JP2007173699A - Magnetic component - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a magnetic component capable of reducing an accommodating space in the inside of a case of a power electronic circuit device. <P>SOLUTION: End portions 12, 14 of a square first coil portion 10 and a square second coil portion 11 of a reactor are led out obliquely for the external peripheral surfaces of the first coil portion 10 and the second coil portion 11. In this way, the protrusion lengths of the end portions 12, 14 can be reduced while ensuring a connection portion thereof. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an improvement in a magnetic component formed by winding a coil around a soft magnetic core. Here, the magnetic component includes both a reactor having one type of coil and a transformer having a plurality of types of coils. However, a reactor normally has a gap for preventing magnetic saturation in a magnetic path, but a transformer is required to minimize the gap.

  For example, in a power electronic circuit device such as a DCDC converter for a patent vehicle described in Patent Document 1 below, magnetic components such as a reactor and a transformer are widely used for current smoothing and input / output electrical insulation. A choke coil having a soft magnetic core is the same as a reactor. The DC-DC converter essentially requires high-speed switching, and superimposes a high-frequency switching noise voltage on the input voltage or output voltage. However, fluctuations in the voltage of the battery, which is a vehicle power supply, adversely affect its life. Therefore, in a DC / DC converter for a vehicle, a smoothing reactor that smoothes the input power or output power is an essential component. A DC / DC converter for a vehicle equipped with this type of reactor (including a choke coil with a core) is described in, for example, the following Patent Document 1 proposed by the present applicant.

  As a reactor used in a power range (several tens of watts to several tens of kW) applied to this type of vehicle power electronic circuit device, a dry reactor that is not immersed in oil is common. An example of this dry reactor is described in Patent Document 2 below, for example.

  The most common type of this dry reactor is the columnar core having two pillars parallel to each other and two beams that magnetically connect the ends of these pillars. Coiled. As another modified form, there is also known a Japanese character core in which one column portion is further added in parallel with the two column portions of the square core and the central column portion is a common magnetic path. Since these square-shaped cores and date-shaped cores have a square core shape, they are also referred to as square cores hereinafter. In addition, a sealed core having a peripheral wall-shaped column portion around a central column portion around which a coil is wound is known. Since this core has a short cylindrical shape or a thick disk shape, it is also referred to as a disk-shaped core hereinafter. A magnetic part having a disk-shaped core has the advantage that the electromagnetic noise is reduced because the coil is surrounded by the peripheral wall-shaped column part, and the coil length can be shortened, compared with the magnetic part having a square core. Usually, there is a disadvantage that the idle space is large in the case of the power electronic circuit device having a rectangular shape.

Both ends of the coil wound around the pillar portion of these cores are drawn in a direction perpendicular to the magnetic path perpendicular to the magnetic path of the pillar portion and connected to external wiring. As a coil conductor of a magnetic component of a power electronic circuit device, a system in which a bus bar-shaped long plate-like conductor piece is curved and used in order to reduce resistance loss is frequently used.
JP 2000-014149 A JP 2004-241475 A

  However, for example, in a vehicle DCDC converter mounted on a hybrid vehicle, a motor, a battery, and the like are mounted in an engine room in addition to an existing engine, and the mounting space and weight allowed for the vehicle DCDC converter are significantly restricted. There was a problem. That is, the present inventor has recognized that further reduction of the space for accommodating magnetic components in the case of a power electronic circuit device such as a DC / DC converter for a vehicle is particularly important in a vehicle application. This problem is essentially the same not only for hybrid vehicles but also for fuel cell vehicles and secondary battery vehicles that are expected to be put to practical use in the future. Similarly, since this problem is the same for the transformer mounted on the DCDC converter for vehicles, hereinafter, the reactor and the transformer are collectively referred to as magnetic parts. However, the magnetic component referred to in this specification does not include an air-core coil type that is not equipped with a soft magnetic core. Further, the above problem is essentially the same in various vehicle power electronic circuit devices other than the vehicle DCDC converter.

