CN117693797A

CN117693797A - Coil component

Info

Publication number: CN117693797A
Application number: CN202280051587.1A
Authority: CN
Inventors: 尹晃锡; 尹钟云
Original assignee: Mst Technology Co ltd
Current assignee: Mst Technology Co ltd
Priority date: 2021-08-12
Filing date: 2022-07-27
Publication date: 2024-03-12
Also published as: WO2023018067A1; KR102603589B1; KR20230024523A

Abstract

The present invention relates to a coil component comprising: a body (100) provided with a transformer bobbin (200) and a single coil bobbin (300); a core (400) coupled to the main body (100); and a plurality of coils (C1, C2, C3) wound around the transformer bobbin (200) and the single coil bobbin (300), respectively, and disposed inside the main body (100), and magnetically coupled to the core (400), wherein the core (400) is composed of an upper core (400) coupled to an upper portion of the main body (100) and a lower core (400) coupled to a lower portion of the main body (100), and the cores (400) are commonly used for the transformer bobbin (200) and the single coil bobbin (300). The invention can execute two functions by one product, thus realizing miniaturization, solving the insulation problem and the heating problem and having the advantage of improving the reliability of the product.

Description

Coil component

Technical Field

The present invention relates to a coil component, and more particularly, to a coil component for an electric and electronic device.

Background

Various coil components are used in the electric and electronic equipment to realize the stabilization of current, the voltage rise and fall, the noise elimination and the like. The coil component includes a transformer, PFC (Power Factor Correction, power factor corrector), an inductor, a capacitor, a line filter, and the like.

The transformer is a power supply conversion device for converting power to a desired value, and is used for increasing and decreasing voltage, and a plurality of different voltages can be obtained by combining a primary coil and a secondary coil. The inductor is used to ensure the stabilization of the current, absorb the variation of the current and achieve the stabilization by using the primary coil and the core. The line filter is provided in the form of a circular core around which a coil is wound in the middle of a signal line or a power line, and removes noise inputted or outputted through the signal line or the power line.

However, the conventional coil component is required to be mounted on a PCB (Printed Circuit Board ) substrate for each purpose, and thus the mounting area of the PCB substrate needs to be ensured, which makes it difficult to miniaturize the electric and electronic equipment.

Disclosure of Invention

Technical problem

The present invention provides a coil component which is manufactured as one product by providing a transformer, a single coil component, and the like in one device in such a manner that miniaturization of an electric and electronic apparatus can be achieved and which can perform two functions.

Technical proposal

According to the features of the present invention for achieving the objects described above, the coil component of the present invention includes: a body provided with a transformer bobbin and a single coil bobbin; a core combined with the body; and a plurality of coils wound around the transformer bobbin and the single coil bobbin, respectively, and disposed inside the main body so as to be magnetically coupled to the core, wherein the core is composed of an upper core coupled to an upper portion of the main body and a lower core coupled to a lower portion of the main body, and the transformer bobbin and the single coil bobbin share the core.

The upper core and the lower core include: a flat plate portion; a first leg portion and a second leg portion protruding vertically from both sides of the flat plate portion; an intermediate partition plate protruding perpendicularly from the flat plate portion between the first and second leg portions; a first intermediate leg portion protruding perpendicularly from the flat plate portion between the first both side leg portions and the intermediate partition plate; and a second intermediate leg portion protruding perpendicularly from the flat plate portion between the second side leg portions and the intermediate partition plate.

The body includes: a first core coupling hole in the transformer bobbin, into which the first middle leg is inserted; a second core coupling hole formed in the single coil bobbin, into which the second intermediate leg is inserted; and a third core coupling hole located in a separation space between the transformer bobbin and the single coil bobbin, into which the intermediate partition plate is inserted.

In the upper core and the lower core, a space where the first side leg portions and the intermediate separator of the upper core meet the first side leg portions and the intermediate separator of the lower core is larger than a space where the second side leg portions and the intermediate separator of the upper core meet the second side leg portions and the intermediate separator of the lower core.

The transformer bobbin of the main body is disposed in a space where the first leg portions and the intermediate separator of the upper core meet the first leg portions and the intermediate separator of the lower core, and the single coil bobbin of the main body is disposed in a space where the second leg portions and the intermediate separator of the upper core meet the second leg portions and the intermediate separator of the lower core.

The leg portions on both sides, the intermediate partition plate, and the intermediate leg portions have different thicknesses.

The thickness of the intermediate partition plate is the thickest.

The thickness of the middle leg is smaller than the thickness of the middle partition plate.

The thickness of the middle leg is 2 times that of the two side legs.

