field	Value
Publication number	US-12462965-B2
Application number	US-202117318358-A
Country	US
Kind code	B2
Filing date	May 12, 2021
Priority date	May 14, 2020
Publication date	Nov 4, 2025
Grant date	Nov 4, 2025

Abstract

A coil device includes a first core, a second core, and a conductor. The first core includes a first leg. The second core is disposed with a gap between the first leg and the second core. The conductor is at least partly disposed between the first core and the second core. A notch is formed on the conductor at a position corresponding to the gap.

First claim

What is claimed is:

1 . A coil device comprising:
a first core including a first leg; a second core disposed with a gap between the first leg and the second core and separated from the first core; and a conductor at least partly disposed between the first core and the second core, wherein a notch is formed on the conductor at a position corresponding to the gap, the conductor is an elongated body having an outer surface and an inner surface opposite to the outer surface, the notch notches the outer surface without penetrating the elongated body from the outer surface to the inner surface, the conductor includes a conductor side part extending along the first leg, and a mounting part being bent substantially perpendicularly to the conductor side part and extending outward along a bottom of the first leg, the notch is formed continuously from the conductor side part to the mounting part, the mounting part is arranged in a notch-shaped side groove formed at an end of the first leg of the first core, a ratio of a width of the notch in a direction perpendicular to an extending direction of the notch to a width of the conductor in a direction perpendicular to an extending direction of the conductor is 0.3 to 0.5, the notch-shaped side groove defines opening connecting an interior of the coil device with an exterior of the coil device, the mounting part is arranged in the opening, an end surface of the mounting part is exposed through the opening to the exterior of the coil device, and the ratio remains 0.3 to 0.5 in the opening.

2 . The coil device according to claim 1 , wherein the notch is formed on the conductor along an edge of the first leg next to the conductor.

3 . The coil device according to claim 1 , wherein a depth of the notch is larger than a width of the gap.

4 . The coil device according to claim 1 , wherein
the second core includes a second leg disposed opposite to the first leg, and the notch is formed on the conductor at a position corresponding to the gap formed between the first leg and the second leg.

5 . The coil device according to claim 2 , wherein
the second core includes a second leg disposed opposite to the first leg, and the notch is formed on the conductor at a position corresponding to the gap formed between the first leg and the second leg.

6 . The coil device according to claim 4 , wherein the notch is made of a concave groove.

7 . The coil device according to claim 1 , wherein
the second core has a flat plate shape, and the notch is formed on the conductor at the position corresponding to the gap formed between the first leg and the second core.

8 . The coil device according to claim 2 , wherein
the second core has a flat plate shape, and the notch is formed on the conductor at the position corresponding to the gap formed between the first leg and the second core.

9 . The coil device according to claim 7 , wherein the notch is made of a chamfered portion obtained by chamfering a side of the conductor.

10 . The coil device according to claim 1 , wherein
the first leg includes a pair of outer legs and a middle leg disposed between the pair of outer legs, and the notch is formed on the conductor at the position corresponding to the gap formed between the second core and at least either one of the outer legs and the middle leg.

11 . The coil device according to claim 2 , wherein
the first leg includes a pair of outer legs and a middle leg disposed between the pair of outer legs, and the conductor includes the notch at the position corresponding to the gap formed between the second core and at least either one of the outer legs and the middle leg.

12 . The coil device according to claim 1 , wherein
the conductor has a curved shape, and the notch is formed on at least either one of an inner circumferential side and an outer circumferential side of the conductor.

13 . The coil device according to claim 1 , wherein
the mounting part is configured to be connected to an external circuit, and the notch is partly formed in the mounting part.

14 . The coil device according to claim 1 , wherein
a ratio of a width in a direction perpendicular to an extending direction of the notch to a width of the gap is 0.5-10.

15 . The coil device according to claim 1 , wherein
a ratio of a depth of the notch to a thickness of the conductor between the outer surface and the inner surface is 0.1-0.5.

16 . The coil device according to claim 1 , wherein
a ratio of a depth of the notch to a width of the gap is 0.5-5.

17 . A coil device comprising:
a first core including a first leg; a second core disposed with a gap between the first leg and the second core; and a plate-shaped conductor at least partly disposed between the first core and the second core and having an outer surface and an inner surface opposite to the outer surface, wherein a notch is formed on the outer surface of the conductor at a position corresponding to the gap, the notch has a first notch part and a second notch part apart from the first notch part along an extending direction of the conductor, the conductor includes a conductor side part extending along the first leg, and a mounting part being bent substantially perpendicularly to the conductor side part and extending outward along a bottom of the first leg, the first notch part is formed continuously from the conductor side part to the mounting part, the mounting part is arranged in a notch-shaped side groove formed at an end of the first leg of the first core, a ratio of a width of the notch in a direction perpendicular to an extending direction of the notch to a width of the conductor in a direction perpendicular to an extending direction of the conductor is 0.3 to 0.5, the notch-shaped side groove defines opening connecting an interior of the coil device with an exterior of the coil device, the mounting part is arranged in the opening, an end surface of the mounting part is exposed through the opening to the exterior of the coil device, and the ratio remains 0.3 to 0.5 in the opening.

18 . A coil device comprising:
a first core including first legs; a second core disposed with gaps between the first legs and the second core; and a conductor at least partly disposed between the first core and the second core, wherein notches are formed on the conductor at a position corresponding to all of the gaps, the conductor includes a conductor side part extending along the first leg, and a mounting part being bent substantially perpendicularly to the conductor side part and extending outward along a bottom of the first leg, at least a portion of the gaps is disposed at the bottom of the first leg, the mounting part is arranged in a notch-shaped side groove formed at an end of the first leg of the first core, a ratio of a width of the notch in a direction perpendicular to an extending direction of the notch to a width of the conductor in a direction perpendicular to an extending direction of the conductor is 0.3 to 0.5, the notch-shaped side groove defines opening connecting an interior of the coil device with an exterior of the coil device, the mounting part is arranged in the opening, an end surface of the mounting part is exposed through the opening to the exterior of the coil device, and the ratio remains 0.3 to 0.5 in the opening.

19 . The coil device according to claim 18 , wherein
the notches have an inner notch formed on an inner circumferential surface of the conductor and an outer

Assignees

• Tdk Corp

Inventors

• Wang Chen
• Sugimoto Satoshi

Classifications

• H01F17/04

  with magnetic core · CPC title

• H01F27/245

  made from sheets, e.g. grain-oriented (H01F27/26 takes precedence) · CPC title

• H01F27/2847

  Sheets; Strips (H01F27/2866 takes precedence) · CPC title

• H01F2027/348

  Preventing eddy currents · CPC title

• H01F27/341

  Preventing or reducing no-load losses or reactive currents · CPC title