  The present invention has been made on the basis of the above-mentioned problem recognition, and an object thereof is to provide a magnetic component capable of reducing the accommodation space in the case of the power electronic circuit device.

  The magnetic component of the present invention, which has been made to solve the above problems, is a soft magnetic rectangular core having a substantially square magnetic path cross section and having at least two pillars parallel to each other to form a closed magnetic circuit. And a coil formed by winding an insulating-coated plate-like coil conductor around the column portion, and the coil is adjacent to one side surface of the column portion and substantially perpendicular to the magnetic path direction of the column portion. A turn part having a start side part and a final side part of the turn part extending in a certain direction and spirally wound around the pillar part a predetermined number of times, and the turn part apart from a side surface of the pillar part In a magnetic component having a terminal part that is drawn out from the outer peripheral surface of the turn part by extending in a direction substantially perpendicular to the magnetic path direction of the column part from the start side part and the last side part of the part, The terminal portion is in a plane substantially perpendicular to the magnetic path direction of the column portion. It is characterized by being drawn at a predetermined angle obliquely to Hajimehen portion and the final side portion of the turn portion Te. In addition, although the square core said here says the core in which especially the column part by which a coil is wound has a flat outer surface, it may be chamfered and curved in the boundary part of two flat outer surfaces. .

  That is, according to the present invention, in the magnetic part having the above-described rectangular core, both end portions (also referred to as terminal portions) of the coil drawn out from the magnetic part are arranged obliquely with respect to each side of the core in the cross section perpendicular to the magnetic path. This is the feature.

  In this way, the length of the protruding portion of the terminal portion from the flat outer surface of the coil formed along the flat outer surface of the pillar portion of the rectangular core is reduced, and the bare portion of the terminal portion necessary for connection is reduced. Length can be secured. In addition, this bare part means the part from which the insulating film was peeled off for electrical connection in the terminal part which is the end part of the coil conductor coated with insulation. That is, according to the present invention, it is possible to reduce the protruding length of the terminal portion protruding from the outer surface of the coil while ensuring the necessary length of the bare portion of the terminal portion necessary for connection with the external wiring, The required storage space for the magnetic component can be reduced, and the power electronic circuit device incorporating the magnetic component can be made compact.

  Furthermore, even if the first side or the last side of the coil is in close proximity to and parallel to the inner surface of the case that houses the power electronic circuit device, the bare portion of the terminal portion is arranged away from the inner surface of the case. Therefore, connection work becomes easy.

  In a preferred aspect, the terminal portion is curved with a predetermined curvature from the leading edge of the turn portion and the tip of the final edge portion. According to this aspect, not only the terminal portion, that is, the portion that protrudes from the outer surface of the coil, but also the portion that begins to separate from the outer surface of the core and reaches the terminal portion within the coil is bent with a predetermined curvature. In this way, the bending operation can be facilitated.

  In a preferred aspect, the turn part includes a first turn part wound around one of the two pillar parts, and a second turn part wound around the other of the two pillar parts. The last side terminal part of the first turn part and the start side terminal part of the second turn part are obliquely arranged in a direction close to each other and cross-coupled. If it does in this way, since the turn part of the above-mentioned coil can be wound around two pillar parts of a core in series, shortening the projection length of a terminal part, the number of turns can be earned.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, preferred embodiments of a reactor adopting the invention will be described with reference to the drawings. This reactor is used for current smoothing of a DCDC inverter for vehicles. However, the present invention should not be construed as being limited to the following embodiments, and it goes without saying that the technical idea of the present invention may be realized using other known techniques.

(First embodiment)
The whole structure of this reactor is shown in FIG.1 and FIG.2. The reactor 1 has a soft magnetic square core 2 and a coil 3 wound around the square core 2.

(core)
The U-shaped core 2 is formed by abutting two U-shaped cores 4 having the same shape. The U-shaped core 4 will be described with reference to FIGS. The U-shaped core 4 has two rectangular column portions 5 and one magnetic coupling portion 6 each formed by molding soft magnetic powder, and is formed in a U shape as a whole.