The upper core has two side legs, a middle partition plate and a middle leg joined to the lower core, respectively.

The upper core has two side legs and an intermediate partition plate joined to the lower core, respectively, and the upper core has an intermediate leg and an intermediate leg spaced apart from each other at opposite ends to form a gap (gap).

In the main body, the transformer bobbin and the single coil bobbin are arranged in parallel with each other while being spaced apart from each other, and are molded by a molding portion.

The transformer bobbin includes: a first transformer bobbin around which a first primary coil is wound, a first terminal pin connected to the first primary coil is provided, and a first core coupling hole is formed at a central portion thereof; and a second transformer bobbin around which a secondary coil is wound, a second terminal pin connected to the secondary coil being provided, a bobbin coupling hole being formed in a central portion, and the first transformer bobbin being coupled to the bobbin coupling hole of the second transformer bobbin such that the secondary coil is disposed outside the first primary coil.

The single coil bobbin includes: a second primary coil wound around the single coil bobbin; a third terminal pin connected to the second primary coil; and a fourth terminal pin having a second core coupling hole formed in a central portion of the single coil bobbin.

The fourth terminal pin is a temporary terminal pin.

The first terminal pin and the third terminal pin are respectively formed in plurality and are arranged at a distance from each other at one side of the body.

ADVANTAGEOUS EFFECTS OF INVENTION

The invention can execute two functions by arranging a transformer, a single coil component and the like in one device to manufacture one product, and form integration by sharing one core, so that the mounting area of a substrate required by a circuit is reduced, thereby having the effect of being beneficial to miniaturization of electronic equipment.

The present invention also has an effect of improving productivity of coil components by forming a separate bobbin structure to wind the coil, and thus, automatic winding can be achieved.

In the present invention, the thickness of the middle leg portion is larger than the thickness of the two side leg portions of the core, and the thickness of the middle partition plate separating the transformer bobbin and the single coil bobbin is made the thickest, so that the problem of heat generation can be solved, and the insulation characteristics can be ensured by insulating the coils of the transformer bobbin and the single coil bobbin by the molding part, thereby having the effect of solving the problem of electromagnetic wave interference.

Drawings

Fig. 1 is a perspective view showing a coil component of an embodiment of the present invention.

Fig. 2 is a plan view showing a coil part of an embodiment of the present invention.

Fig. 3 is a cross-sectional view taken along line A-A in fig. 1.

Fig. 4 is a perspective view showing a state before the core in the coil component of the embodiment of the present invention is coupled to the body.

Fig. 5 is a cross-sectional view showing shapes before and after bonding of the upper core and the lower core of the embodiment of the present invention.

Fig. 6 is a cross-sectional view showing the shape of the combined upper core and lower core of another embodiment of the present invention.

Fig. 7 is a core cross-sectional view of a comparative example for comparison with an embodiment of the present invention and another embodiment.

Fig. 8 is a view showing a cross section of a body cut through an embodiment of the present invention.

Fig. 9 is a perspective view illustrating a first transformer bobbin and a second transformer bobbin according to an embodiment of the present invention.

Fig. 10 is a perspective view illustrating a state in which a first transformer bobbin and a second transformer bobbin are combined according to an embodiment of the present invention.

Fig. 11 is a perspective view showing a single coil bobbin according to an embodiment of the present invention.

Fig. 12 is a perspective view showing a state in which a transformer bobbin and a single coil bobbin of an embodiment of the present invention are spaced apart and arranged side by side.

Fig. 13 is a perspective view showing a body of an embodiment of the present invention.

Fig. 14 is a diagram showing a coil junction diagram of an embodiment of the present invention.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

As an example, a Transformer and a Power Factor Correction (PFC) inductor have been conventionally configured by respective coil members, but in the present invention, the Transformer (Transformer) and the Power factor correction (PFC-Factor Correction) inductor share a single core and are integrated. In order to solve the problem of mutual interference caused by the common core, the shapes of the body and the core are specified.

Fig. 1 is a perspective view showing a coil component according to an embodiment of the present invention, fig. 2 is a plan view showing the coil component according to an embodiment of the present invention, fig. 3 is a sectional view taken along line A-A in fig. 1, and fig. 4 is a perspective view showing a state before a core in the coil component according to an embodiment of the present invention is coupled to a body.

As shown in fig. 1 to 3, a coil part 10 of an embodiment of the present invention includes a body 100 and a core 400 coupled to the body 100.

