COIL COMPONENT AND DISPLAY DEVICE INCLUDING THE SAME

There are provided a coil component capable of easily mounting in a narrow mounting space, and a display device including the same. The coil component including: a bobbin including a cylindrical body part having a plurality of coils wound on an outer peripheral surface thereof, flange parts formed at both ends of the body part, and at least one or more core support parts protruded from outer surfaces of the flange parts; and a core coupled to the bobbin and seated on and fixed to the core support part.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1is a perspective view schematically showing a coil component according to an embodiment of the present invention andFIG. 2is an exploded perspective view ofFIG. 1. In addition,FIG. 3is a side view of the coil component ofFIG. 1andFIGS. 4 and 5are side views of a bobbin ofFIG. 2. Here,FIG. 5is a view showing the core coupled to the bobbin. In addition, the coil is omitted inFIGS. 2 and 3for convenience of explanation.

Referring toFIGS. 1 through 5, a coil component100according to an embodiment of the present invention may be an insulating type switching transformer mounted in a switch mode power supply (SMPS), an adapter, or the like, and may include a bobbin10, a core40, and a coil50.

The bobbin10may form an entire body of the coil component. The bobbin10may be easily manufactured by injection molding, but is not limited thereto. In addition, the bobbin10according to the present embodiment may be formed of an insulating resin and be formed of a material having high heat resistance and high voltage resistance. As a material of the bobbin10, for example, polyphenylenesulfide (PPS), liquid crystal polyester (LCP), polybutyleneterephthalate (PBT), polyethyleneterephthalate (PET), phenolic resin, and the like, may be used.

The bobbin10may include a winding part12having the coil50wound thereon and a terminal connection part20formed at one end of the winding part12.

The winding part12may include a body part13having a cylindrical shape and a flange part15extended from both ends of the body part13in an outer diameter direction.

An inner portion of the body part13may be provided with a through-hole11into which a portion of the core40is inserted. In the present embodiment, the through-hole11may be formed to have an oval shape (or a shape in which corner portions of a rectangular are rounded in a curved manner) elongated in a vertical direction. This configuration allows the coil component100according to the present embodiment to have a narrow width. Therefore, the present invention is not limited thereto, but may be changed as needed.

The coil50is wound on an outer surface of the body part13. The body part13may include at least one partition wall14formed on the outer peripheral surface thereof, and the partition wall14partitions a space in a length direction of the body part13. In this configuration, the coil50may be wound in each of the spaces partitioned by the partition wall14.

The winding part12according to the present embodiment may include a single partition wall14. Therefore, the winding part12according to the present embodiment may include two partitioned spaces. However, the present invention is not limited thereto. That is, a plurality of spaces may be formed through a plurality of partition walls as needed.

Meanwhile, although the case in which the partition wall14is formed integrally with the bobbin10is described by way of example in the present embodiment, the present invention is not limited thereto, but may be variously modified. For example, the partition wall14may also be formed as a separate member and be then coupled to the bobbin20.

The flange part15may protrude and to be extended from both ends, that is, upper and lower ends, of the body part13in the outer diameter direction. The flange part15according to the present embodiment may be divided into a first flange part15aand a second flange part15baccording to a formation position thereof.

In addition, a space between the first and second flange parts15aand15bon the outer peripheral surface of the body part13may be used as a winding space in which the coil50is wound. Therefore, the flange part15may serve to protect the coil50from the outside and secure an insulation property therebetween, while supporting the coil50wound in the winding space at both sides thereof.

Particularly, the bobbin10according to the present embodiment includes a core support part18for supporting the core40. The core support part18may be formed as a protrusion on the outer surface of the flange part15.

The core support part18is included to stably support the core40when the core40is coupled to the bobbin10. To this end, two core support parts18may be formed on one side of the flange part15(that is, a total of four core support parts18) so that connection parts43aand43bof the core40are supported in both directions of the flange part15. In addition, the two core support parts18formed on one side of the flange part15may be symmetrically disposed based on the through-hole11.

In addition, each of the core support parts18may include a supporting surface18ain contact with the core40to support the core40.

The supporting surface18aof the core support part18contacts the connection parts43aand43bof the core40and supports the core40. The core support parts18may have a shape corresponding to the shape of the connection parts43aand43bso as to stably support the core40.

In the present embodiment, the connection parts43aand43bof the core40may be formed to have a width increased in a direction toward second legs42aand42b, that is, in an upward direction thereof. Corresponding to the shape of the above-mentioned connection parts43aand43b, the two core support parts18facing each other may be formed in a shape in which an interval between the two core support parts is increased in a direction toward an upper portion of the supporting surface18aaccording to the shape of the connection parts43aand43bof the core40.

The terminal connection part20may be formed to be extended from the flange part15. More specifically, the terminal connection part20according to the present embodiment may be formed on each of the flange parts15aand15band may be protruded from lower portions of the flange parts15aand15b.