  The square column part 5 has two end faces (hereinafter also referred to as magnetic path end faces) through which magnetic flux enters and exits, and these two magnetic path end faces are arranged in parallel so as to face away from each other. The magnetic coupling portion 6 is a member that magnetically couples two rectangular column portions 5 that are arranged in parallel to each other, and has a small number of column portions that are continuous with the rectangular column portion 5. Bolt fastening holes 7 are formed in each corner of the magnetic coupling part 6 in the direction perpendicular to the magnetic path. The magnetic coupling part 6 has two magnetic path end faces on the same plane, and a magnetic path gap is formed between one magnetic path end face of the magnetic coupling part 6 and one magnetic path end face of one rectangular column part 5. A non-magnetic and electrically insulating spacer 8 is formed for forming the. In the U-shaped core 4 shown in FIGS. 3 and 4, the end surfaces of the magnetic paths on the side opposite to the spacer 8 of the two rectangular column parts 5 are exposed. The exposed magnetic path end faces of the two rectangular column parts 5 are also referred to as exposed magnetic path end faces 9. The B-shaped core 2 is configured by individually butting two exposed magnetic path end faces 9 of the two U-shaped cores 4 respectively. Note that a spacer similar to the spacer 8 is interposed between the two exposed magnetic path end faces 9 that are abutted with each other, as will be described later. The two rectangular column parts 5 which are abutted with each other are substantially accommodated in the coil 3 to form the column part referred to in the present invention. Therefore, the square-shaped core 2 is composed of two pillar portions and two magnetic coupling portions 6. Hereinafter, the two pillar portions may be referred to as a first pillar portion and a second pillar portion.

(coil)
The coil 3 is shown in FIG. The coil 3 is formed by connecting a first coil portion 10 wound around the first pillar portion of the lower core 2 and a second coil portion 11 wound around the second pillar portion of the lower core 2 in series. Become. Since a total of four rectangular column parts 5 constituting the first column part and the second column part each have a rectangular column shape, the first coil part 10 and the second coil part 11 each have a rectangular cylindrical coil shape. The first coil portion 10 and the second coil portion 11 are configured by bending a thick plate-like rectangular wire whose surface is coated with an insulating film in the width direction. The coil 3 is formed by winding a single flat wire, and the thickness direction of the flat wire is parallel to the magnetic path direction of the rectangular column portion 5.

  The coil 3 will be described in more detail with reference to FIG.

  Reference numerals 12 to 15 denote end portions (also referred to as terminal portions) of the first coil portion 10 and the second coil portion 11, and the insulating film at the tip portions is peeled off by a predetermined dimension. The first end portion 12 of the first coil portion 10 protrudes forward from the lower left side of the first coil portion 10, and the end portion 13 of the first coil portion 10 protrudes forward from the upper right side of the first coil portion 10. The end portion 14 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11, and the start end portion 15 of the second coil portion 11 protrudes forward from the upper left side of the second coil portion 11. Further, the terminal end portion 13 of the first coil portion 10 and the start end portion 15 of the second coil portion 11 are overlapped and welded in the vertical direction in FIG. 5, that is, in the magnetic path direction (column portion magnetic path direction) of the rectangular column portion 5. ing.

(Half core)
The U-shaped core 4 and the spacer 8 described above are integrated by resin insert molding to constitute a U-shaped half core 16 shown in FIG. That is, the U-shaped half core 16 includes the U-shaped core 4 and the spacer 8 and the resin coating portion 17 that covers them. As shown in FIG. 6, the resin coating portion 17 has irregularities for engaging and fitting the two U-shaped half cores 16. In this embodiment, the exposed magnetic path end surfaces 9 of the two rectangular column parts 5 are exposed from the resin coating part 17, but may be covered by the resin coating part 17 to a substantially constant thickness. In this case, the portion of the resin coating portion 17 that covers the exposed magnetic path end face 9 constitutes a spacer.