The body 100 is internally provided with coils C1, C2, C3. The body 100 includes a transformer bobbin 200 and a single coil bobbin 300, and coils C1, C2, and C3 are wound around the transformer bobbin 200 and the single coil bobbin 300, respectively. The coils C1, C2, C3 are magnetically coupled with the core 400 coupled to the body 100.

In the main body 100, a transformer bobbin 200 around which coils C1, C2, and C3 are wound and a single coil bobbin 300 are arranged side by side with a predetermined interval therebetween, and are molded by a molding portion 110. The molding portion 110 is made of an insulating material, and insulates the coils C1, C2, and C3 from the outside, and protects the coils C1, C2, and C3 in a wet environment.

According to fig. 3 and 4, the body 100 is formed in a substantially flat hexahedral shape, forming the molding flanges 111 on both sides, and forming the core coupling portion 113 in the middle thereof. The molded flange 111 is formed by surrounding the both side flange portions of the bobbin 200 and the single coil bobbin 300 around which the coils C1, C2, and C3 are wound by the molded portion 110, and the core joint portion 113 is a portion where a height difference is formed between the both side molded flanges 111, and is formed by surrounding the portion between the both side flanges of the bobbin 200 and the single coil bobbin 300 around which the coils C1, C2, and C3 are wound by the molded portion 110.

As shown in fig. 2 to 4, the body 100 includes terminal pins P1, P2, P3, P4 for connecting the coils C1, C2, C3 at the outside. The terminal pins P1, P2, P3, P4 are provided in plurality on one side and the other side of the body 100, and the respective terminal pins P1, P2, P3, P4 are arranged to be spaced apart from each other. In the embodiment, the plurality of first and third terminal pins P1 and P3 are arranged to be spaced apart from each other at one side of the body 100, and the plurality of second and fourth terminal pins P2 and P4 are arranged to be spaced apart from each other at the other side of the body 100.

The first terminal pin P1 may be an input terminal and the second terminal pin P2 may be an output terminal. The third terminal pin P3 includes both an input terminal and an output terminal, and the fourth terminal pin P4 may be a temporary terminal pin. As an example, the first terminal pin P1 is an input terminal of the transformer bobbin 200, the second terminal pin P2 is an output terminal of the transformer bobbin 200, and the third terminal pin P3 includes both the input terminal and the output terminal of the single coil bobbin 300. Also, the third terminal pin P3 may partially include a temporary terminal pin for maintaining balance with other terminal pins.

The main body 100 is formed with core coupling holes 215, 305, 115 penetrating the core coupling portion 113 up and down. The core 400 is bonded to the core bonding portion 113 and the core bonding holes 215, 305, 115. The core coupling holes 215, 305, 115 include a first core coupling hole 215, a second core coupling hole 305, and a third core coupling hole 115. The first core coupling hole 215, the second core coupling hole 305, and the third core coupling hole 115 are formed in parallel with each other at a predetermined interval in the core coupling portion 113.

In essence, the first core coupling hole 215 is formed in the transformer bobbin 200, the second core coupling hole 305 is formed in the single coil bobbin 300, and the third core coupling hole 115 is formed in the separate space of the transformer bobbin 200 and the single coil bobbin 300, and is finally formed by the molding part 110 covering the coils C1, C2, and C3 of the transformer bobbin 200 and the single coil bobbin 300.

The interval between the first core coupling hole 215 and the second core coupling hole 305 and the interval between the second core coupling hole 305 and the third core coupling hole 115 correspond to the interval between the intermediate leg portion and the intermediate partition plate of the core 400, which will be described later. The core 400 is vertically coupled to the core coupling portion 113, the first core coupling hole 215, the second core coupling hole 305, and the third core coupling hole 115 of the body 100.

The core 400 includes: an upper core 410 coupled with an upper portion of the body 100; and a lower core 420 coupled to a lower portion of the body 100, the transformer bobbin 200 and the single coil bobbin 300 sharing the core 400. The core 400 surrounds the coils C1, C2, C3 included in the body 100 to form a magnetic circuit, thereby controlling the current flow of the coils.

Fig. 5 is a sectional view showing the shapes before and after the combination of the upper core and the lower core of the embodiment of the present invention, fig. 6 is a sectional view showing the shapes after the combination of the upper core and the lower core of another embodiment of the present invention, and fig. 7 is a core sectional view of a comparative example for comparison with the embodiment of the present invention and the other embodiment.

As shown in fig. 5, the core 400 includes an upper core 410 and a lower core 420 formed in a vertically symmetrical shape. The upper core 410 and the lower core 420 are formed in a shape including a flat plate portion a, both side leg portions b, f, and a middle separator d, and middle leg portions c, e.