Meanwhile, referring toFIG. 2, since the terminal connection part20according to the present embodiment is partially extended from the flange part15, it may be difficult to clearly distinguish between the flange part15and the terminal connection part20. Therefore, the terminal connection part20according to the present embodiment may be perceived as a portion of the flange part15.

The terminal connection part20may include a plurality of external connection terminals34connected thereto.

The core40may be partially inserted into the through-hole11formed in the bobbin10and be electromagnetically coupled to the coil50to form a magnetic path.

The core40according to the present embodiment may be provided in pair. The pair of cores40may be partially inserted into the through-hole11of the bobbin10to thereby be coupled to each other.

The core40, which is a ferrite core formed to have an approximately U shape, may be used as a path of magnetic field generated according to flow of current in the coil.

The pair of cores40aand40bmay be formed to have the same shape such that they are symmetrical to each other. In this case, the pair of cores40may be simply manufactured, and assembly thereof may be facilitated.

In addition, the pair of cores40aand40bincludes first legs41aand41band the second legs42aand42b, and the first legs41aand41band the second legs42aand42bare connected by the connection parts43aand43b. The first legs41aand41bare coupled to face each other and the second legs42aand42bare coupled to face each other, thereby forming a continuous magnetic flux loop.

The first legs41aand41bare inserted into the through-hole11of the body part13. Therefore, cross-sections of the first legs41aand41bmay correspond to a cross-section of the through-hole11and the first legs41aand41bmay have a cross-sectional area smaller than that of the through-hole11so as to be easily inserted into the through-hole11.

In the present embodiment, the through-hole11has an oval-like cross-section. Therefore, the first legs41aand41balso have an oval-like cross-section.

Ends of the above-mentioned first legs41aand41bmay face each other at a central portion of the through-hole11and may be coupled to each other.

The second legs42aand42bmay be disposed in parallel with the body part13outside the bobbin10. In addition, the second legs42aand42baccording to the present embodiment may be formed to have a width wider than that of the first legs41aand41b.

More specifically, the second legs42aand42bmay partially enclose the bobbin10. In the present embodiment, the second legs42aand42bare disposed to entirely cover the upper portion of the bobbin10.

To this end, inner surfaces of the second legs42aand42b, that is, surfaces thereof facing the bobbin10may be formed to correspond to the shape of the bobbin10. In the present embodiment, the flange part15forming the upper portion of the bobbin10may be formed to have a semicircular (or an arc) shape. Therefore, the inner surfaces of the second legs42aand42bmay be concavely formed to have the semicircular shape correspondingly.

However, the present invention is not limited thereto, and in the case in which an upper end of the bobbin10is formed to have an angled shape, as shown inFIG. 7, the inner surfaces of the second legs42aand42bmay also be formed to have the angled shape.

The shape of the second legs42aand42bis intended to shield electromagnetic wave introduced from the outside. That is, the coil component100according to the present embodiment may maximally block the electromagnetic wave introduced from the outside to the coil50through the second legs42aand42bby forming an external area of the second legs42aand42bas widely as possible.

The connection parts43aand43bmay be used to make connection between the first legs41aand41band the second legs42aand42b. As described above, the second legs42aand42bmay be formed to have a width wider than that of the first legs41aand41b. Therefore, the connection parts43aand43bmay be formed to be expanded in the direction toward the second legs42aand42bsides.

In addition, both sides of the connection parts43aand43bcontact the supporting surface18aof the core support part18. That is, both sides of the connection parts43aand43bcontact the supporting surface18aof the core support part18, such that the core40is seated on the core support part18by gravity, whereby movement of the core40is fixed.

The core40may be formed of Mn—Zn based ferrite having higher permeability, lower loss, higher saturation magnetic flux density, higher stability, and lower production cost, as compared to other materials. However, in the embodiment of the present invention, a material of the core40is not limited.

Meanwhile, in order to secure insulation properties between the coil50wound on the bobbin10and the core40, an insulating cover (not shown) may be interposed between the bobbin10and the core40.

The insulating cover may be interposed between the bobbin10and the core40corresponding to the entire inner surface of the core40facing the bobbin10or be partially interposed therebetween only where the coil50and the core40face each other.

As the insulating cover, a cover formed of an insulating tape or a resin material may be used. However, the present invention is not limited thereto.

The coil50may be wound on the winding part12of the bobbin10and include primary and secondary coils.

Each of the primary coil and the secondary coil may include a plurality of individual coils that are electrically insulated from each other. Here, the number of the primary and secondary coils may be appropriately changed as needed.

Each of the primary and the secondary coils according to the embodiment of the present invention may be wound in the winding space partitioned by the partition wall14. Therefore, the insulation properties between the primary coil and the secondary coil may be secured by the partition wall14.

As the coil50according to the present embodiment, a general insulated coil (for example, a polyurethane wire, or the like), and a coil formed by twisting several strands of wires (for example, a Litz wire, or the like) may be used. In addition, a multi-insulated coil (for example, a triple insulated wire (TIW), or the like) having high insulation properties may be used. That is, types of the coils may be selected as needed.