  The resin coating portion 17 is located at the center in the left-right direction of the two rectangular column portions 5 (actually covered by the resin coating portion 17) arranged in parallel with each other, and extends in the front-rear direction. The support 18 is integrally provided. The sensor holding spacer 18 may be manufactured separately from the resin coating portion 17. The sensor holding spacer 18 is a resin plate and is nonmagnetic and electrically insulating. Eventually, the square core 2 of the reactor 1 has a total of six magnetic gaps. The sensor holding spacer 18 is chamfered at the front and upper corners to constitute a linear taper surface 19 for defining a groove for inserting a temperature sensor described later.

(Assembly of reactor 1)
The assembly of the two U-shaped half cores 16 and the coil 3 will be described with reference to FIG. A spacer 20 is disposed between the exposed magnetic path end faces 9 of the two U-shaped half cores 16. The spacer 20 is, for example, a plate material such as resin, glass, or ceramic, and is fixed to the core end surface with an adhesive. Reactor 1 formed in this way is housed in a metal case 21 made of an aluminum alloy having a front end opening as shown in FIG. 8. Mold resin 22 is sealed in metal case 21 to seal reactor 1. ing.

  As shown in FIG. 8, the metal case 21 has a stepped protrusion 23 a protruding rearward at the center in the vertical direction of the bottom surface 23 on the rear end side. The metal case 21 has case holes 24 (see FIG. 9) respectively communicating with the two bolt fastening holes 7 provided in either of the two U-shaped cores 4. In FIG. 24 is not visible.

(Vehicle DCDC converter)
Next, the operation of assembling the reactor 1 to the vehicle DCDC converter will be described below with reference to FIG. FIG. 9 is a diagram illustrating a main part of the DC-DC converter for a vehicle.

  25 is a liquid-cooled inverter device for a DC-DC converter for a vehicle, and this inverter device 25 has a semiconductor card module 26 in which main electrodes are exposed on a total of 12 surfaces each incorporating a semiconductor element. The card module 26 is alternately stacked with a total of 13 liquid cooling fins 27. In addition, an electrical insulating film or sheet is interposed between the semiconductor card module 26 and the liquid cooling fin 27 for electrical insulation during the lamination. Note that a total of 12 semiconductor card modules 26 constitute switching elements or flywheel diodes for each of the three-phase arms. The liquid cooling fins 27 are formed by overlapping two identical aluminum plates and brazing their outer peripheral edges, and a liquid flow path is formed in the vertical direction inside. In addition, among the liquid cooling fins 27, black thick lines extending vertically in FIG. 9 indicate outer peripheral edges of the brazed liquid cooling fins 27. The upper ends of the liquid cooling fins 27 are brazed so that the liquid flow paths are formed in the left-right direction, thereby forming a so-called inflow header. Similarly, the lower end portion of each liquid cooling fin 27 is brazed so that the liquid flow path is formed in the left-right direction, thereby forming a so-called outflow header. In FIG. 9, a cooling liquid inflow pipe 29 and a cooling liquid outflow pipe 30 are brazed to the rightmost liquid cooling fin 27. Of course, the coolant inflow pipe 29 communicates with the right end of the inflow header, and the coolant outflow pipe 30 communicates with the right end of the outflow header.

  Reference numeral 31 denotes an aluminum alloy converter housing (case referred to in the present invention) that houses a DCDC converter for a vehicle, and is die-cast in a square box shape with one end opening. The above-described liquid cooling type inverter device 25 is fixed to the converter casing 31 together with the liquid cooling device having the SPS structure described above.