Specifically, the upper core 410 and the lower core 420 vertically protrude from both sides of the flat plate portion a to form first both side leg portions b and second both side leg portions f, and the intermediate partition d vertically protrudes from the flat plate portion a between the both side leg portions b, f, and the first intermediate leg portion c and the second intermediate leg portion e are formed in a shape vertically protruding from the flat plate portion a between the both side leg portions b, f and the intermediate partition d. That is, the upper core 410 and the lower core 420 form the following structure: between the first and second side legs b, f, 2 intermediate legs c, e and 1 intermediate partition d are formed.

When the upper core 410 and the lower core 420 are coupled to the main body 100, the flat plate portions a of the upper core 410 and the lower core 420 are respectively coupled to the upper surface and the lower surface of the core coupling portion 113, the first side leg portions b and the second side leg portions f are respectively coupled to the side surfaces of the core coupling portion 113, the first middle leg portions c and the second middle leg portions e are respectively inserted into the first core coupling hole 215 and the second core coupling hole 305, and the middle separator d is inserted into the third core coupling hole 115.

As shown in fig. 5, in the upper core 410 and the lower core 420, the two spaces s1, s2 on the left side in the drawing are larger than the two spaces s3, s4 on the right side with respect to the intermediate partition d. The left two spaces s1, s2 are combined with the transformer bobbin 200 of the body 100, and the right two spaces s3, s4 are combined with the single coil bobbin 300 of the body 100.

Specifically, in the upper core 410 and the lower core 420, the spaces s1, s2 formed by the first side leg portions b of the upper core 410 and the intermediate separator d meeting the first side leg portions b of the lower core 420 and the intermediate separator d are larger than the spaces s3, s4 formed by the second side leg portions f of the upper core 410 and the intermediate separator d meeting the second side leg portions f of the lower core 420 and the intermediate separator d. The transformer winding bobbin 200 of the main body 100 is disposed in spaces s1 and s2 formed by the first side leg portions b and the intermediate separator d of the upper core 410 and the first side leg portions b and the intermediate separator d of the lower core 420, and the single coil winding bobbin 300 of the main body 100 is disposed in spaces s3 and s4 formed by the second side leg portions f and the intermediate separator d of the upper core 410 and the second side leg portions f and the intermediate separator d of the lower core 420.

In the upper core 410 and the lower core 420, the thicknesses of the both side leg portions b, f and the intermediate separator d and the intermediate leg portions c, e are different from each other. Since the coil part 10 is formed in a structure in which a transformer and a single coil part (for example, PFC inductor) are integrated by sharing one core 400, it is important to prevent leakage of a magnetic circuit or electromagnetic interference (EMI) problems and reduce heat generation. For this purpose, the thicknesses of the two side leg portions b, f and the intermediate partition d and the intermediate leg portions c, e are made different from each other.

Preferably, in the upper core 410 and the lower core 420, the thickness of the middle leg portions c, e and the thickness of the middle partition d are greater than the thickness of the both side leg portions b, f. Alternatively, in the upper core 410 and the lower core 420, the thickness of the intermediate partition d is greater than the thickness of the intermediate leg portions c, e. That is, the thickness of the intermediate leg portions c, e is smaller than the thickness of the intermediate partition plate d.

More preferably, in the upper core 410 and the lower core 420, the thickness of the middle leg portions c, e is greater than the thickness of the both side leg portions b, f, and the thickness of the middle spacer d is greater than the thickness of the middle leg portions c, e.

Since the two side leg portions b and f are required to solve the problem of leakage of the magnetic circuit, miniaturization of the coil component 10 can be facilitated by minimizing the thickness, the magnetic circuit can be facilitated by making the thickness of the intermediate leg portions c and e larger than the thickness of the two side leg portions b and f, and heat generation can be reduced by making the thickness of the intermediate spacer d larger than the thickness of the intermediate leg portions c and e. When the thickness of the intermediate separator d separating the transformer bobbin 200 and the single coil bobbin 300 is made larger than the thickness of the intermediate legs c, e, the amount of heat generation is small, as compared with the case where the intermediate legs c, e and the intermediate separator d existing between the both side legs b, f are made to have the same thickness. This is because the intermediate separator d will prevent interference between the coils C1, C2 of the transformer and the coil C3 of the single coil part.

If the thickness of the intermediate separator d separating the transformer bobbin 200 and the single coil bobbin 300 is made the same as the thickness of the intermediate leg portions C, e, the coils C1, C2 of the transformer and the coil C3 of the single coil part interfere and EMI problems easily occur, and thus a heat generation phenomenon occurs. If the heat generation is serious, there is a problem that the function of the electronic device to which the coil component is attached is lowered, and thus it is important to reduce the heat generation.