The coil component100according to the present embodiment configured as described above has the second legs42aand42bof the core40disposed above the upper portion of the bobbin10, such that it may be manufactured to have a narrow width. Therefore, the coil component may also be easily mounted in a narrow mounting space.

In addition, in the coil component100according to the present embodiment, the core40disposed outside the bobbin10partially encloses the bobbin10. Therefore, electromagnetic wave introduced into the bobbin10may be maximally blocked without any additional element.

In addition, the core40according to the present embodiment is supported by the core support part18formed on the bobbin10, such that an interval between the bobbin10and the core40inserted into the bobbin may be equally maintained even when a plurality of coil components100are manufactured. A detailed description thereof will be provided below.

FIG. 6, a view illustrating a coil component according to an embodiment of the present invention, shows that the bobbin10has no core support part.

In order to easily insert the core40into the through-hole11of the bobbin10, the core40inserted into the through-hole11needs to have a cross-sectional area smaller than that of the through-hole11. Therefore, in the case in which the core support part18is omitted as shown inFIG. 6, the first legs41aand41bneed to be supported by contacting the inner wall of the through-hole11. In this case, the core40is coupled to the bobbin10while being tilted toward direction A or direction B.

That is, in the case in which the core support part18is not present, the core40of the coil component is fixed to the bobbin10in a state in which it is tilted toward the direction A or the direction B. Therefore, the interval between the core40and the coil50may be differently formed, such that the respective coil components100have different leakage inductance.

However, the coil component according to the present embodiment has the core40supported by the core support part18. In addition, the core support part18supports the connection parts43aand43brather than the first legs41aand41b.

Due to this configuration, the first legs41aand41bof the core40are always disposed at the same position (that is, the center of the through-hole) by the core support part18and the gravity without being tilted in a horizontal direction or a downward direction. Therefore, the core40according to the present embodiment may maintain a state in which the first legs41aand41bdo not support or contact the inner wall of the through-hole11, but are spaced apart from the inner wall of the through-hole by a predetermined interval, whereby a change or an increase in leakage inductance according to the position of the core may be minimized.

Meanwhile, the present invention is not limited to the above-mentioned configuration, but may be variously modified as needed.

FIG. 7is a side view showing a bobbin according to another embodiment of the present invention, corresponding toFIG. 5.

Referring toFIG. 7, in the coil component according to the present embodiment, the through-hole11of the bobbin10has a rectangular cross-section, and the first legs41aof the core40also have a rectangular cross-section.

In addition, the core40has the connection part43aseated on the core support part18and is coupled to the bobbin10.

As in the present embodiment, even in the case in which the through-hole11has the rectangular cross-section, an interval is generated between the first leg41aof the core40and the through-hole11of the bobbin10. Therefore, in the case in which the core support part18is not present, it is difficult for the core40to be fixed at an accurate position.

However, the coil component according to the present embodiment has the core40fixedly seated at the accurate position by the core support part18, whereby a change in leakage inductance due to the movement of the core40may be minimized.

FIG. 8is an exploded perspective view schematically showing a display device according to an embodiment of the present invention.

Referring toFIG. 8, a display device1according to the embodiment of the present invention may include a display panel4, a power supply5having the coil component100mounted therein, and covers2and8.

The covers2and8may include a front cover2and a back cover8and may be coupled to each other to thereby form a space therebetween.

The display panel4may be disposed in the internal space formed between the covers2and8. As the display panel4, various flat panel display panels such as a liquid crystal display (LCD), a plasma display panel (PDP), an organic light emitting diode (OLED), and the like, may be used.

The power supply (SMPS)5may provide power to the display panel4. The power supply5may be formed by mounting a plurality of electronic components on a printed circuit board6and particularly, may include at least one of the coil components100according to the above-mentioned embodiments mounted therein.

The power supply5may be fixed to a chassis7and be fixedly disposed in the internal space formed between the covers2and8together with the display panel4.

The coil component and the display device including the same are not limited to the above-described embodiments, and those skilled in the art will appreciate that various modifications, additions and substitutions are made, without departing from the scope and spirit of the invention.

In addition, in the above-described embodiment, the insulating type switching transformer has been described as an example of coil components. However, the present invention is not limited thereto, but may be variously applied to a component using a coil wound thereon such as a transformer for an inverter, a high frequency filter or the like, and an electronic device including the same.

As set forth above, in a coil component according to the embodiments of present invention, legs of a core disposed outside a bobbin are disposed above an upper portion of the bobbin, whereby the coil component may be manufactured to entirely have a narrow width. Therefore, the coil component may be easily mounted in a narrow mounting space.

In addition, since the core disposed outside the bobbin partially encloses the bobbin, electromagnetic wave introduced into the bobbin may be maximally blocked without any additional element.

In addition, the core is supported by a core support part formed on the bobbin, whereby the legs of the core do not support or contact an inner wall of a through-hole, but maintain a predetermined interval from the inner wall. Therefore, a change or increase in leakage inductance according to the position of the core may be minimized.