  Adjacent to the right end of the liquid-cooled inverter device 25, the reactor 1 is fixed by a bolt (not shown) that passes through the bolt fastening hole 7 and the case hole 24 and is fastened to the converter housing 31. . Only the bolt fastening hole 7 of the magnetic connecting portion 6 on the upper end side of the reactor 1 is fastened, but the bolt fastening hole 7 of the magnetic connecting portion 6 on the lower end side of the reactor 1 is free. That is, the reactor 1 and the metal case 21 to be accommodated do not have the case hole 24 communicating with the bolt fastening hole 7 of the magnetic coupling portion 6 on the lower end side of the reactor 1, and as a result, the reactor 1 is connected to the converter housing 31. One end is supported in the column magnetic path direction (vertical direction in FIG. 9), and the magnetic coupling portion 6 on the lower end side of the reactor 1 is a free end with respect to the converter housing 31 in the metal case 21.

  A side wall 21 a on the left end side of the metal case 21 that houses the reactor 1 is disposed in close contact with the right main surface of the rightmost liquid cooling fin 27 that forms the right end surface of the liquid cooling inverter device 25. In addition, in order to improve the adhesiveness between the left end side wall 21a of the metal case 21 and the rightmost liquid cooling fin 27, heat conductive grease may be applied, or both may be joined by various methods. .

  Of the first coil portion 10 and the second coil portion 11 in the metal case 21, the outer peripheral surface of the first coil portion 10 is the rightmost side via the mold resin in the metal case 21 and the side wall 21 a of the metal case 21. The liquid cooling fins 27 are cooled. That is, among the liquid cooling fins 27 of the liquid cooling type inverter device 25, the outer main surface of the outermost liquid cooling fin 27 is not used for cooling the semiconductor module. The outer main surface of the cold fin 27 is used for heat transfer cooling of the reactor 1.

  In this embodiment, the outermost liquid cooling fin 27 faces the outer peripheral surface of the first coil portion 10 through the side wall of the metal case 21 and the mold resin. Thereby, the coil 3 that needs to be cooled in preference to the core is cooled well. The second coil part 11 is cooled well through the excellent thermal conductivity of the rectangular wire constituting the first coil part 10. Note that the arrangement of the reactor 1 may be changed so that both the outer peripheral surface of the first coil unit 10 and the outer peripheral surface of the second coil unit 11 are opposed to the outermost liquid cooling fin 27.

  Further, since the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 are interposed, the metal case 21 is accommodated in the metal case 21 by bringing the cooling liquid inflow pipe 29 and the cooling liquid outflow pipe 30 into contact with each other. The reactor 1 thus made can be cooled well from three sides.

(Modification)
In the above embodiment, the metal case 21 and the converter housing 31 are configured separately and fastened. However, as shown in FIG. 10, the metal case 21 that accommodates the reactor 1 and the converter housing 31 are integrally formed with a die. It may be cast to form an integral case. In this case, the side wall 21 a, which is one of the four rectangular side walls corresponding to the metal case 21 of the integral case, comes into contact with the outermost liquid cooling fin 27.

  The four side walls of the metal case 21 include a side wall 21 a that faces the outer peripheral surface of the first coil unit 10, a side wall that faces the outer peripheral surface of the second coil unit 11, and two side walls that face the magnetic coupling unit 6. . Here, when the side wall 21a of the metal case 21 facing the first coil portion 10 (or the outer peripheral surface of the second coil portion 11) is in close contact with the outermost liquid cooling fin 27 (when the coil is brought close to the cooler) a When the side wall of the metal case 21 facing the magnetic coupling portion 6 of the square core 2 is in close contact with the outermost liquid cooling fin 27 (when the core is brought close to the cooler) b, The center temperature of the reactor 1 was measured. The measurement results are shown in FIG. In FIG. 11, with the passage of time in a state where a constant current was passed through the coil, in the case of a, the temperature slightly exceeded 100 ° C., but in the case of b, the value was close to 120 ° C. .