Preferably, the thickness of the middle leg portions c, e is 2 times the thickness of the two side leg portions b, f, and the thickness of the middle partition d is 1.3 times the thickness of the middle leg portions c, e. For example, the thickness of the leg portions b and f is 2.2mm, the thickness of the leg portions c and e is 4.4mm, and the thickness of the intermediate separator d is 5.7mm.

The both side legs b, f of the upper core 410 and the intermediate separator d and the intermediate legs c, e are joined to the both side legs b, f of the lower core 420 and the intermediate separator d and the intermediate legs c, e, respectively, by epoxy resin. The epoxy may be a special epoxy adhesive. The epoxy resin fixes the coupled state of the core 400 and the body 100, and stably maintains the state in which the both side legs b and f of the upper core 410 and the lower core 420 and the middle spacers d and the middle legs c and e are in contact with each other.

Alternatively, as another example, as shown in fig. 6, the both side legs b, f of the upper core 410-1 and the middle spacer d are joined with the both side legs b, f of the lower core 420-1 and the middle spacer d by epoxy, and the middle legs c, e of the upper core 410-1 and the middle legs c, e of the lower core 420-1 may be spaced apart from each other at opposite ends to form a gap (gap). The gap (gap) may be used for tuning the inductance value of each of the transformer and the single coil component.

As shown in fig. 7, although the both side legs b, f of the upper core 410a and the lower core 420a are bonded by epoxy resin, if the intermediate separator d and the intermediate legs C, e of the upper core 410a and the intermediate separator d and the opposite ends of the intermediate legs C, e of the lower core 420a are all spaced apart to form a gap (gap), the coils C1, C2 of the transformer and the coil C3 of the single coil component interfere with each other and EMI problems are likely to occur, and thus, problems of heat generation may occur, which is not preferable. For reference, the both side legs b, f of the upper core 410a and the lower core 420a may be joined by other adhesives than epoxy.

Further, although the intermediate separator d of the upper core 410b and the lower core 420b are bonded by epoxy resin, if the facing ends of the leg portions f on the single coil component side of the upper core 410b and the leg portions f on the single coil component side of the lower core 420b are further separated to form a gap (gap), magnetic tilt of the single coil component occurs, which is not preferable.

Therefore, if a gap (gap) is formed in the core in order to adjust the inductance value, it is preferable to form the gap (gap) by separating the opposite ends of the middle legs c, e of the upper core 410-1 and the middle legs c, e of the lower core 420-1 as shown in fig. 6.

The core 400 is formed of a ferromagnetic substance so that a ferromagnetic beam can be obtained. The ferromagnetic substance may be ferrite, and may preferably be Mn-Zn ferrite.

As shown in fig. 8, the body 100 includes a transformer bobbin 200 and a single coil bobbin 300. The transformer bobbin 200 is a power supply conversion device for converting electricity into a desired value, and is intended to raise and lower a voltage, and can be used as a transformer for obtaining various voltages by combining a primary coil and a secondary coil. The single coil bobbin 300 is used to achieve current stabilization and may be used as a PFC inductor that absorbs current variation and achieves stabilization using a primary coil and core. Although one coil is wound on the single coil bobbin 300 as an example, two or more coils may be wound according to the design. However, two or more coils wound around the single coil bobbin 300 do not mean a primary coil and a secondary coil.

In the main body 100, a transformer bobbin 200 and a single coil bobbin 300 are arranged side by side with a predetermined distance therebetween, and are molded by a molding portion 110.

The transformer bobbin 200 includes: a first transformer bobbin 210 around which a first primary coil C1 is wound; and a second transformer bobbin 230 around which the secondary coil C2 is wound. In the transformer bobbin 200, the first transformer bobbin 210 is engaged with the bobbin engaging hole 235 of the second transformer bobbin 230, and the secondary coil C2 is disposed outside the first primary coil C1. The second primary coil C3 is wound around the single coil bobbin 300.

Fig. 9 is a perspective view illustrating a first transformer bobbin and a second transformer bobbin according to an embodiment of the present invention, and fig. 10 is a perspective view illustrating a state in which the first transformer bobbin and the second transformer bobbin according to an embodiment of the present invention are combined.

As shown in fig. 9, the first transformer bobbin 210 includes: a first winding portion 211 that winds the first primary coil C1; and a first upper flange 213 and a first lower flange 214, each of which extends outward through the first winding portion 211 so as to support the first primary coil (reference numeral C1 in fig. 8). The first transformer bobbin 210 is provided with a first terminal pin P1 for connection with the first primary coil C1 at one side of the first lower flange 214, and a first core coupling hole 215 is formed at a central portion.

