Coil part

Patent metadata

Field	Value
Publication number	US-9728319-B2
Application number	US-201414496597-A
Country	US
Kind code	B2
Filing date	Sep 25, 2014
Priority date	Oct 11, 2013
Publication date	Aug 8, 2017
Grant date	Aug 8, 2017

Abstract

There is to provide a coil part capable of reducing the number of fastening means such as screws and so on required when attaching it to a substrate. A coil part includes a transformer unit and a reactor unit, wherein the transformer unit includes: a primary winding part formed by winding a flat wire around a primary side hollow part; secondary winding parts, the secondary winding part being formed by winding a flat wire around a secondary side hollow part communicating with the primary side hollow part, arranged in pairs in a state of facing one side and another side of the primary winding part respectively; and a first core inserted into the primary side hollow part and the secondary side hollow part, and the reactor unit includes: a reactor winding part formed by extending one terminal side of the flat wire constituting the secondary winding part and winding the flat wire around a reactor side hollow part; and a second core inserted into the reactor side hollow part.

First claim

What is claimed is:

1. A coil part comprising:
a transformer unit and a reactor unit, wherein
the transformer unit comprises:
a primary winding part formed by winding a flat wire around a primary side hollow part;
secondary winding parts, the secondary winding part being formed by winding a flat wire around a secondary side hollow part communicating with the primary side hollow part, arranged in pairs in a state of facing one side and another side of the primary winding part respectively; and
a first core inserted into the primary side hollow part and the secondary side hollow part, and

the reactor unit comprises:
a reactor winding part formed by extending one terminal side of the flat wire constituting the secondary winding part and winding the flat wire around a reactor side hollow part; and
a second core inserted into the reactor side hollow part,

wherein
the transformer unit and the reactor unit are each supported by a base and a cover;
the base is provided with a pedestal part, and a hollow support part extending from the pedestal part and inserted to the primary side hollow part or the secondary side hollow part;
the cover is provided with an upper positioning part having a stepped portion receiving the hollow support part and positioning at least a part of the first core or a part of the second core, and a side positioning part extending from both ends in the longitudinal direction of the upper positioning part and positioning at least a part of the first core or a part of the second core which opposes the hollow support part;
the primary winding part and the secondary winding parts of the transformer unit, or the reactor winding part of the reactor unit, penetrates through a space surrounded by the pedestal part, the hollow support part, the upper positioning part and the side positioning part.

2. The coil part according to claim 1 , wherein
the second core is composed of two core members butted each other via a magnetic gap member.

3. The coil part according to claim 2 , wherein
at least one of the primary winding part and the secondary winding part has a region where on an outer peripheral side of a winding part with a small diameter, a winding part with a diameter larger than the winding part with a small diameter is arranged adjacent thereto.

4. The coil part according to claim 1 , wherein
the secondary winding part is made by winding a plurality of the flat wires adjacent to each other, and
the reactor winding part is also made by winding the plurality of the flat wires adjacent to each other.

5. The coil part according to claim 2 , wherein
the secondary winding part is made by winding a plurality of the flat wires adjacent to each other, and
the reactor winding part is also made by winding the plurality of the flat wires adjacent to each other.

6. The coil part according to claim 1 , wherein
at least one of the primary winding part and the secondary winding part has a region where on an outer peripheral side of a winding part with a small diameter, a winding part with a diameter larger than the winding part with a small diameter is arranged adjacent thereto.

7. The coil part according to any one of claim 1 , wherein
a first magnetic path formed by the first core and a second magnetic path formed by the second core are provided to be almost parallel or almost perpendicular to each other.

8. The coil part according to claim 7 , wherein
the first magnetic path and the second magnetic path are provided to be almost perpendicular to each other,
the first core is constituted by two E-shaped cores butted each other, the E-shaped core being made by erecting outer legs at both ends of a columnar coupling base part respectively and erecting a middle leg between both the outer legs, and the butting is implemented in a state where the middle leg is inserted into the primary side hollow part and the secondary side hollow part, and
the second core is constituted by two U-shaped cores butted each other, the U-shaped core comprising a coupling part and a pair of outer legs coupled to the coupling part and opposite each other, and the butting is implemented in a state where one of the outer legs is inserted into the reactor side hollow part and another of the outer legs is located on a side away from the first core.

9. The coil part according to claim 1 , wherein
at least one of the primary winding part, the secondary winding part, and the reactor winding part is formed by edgewise-winding.

10. The coil part according to claim 1 , wherein
the first core is formed by abutting a pair of first E-shaped cores, and the first E-shaped core is provided with a first coupling base part, first outer legs erecting from both ends of the first coupling base part, and a first middle leg erecting between the first outer legs of the first coupling base part;
the second core is formed by abutting a pair of second E-shaped cores, and the second E-shaped core is provided with a second coupling base part and second outer legs erecting from both ends of the second coupling base part and second middle leg erecting from between the second outer legs of the second coupling base part;
the hollow support part supports the middle leg;
the upper positioning part positions the coupling base part, and the side positioning parts position the outer legs; and
the upper positioning part is provided with a through hole into which the middle leg passes from a side of the upper positioning part, and the stepped portion is provided around the through hole at the side from which the hollow support part passes.

Assignees

• Sumida Corp
• Toyota Motor Co Ltd

Inventors

• Kawashima Hiroshi
• Muto Jun
• Hirano Takahiro

Classifications

• H01F27/306

  Fastening or mounting coils or windings on core, casing or other support · CPC title

• H01F27/24

  Magnetic cores · CPC title

• H01F27/2823 Primary

  Wires (H01F27/2866 takes precedence) · CPC title

• H01F27/26

  Fastening parts of the core together; Fastening or mounting the core on casing or support (on coil H01F27/30) · CPC title

• H01F37/00

  Fixed inductances not covered by group H01F17/00 · CPC title