  Next, the arrangement of the temperature sensor 32 used for the temperature detection will be described with reference to FIGS. The temperature sensor 32 has a built-in thermistor and is disposed at a central position X (see FIG. 2) in the column magnetic path direction of the coil 3 in an intermediate gap between the first coil unit 10 and the second coil unit 11. Yes. Moreover, it arrange | positions in the front-back direction center part (refer FIG. 8) which is the axial direction of the 1st coil part 10 and the 2nd coil part 11. As shown in FIG. That is, the temperature sensor 32 is arranged at the three-dimensional center position X of the reactor 1. This position is a portion where the temperature is highest in the reactor 1 due to heat generated by the first coil unit 10 and the second coil unit 11 on both sides, and the temperature sensor 32 detects the maximum temperature of the reactor 1. The measurement result of each part temperature of the reactor 1 is shown in FIG. It can be seen that the temperature at the central position X of the reactor 1 is considerably higher than the coil temperature (peripheral part) and the core temperature (peripheral part).

  The arrangement of the temperature sensor 32 will be described in more detail with reference to FIG.

  The sensor holding spacer 18 integrally formed with the resin coating portions 17 of the two U-shaped cores 4 faces the vertical direction and forms a groove portion 18A in which the temperature sensor 32 is accommodated. The groove 18A has an opening that is partitioned by the linear tapered surfaces 19 of the two sensor holding spacers 18 and gradually increases toward the front. The straight bar-shaped temperature sensor 32 is inserted from the opening of the groove 18A to the center position (see FIG. 2) X. After the temperature sensor 32 is inserted, a liquid or jelly-like mold resin is injected into the metal case 21 and solidified, whereby the reactor 1 and the temperature sensor 32 are fixed at predetermined positions. The sensor holding spacer 18 holds the temperature sensor 32 when the mold resin is injected to prevent displacement. In the case where the two sensor holding spacers 18 are formed separately from the resin coating portion 17, the two sensor holding spacers 18 can be replaced by one grooved resin plate.

(End shape of coil 3)
Next, details of the end shape of the coil 3 will be described in detail with reference to FIGS. 5 and 13.

  The first coil portion 10 includes a turn portion which is a portion of a rectangular wire wound around a portion parallel to the rectangular column portion 5 and a column portion including the rectangular column portion 5 of the magnetic coupling portion 6 illustrated in FIG. 3. And terminal portions which are both ends of a rectangular wire extending away from the side surface of the column portion.

  Therefore, the terminal portion of the first coil portion 10 is composed of the start end portion 12 and the termination portion 13, and the terminal portion of the second coil portion 11 is composed of the start end portion 15 and the termination portion 14. The insulating films are peeled off from the start end portions 12 and 15 and the end portions 13 and 14 at the tip portions separated from the outer peripheral surface of the turn portion by a predetermined dimension.

  As shown in FIGS. 5 and 13, the start end portion 12 of the second coil portion 11 has the same direction as the left side 10 a from the boundary portion between the left side 10 a and the front side 10 b of the turn portion of the first coil portion 10 (frontward). ), But is bent toward the front side 10b and protrudes obliquely forward with respect to the left side 10a. In this way, since the protrusion length Lmax1 to the front of the start end 12 can be shortened, the arrangement space for the start end 12 provided in front of the front side 10b of the coil 3 can be shortened.

  More specifically, the front end portion 12a from which the insulating film of the start end portion 12 is peeled is a portion connected to the external wiring by bonding or the like, but is predetermined from the outer peripheral surface of the turn portion of the first coil portion 10 for electrical insulation. Must be spaced apart by dimension. Further, since the left side 10 a of the first coil portion 10 is adjacent to the inner side surface of the metal case 21, there is a problem in securing electric insulation of the start end portion 12. From this viewpoint, in this embodiment, the start end portion 12 of the first coil portion 10 is bent inward.

  Thereby, the protrusion length Lmax1 to the front of the start end portion 12 is reduced while the tip end portion 12a of the start end portion 12 from which the insulating film is peeled is separated from the outer peripheral surface of the turn portion of the first coil portion 10 by a predetermined distance L. The reactor 1 can also be made compact. In FIG. 5, only the starting end portion 12 of the first coil portion 10 is provided obliquely, but other terminal portions may be provided obliquely in the same manner. Note that the start end 15 and the end end 13 in FIG. 13 are provided slightly closer to the second coil portion 11 than the start end 15 and the end end 13 shown in FIG.