The plurality of first terminal pins P1 are arranged in a row on one side of the first lower flange 214. The first transformer bobbin 210 is formed of an insulating material, preferably a plastic injection molding.

The second transformer bobbin 230 includes: a second winding portion 231 that winds the secondary coil (reference numeral C2 in fig. 8); and a second upper flange 233 and a second lower flange 234, each of which is formed to extend outward through a second winding portion 231 so as to support the secondary coil C2. The second transformer bobbin 230 is provided with a second terminal pin P2 for connecting the secondary coil C2 at the other side of the second upper flange 233, and a bobbin coupling hole 235 is formed at the central portion.

The plurality of second terminal pins P2 are arranged in a row on the other side of the second upper flange 233. The second transformer bobbin 230 is formed of an insulating material, preferably a plastic injection molded article.

The second transformer bobbin 230 forms a relatively thin tapered portion 236 of a thickness gradually sloping downward toward the edge at the upper surface of the second upper flange 233. The tapered portion 236 is a portion for securing the thickness of the molding portion 110 by thinning the outer portion of the second upper flange 233 of the second transformer bobbin 230, and reinforces the overall structure of the body 100. That is, since the thickness of the molding part 110 corresponding to the space of the tapered part 236 is secured, the bonding strength of the transformer bobbin 200 and the molding part 110 is made stronger.

As shown in fig. 10, the first transformer bobbin 210 is engaged with the bobbin engaging hole 235 of the second transformer bobbin 230, and as shown in fig. 8, the secondary coil C2 is disposed outside the first primary coil C1.

Fig. 11 is a perspective view showing a single coil bobbin according to an embodiment of the present invention, fig. 12 is a perspective view showing a state in which the transformer bobbin and the single coil bobbin according to an embodiment of the present invention are spaced apart and arranged side by side, and fig. 13 is a perspective view showing a body according to an embodiment of the present invention.

As shown in fig. 11, the single coil bobbin 300 includes: a third winding unit 301 that winds the second primary coil C3; and a third upper flange 303 and a third lower flange 304, each of which is formed to extend outward through a third winding portion 301 so as to support the second sub-coil C3. The single coil bobbin 300 is provided with a third terminal pin P3 on one side of the third upper flange 303 and a fourth terminal pin P4 on the other side of the third upper flange 303. The fourth terminal pin P4 is a temporary terminal pin for maintaining balance with the third terminal pin P3, and the third terminal pin P3 may also include a part of the temporary terminal pin. The single coil bobbin 300 is formed with a second core coupling hole 305 penetrating up and down at a central portion.

The plurality of third terminal pins P3 are arranged in one side of the third upper flange 303, and the plurality of fourth terminal pins P4 are arranged in one row on the other side of the third upper flange 303. The single coil bobbin 300 is formed of an insulating material, preferably a plastic injection molded article.

As shown in fig. 12 and 13, the transformer bobbin 200 and the single coil bobbin 300 are wound with coils, respectively, and each coil is arranged in parallel with a fixed interval after being connected to a corresponding terminal pin by soldering or the like. In this state, the body 100 is formed by insert molding the transformer bobbin 200 and the single coil bobbin 300 and molding the same by the molding part 110. The heights of the transformer bobbin 200 and the single coil bobbin 300 are the same to facilitate molding.

The molding part (reference numeral 110 in fig. 8) surrounds the coils C1, C2, C3 of the transformer bobbin 200 and the single coil bobbin 300 and causes the ends of the coils C1, C2, C3 to be drawn out of the body 100 and bonded to the transformer bobbin 200 and the single coil bobbin 300 except for the core bonding holes 215, 305, 115 in such a manner as to leave the core bonding holes 215, 305, 115 and to be injection-molded. The molding 110 physically and firmly encloses the coils C1, C2, C3 and is electrically insulated from the outside. If the molding portion 110 is formed by injection molding the remaining portions except the core coupling holes 215, 305, 115, the coils C1, C2, C3 are not exposed to the outside, and thus the insulation performance is improved.

The molding portion 110 is injection molded so as not to expose the end portions of the coils C1, C2, and C3 connected to the terminal pins P1, P2, and P3, and is also formed to be thin in the winding portions 231 and 301, so that only the coils C1, C2, and C3 can be injection molded so as not to be exposed to the outside. Since such a molding portion 110 can secure insulation characteristics without increasing the size of the body 100 so much, miniaturization of components will be facilitated. Like the transformer bobbin 200 and the single coil bobbin 300, the molding part 110 is formed of a plastic injection molding.

If the transformer bobbin 200 and the single coil bobbin 300 are insert molded and formed by the molding part 110, the third core coupling hole 115 is formed between the transformer bobbin 200 and the single coil bobbin 300.

The first, second, third and fourth terminal pins P1, P2, P3, P4 may be formed in a shape in which copper (Cu) and tin (Sn) are coated on an iron (Fe) material to achieve excellent conductivity and excellent solder wettability and adhesion strength on a substrate. Alternatively, the first, second, third and fourth terminal pins P1, P2, P3, P4 may be formed in a shape in which an iron (Fe) material is coated with an alloy of copper (Cu) and tin (Sn).

As shown in fig. 14, the first transformer bobbin 210 winds 2 first primary coils, and respective ends may be connected with 4 first terminal pins P1. Further, 3 secondary coils are wound around the second transformer bobbin 230, and each end portion thereof may be connected to 6 second terminal pins P2. Further, 2 second primary coils are wound around the single coil bobbin 300, and each end portion may be connected to 2 third terminal pins P3.

As an example, the total volume of the coil component 10 may be 68mm×60mm×13mm. The coils C1, C2, C3 may use USTC copper wire. The small wire diameter of the USTC copper wire is 0.1mm, the number of the small wires is 50-60, and the diameter can reach about 1.0-1.15 mm. Although the USTC copper wire has an advantage of low cost, it has a disadvantage that it is necessary to fill an epoxy resin or to use an insulation tube or an insulation tape to the maximum extent for insulation, and in an embodiment, the first primary coil C1 and the second coil C2 can be insulated by using the molding part 110, and the coils C1 and C2 of the transformer bobbin 200 and the coil C3 of the single coil bobbin 300 can be completely separated for insulation, so that insulation characteristics can be ensured without using an expensive triple insulated copper wire.

Alternatively, coils C1, C2, C3 may be used by mixing a USTC copper wire and a LITZ copper wire. LITZ copper wire is formed by bundling copper wires of the same thickness or different thicknesses in parallel. Like the USTC copper wire, the LITZ copper wire also has the advantage of low cost, but has a problem of insulation, but insulation characteristics can be ensured by using the molding part 110 of the present invention.

In the embodiment of the invention, the transformer, the single coil component and the like are arranged on one device to manufacture one product and can perform two functions, and the volume and the area of the product can be reduced to 47% at maximum, so that the area reduction design of the PCB substrate can be realized and the simplified design of the PCB substrate can be realized.

Also, in the embodiment of the present invention, automatic winding may be achieved by the independent bobbin structures of the first transformer bobbin 210, the second transformer bobbin 230, and the single coil bobbin 300, and thus productivity of the coil part may be improved. In addition, the conventional two or more products can be manufactured as one product to realize the design change of the EMI Block (Block) circuit.

Table 1 below shows an example in which the embodiments of the present invention are manufactured into products and applied.

TABLE 1

As shown in table 1, the leakage inductance Lk of No. 1, no. 3, no. 2, and No. 4 were measured by shorting the first terminal pin No. 2 and the first terminal pin No. 4 on the substrate. As a result of the measurement, the leakage inductance Lk was measured to be 90uH or less. From the above results, it can be confirmed that the insulating property can be ensured by manufacturing two or more components as one product.

Further, the experimental results showed that, when the thickness of the intermediate separator forming the boundary between the transformer bobbin and the single coil bobbin was made the same as the thickness of the intermediate leg portion, heat generation occurred at the boundary between the transformer bobbin and the single coil bobbin, but if the thickness of the intermediate separator was made 130% of the thickness of the intermediate leg portion, the heat generation was reduced.

Therefore, in the present invention, the problem of heat generation can be solved by making the thickness of the intermediate separator of the core the thickest, the transformer bobbin and the single coil bobbin can be separated by making the intermediate separators of the upper core and the lower core facing each other in contact, and the transformer bobbin and the single coil bobbin can be insulated by the molding part, whereby insulation characteristics can be ensured, and the problem of electromagnetic wave interference can be solved.

In the above embodiment, the description has been made taking an example in which the transformer, the single coil component, and the like are provided in one device to manufacture one product and perform two functions, but the present invention is not limited to this, and two coil components having different functions may be manufactured as one product. However, the manufacturing of two transformers as one component will affect each other and thus cannot constitute one product.