(Second Embodiment)
Other shapes of the first end portions 12 and 15 and the end portions 13 and 14 of the first coil portion 10 and the second coil portion 11 will be described with reference to FIG. In this embodiment, in FIG. 5, the start end portion 15 and the end end portion 13 protruding straight forward are obliquely bent toward the first coil portion 10 side.

  In this case, in FIG. 5 and FIG. 13, it is necessary to bend at a substantially right angle, and since the bending angle of the start end portion 15 whose forward protrusion length is increased from the limit of the radius of curvature decreases, the start end portion 15 is moved forward. The protrusion length Lmax1 can be reduced as compared with the cases of FIGS. As for the end portion 13, since the bending angle is originally small, the forward protrusion length may be smaller than that of the start end portion 15. Reference numeral 13a denotes a tip portion from which the insulating film of the end portion 13 is peeled off, and 15a denotes a tip portion from which the insulating film of the start end portion 12 is peeled off.

  Further, the start end portion 12 will be described. The start end portion 12 becomes a terminal portion, that is, the start end portion 12 away from the outer peripheral surface of the rectangular column portion 5 from the position y in the front-rear direction. In addition, a corner portion of a substantially quarter circle, which is a boundary portion between the left side 10a and the front side 10b of the first coil unit 10, is continuous with the front side 10b at a position Z in the left-right direction. The front edge of this corner is located behind the front edge of the left side 10a. Therefore, when the corner portion V of the tip end portion 12a from which the insulating film of the start end portion 12 is peeled is arranged on the left side of the position Z, the protrusion length Lmax1 forward of the start end portion 12 can be reduced. That is, the bending of the start end portion 12 is preferably performed within this range.

(Third embodiment)
Other shapes of the first end portions 12 and 15 and the end portions 13 and 14 of the first coil portion 10 and the second coil portion 11 will be described with reference to FIG. In this embodiment, the starting end portion 12 bent obliquely in FIG. 13 is bent substantially parallel to the front side 10b of the first coil portion 10 and bent approximately 90 degrees. However, a predetermined gap is ensured between the front end portion 12 a from which the insulating film of the start end portion 12 is peeled off and the front side 10 b of the first coil portion 10. In this way, the protrusion length Lmax3 to the front of the start end portion 12 can be further shortened.

(Fourth embodiment)
Other shapes of the terminal end portion 13 of the first coil portion 10 and the start end portion 15 of the second coil portion 11 will be described with reference to FIG. In this embodiment, the tip end portion 13a from which the insulating coating of the terminal end portion 13 is peeled and the tip end portion 14a from which the insulating coating of the starting end portion 15 is peeled are overlapped so as to be substantially orthogonal. In this way, the bending angle between the end portion 13 and the start end portion 15 can be reduced as compared with FIG. 13 and FIG. 14, so that the forward protrusion length can be further reduced.

(Fifth embodiment)
Other shapes of the start end portion 12 of the first coil portion 10 and the end portion 14 of the second coil portion 11 will be described with reference to FIG. In this embodiment, the end portion 14 and the start end portion 12 are obliquely arranged so as to be close to each other at the intermediate portion in the left-right direction of the first coil portion 10 and the second coil portion 11. However, as in other embodiments, the tip end portion 12a from which the insulating film of the start end portion 12 has been peeled is disposed at a predetermined distance from the front side 10b of the first coil portion 10, and the insulating film of the end portion 14 has been peeled off. The distal end portion 14 a is arranged at a predetermined distance from the front side 11 b of the second coil portion 11.

  However, in this embodiment, the tip from which the insulating film of the starting end portion 12 is peeled along the oblique outer peripheral surface of the curved corner (boundary portion) between the front side 10b and the right side 10c of the first coil portion 10. Since the part 12a can be arrange | positioned, the protrusion length Lmax4 to the front can be reduced.

  Similarly, the tip end portion 14a from which the insulating film of the terminal end portion 14 is peeled can be disposed along the oblique outer peripheral surface of the curved corner portion (boundary portion) between the front side 11b and the left side 11c of the second coil portion 11. Therefore, the forward protrusion length Lmax4 can be reduced. In order to give this shape to the end portion 14 and to arrange the start end portion 12 in front of the right side 10c of the first coil portion 10, the end portion 14 is once bent rightward and then bent leftward again. Yes.

It is a perspective view of the reactor of Embodiment 1. It is a front view of the reactor of Embodiment 1. It is a front view which shows a U-shaped core. It is a disassembled perspective view of a U-shaped core. It is a perspective view of a coil. It is a perspective view of a U-shaped half core. It is a disassembled perspective view of the reactor of Embodiment 1. FIG. It is an AA arrow directional cross-sectional view of the reactor of Embodiment 1. It is a partial front view of the DCDC converter for vehicles by which the reactor was mounted. It is a disassembled perspective view of the DCDC converter for vehicles by which the reactor was mounted. It is a characteristic view which shows the difference in coil temperature at the time of making the core side surface and coil side surface of a reactor close to a liquid cooling fin. It is a characteristic view which shows the difference in the temperature of each part of a reactor. FIG. 3 is a partial cross-sectional view illustrating a terminal portion shape of a coil in the first embodiment. It is a fragmentary sectional view which shows the terminal part shape of the coil in Embodiment 2. FIG. It is a fragmentary sectional view which shows the terminal part shape of the coil in Embodiment 3. It is a fragmentary sectional view which shows the terminal part shape of the coil in Embodiment 3. It is a fragmentary sectional view which shows the terminal part shape of the coil in Embodiment 4.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor 2 B-shaped core 3 Coil 4 U-shaped core 5 Square column part 6 Magnetic coupling part 7 Bolt fastening hole 8 Spacer 9 Exposed magnetic path end surface 10 Coil part 10a Left side 10b Front side 10c Right side 11 Coil part 11b Front side 11c Left side 12 Start end portion 12a End portion 13 End portion 13a End portion 14 End portion 14a End portion 15 Start end portion 16 U-shaped half core 17 Resin coating portion 18 Sensor holding spacer 18A Groove portion 19 Linear taper surface 20 Spacer 21 Metal case 21a Side wall 22 Mold resin 23 Bottom surface 23a Step protrusion 24 Case hole 25 Liquid cooling type inverter device 26 Semiconductor card module 27 Liquid cooling fin 29 Cooling liquid inflow pipe 30 Cooling liquid outflow pipe 31 Converter housing 32 Temperature sensor

Claims (3)

A soft magnetic core having a substantially square magnetic path cross section and having at least two pillars parallel to each other to form a closed magnetic circuit;
A coil formed by winding a plate-like coil conductor coated with insulation around the column;
With
The coil is
The turn part has a start side part and a last side part that extend in a direction substantially perpendicular to the magnetic path direction of the pillar part while adjacent to one side surface of the pillar part, and spiral around the pillar part a predetermined number of times. A turn part wound around,
By extending from the start side and the last side of the turn part away from the side surface of the column part in a direction substantially perpendicular to the magnetic path direction of the column part, the turn part is drawn outside the outer peripheral surface of the turn part. A terminal portion
In a magnetic component having
The terminal portion is
A magnetic component that is drawn obliquely at a predetermined angle with respect to a start side portion and a final side portion of the turn portion in a plane substantially perpendicular to the magnetic path direction of the column portion. The magnetic component according to claim 1,
The terminal portion is
A magnetic component that is curved with a predetermined curvature from the leading edge and the trailing edge of the turn portion. The magnetic component according to claim 1,
The turn part is
A first turn portion wound around one of the two pillar portions;
A second turn portion wound around the other of the two pillar portions;
Have
The final side terminal portion of the first turn portion and the start side terminal portion of the second turn portion are:
A magnetic component characterized in that it is cross-coupled obliquely in directions close to each other.

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