An embodiment of the invention is characterized in that the transformer and the single coil part are manufactured as one product by arranging them in one device, preferably the single coil part is a PFC inductor. A transformer means a component including a primary coil and a secondary coil, and a single coil component means a component including only the primary coil.

The invention is disclosed in the drawings and specification in the form of a number of preferred embodiments. Although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the claims. Thus, it will be appreciated by those skilled in the art that various modifications and other embodiments of the invention will be made, and equivalents will be formed, thereto. Accordingly, the true technical scope of the present invention should be determined according to the technical ideas within the scope of the appended claims.

Claims

1. A coil component is characterized in that,

comprising the following steps:

a body provided with a transformer bobbin and a single coil bobbin;

a core combined with the body; and

a plurality of coils wound around the transformer bobbin and the single coil bobbin, respectively, disposed inside the body and magnetically coupled to the core,

the core is composed of an upper core combined with the upper part of the body and a lower core combined with the lower part of the body, and the transformer bobbin and the single coil bobbin share the core.

2. The coil component of claim 1, wherein said upper core and said lower core comprise:

a flat plate portion;

a first leg portion and a second leg portion protruding vertically from both sides of the flat plate portion;

an intermediate partition plate protruding perpendicularly from the flat plate portion between the first and second leg portions;

a first intermediate leg portion protruding perpendicularly from the flat plate portion between the first both side leg portions and the intermediate partition plate; and

and a second intermediate leg portion protruding perpendicularly from the flat plate portion between the second side leg portions and the intermediate partition plate.

3. The coil component of claim 2, wherein said body comprises:

a first core coupling hole in the transformer bobbin, into which the first middle leg is inserted;

a second core coupling hole formed in the single coil bobbin, into which the second intermediate leg is inserted; and

and a third core coupling hole located in a separation space between the transformer bobbin and the single coil bobbin, into which the intermediate partition plate is inserted.

4. A coil component as claimed in claim 2, characterized in that,

in the above upper core and the above lower core,

the space formed by the first two side legs and the middle partition plate of the upper core and the first two side legs and the middle partition plate of the lower core is larger than the space formed by the second two side legs and the middle partition plate of the upper core and the second two side legs and the middle partition plate of the lower core,

a transformer bobbin having the main body disposed in a space where the first leg portions and the intermediate partition plate of the upper core meet the first leg portions and the intermediate partition plate of the lower core,

and a single coil bobbin of the main body is disposed in a space where the second leg portions and the intermediate separator of the upper core meet the second leg portions and the intermediate separator of the lower core.

5. The coil component according to claim 2, wherein thicknesses of the two side leg portions, the intermediate partition plate, and the intermediate leg portion are different from each other.

6. A coil component according to claim 2, wherein the thickness of the intermediate separator is the greatest.

7. The coil component of claim 2, wherein the thickness of the intermediate leg is less than the thickness of the intermediate spacer.

8. The coil component of claim 2, wherein the thickness of said middle leg is 2 times the thickness of said two side legs.

9. The coil component of claim 2, wherein the upper core has two side legs, the intermediate separator and the intermediate leg respectively engaged with the lower core.

10. A coil component as claimed in claim 2, characterized in that,

the two side legs and the middle partition board of the upper core are respectively connected with the two side legs and the middle partition board of the lower core,

the middle leg of the upper core and the middle leg of the lower core are spaced apart from each other at opposite ends to form a gap.

11. The coil component according to claim 1, wherein the transformer bobbin and the single coil bobbin are arranged in the main body in a spaced apart and side-by-side relationship and are molded by a molding portion.

12. The coil component of claim 1, wherein the coil component comprises a coil,

the transformer bobbin includes:

a first transformer bobbin around which a first primary coil is wound, a first terminal pin connected to the first primary coil is provided, and a first core coupling hole is formed at a central portion thereof; and

a second transformer bobbin around which a secondary coil is wound, a second terminal pin connected to the secondary coil is provided, a bobbin coupling hole is formed at a central portion,

the bobbin coupling hole of the second transformer bobbin is engaged with the first transformer bobbin such that the secondary coil is disposed outside the first primary coil.

13. The coil component of claim 12, wherein the coil component comprises a coil,

the single coil bobbin includes:

a second primary coil wound around the single coil bobbin;

a third terminal pin connected to the second primary coil; and

a fourth terminal pin is provided which is provided with a third pin,

a second core coupling hole is formed at a central portion of the single coil bobbin.

14. The coil component of claim 13, wherein said fourth terminal pin is a temporary terminal pin.

15. The coil component of claim 13, wherein the first terminal pin and the third terminal pin are formed in plural numbers, respectively, and are arranged to be spaced apart from each other on one side of the body.