JP2008028304A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor capable of reducing manufacturing costs without reducing noise characteristics, or the like and improving assembly working efficiency. <P>SOLUTION: The reactor comprises: an annular core 2 composed by assembling a plurality of blocks 6a, 6b; a spacer 7a for setting a prescribed gap 9 between the blocks; and a coil provided at the outer periphery of the core 2. In the reactor, one portion or entire portion of the plurality of blocks is formed by magnetic powder, and each block is held via one or not less than two spacers arranged at one portion of the gap. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a reactor mounted on an electric vehicle such as a hybrid vehicle or a fuel cell vehicle.

  In recent years, automobiles that run by driving a motor with a DC power source such as a hybrid vehicle and a fuel cell vehicle have been developed due to environmental problems. The automobile as described above is equipped with a boost converter that boosts the voltage of a battery that is a DC power source, and a reactor is a main component of the boost converter.

  The reactor is configured by attaching a coil to an outer periphery of an annular core via a bobbin that is an insulating member. For example, as described in Patent Document 1, the core is configured by annularly assembling a plurality of blocks, and a spacer formed of a nonmagnetic material is inserted between the blocks. .

  The spacer is a component for adjusting the inductance according to the frequency, and the total thickness of the gaps of the entire core, that is, the total spacer thickness is set to a predetermined dimension.

JP2003-1224039

  An automobile reactor is configured to be able to supply optimum power between a battery and a motor by appropriately controlling a switching circuit.

  However, the core may periodically contract due to repeated on-off of the switching circuit, and noise may be generated. In particular, noise often occurs due to the displacement of the gaps set between the blocks. In order to alleviate the above problem, it is preferable to provide a hard ceramic spacer formed by sintering alumina or the like in the gap so as to prevent displacement of the opposing surface.

  However, hard ceramic spacers are expensive. For this reason, if it sets so that the said clearance gap may be filled up as it describes in patent document 1, a manufacturing cost will increase. In addition, the spacer and the core are often joined by a heat-resistant adhesive. However, if the spacer is set so as to fill the entire gap, the amount of the adhesive used increases, which increases the manufacturing cost. Moreover, workability in the bonding process is also poor.

  The present invention provides a reactor that can reduce the manufacturing cost without deteriorating noise characteristics and the like, and can further improve the assembly workability.

  A reactor according to the present invention is a reactor including an annular core configured by assembling a plurality of blocks, a spacer for setting a predetermined gap between the blocks, and a coil provided on the outer periphery of the core. In addition, some or all of the plurality of blocks are formed using magnetic powder, and each block is held via one or more spacers disposed in a part of the gap. .

  In the present invention, some or all of the plurality of blocks constituting the annular body are formed using magnetic powder. By adopting a block formed by compacting magnetic powder, the manufacturing cost can be reduced as compared with a conventional core made of laminated steel sheets. Moreover, compared with the core which consists of a conventional laminated steel plate, freedom, such as a shape, is high. For this reason, a reactor can be manufactured according to the required dimensional shape and the like. In addition, the core can also be formed by mixing blocks formed by compacting magnetic powder and blocks made of laminated steel sheets.

  Each of the above blocks is held with a predetermined gap through one or more spacers arranged in a part of each gap. That is, as described in Patent Document 1, the entire gap is not filled with spacers, but a predetermined gap is secured between the blocks and at least one or more spacers are provided within a range that does not reduce vibration identification. It is arranged and configured.

  The material of the spacer is not particularly limited. For example, it can be formed by sintering ceramic powder such as alumina which is a non-magnetic material.

  Also, the form of the spacer is not particularly limited. Various types of spacers such as a rectangular plate shape and a circular plate shape can be employed. Moreover, it is not limited to plate shape, A spherical spacer can also be employ | adopted. Further, the number of the spacers is not limited. For example, a single plate-like spacer can be provided in the central portion, and a plurality of spacers can be arranged in the vicinity of the edge portion of the opposing surface at a predetermined interval.

  By adopting the above configuration, the material required for manufacturing the spacer is reduced, and the manufacturing cost can be reduced. Moreover, since the adhesion surface with respect to the block of a spacer decreases, the usage-amount of an adhesive agent also decreases. Therefore, it becomes possible to reduce the manufacturing cost of the reactor.

  In the invention described in claim 2 of the present application, a concave portion or a convex portion capable of positioning and holding the spacer is provided on one or both of the assembly facing surfaces of the block.

  When a plurality of spacers are provided in a part of the gap between the blocks, it is preferable to position these at predetermined positions on the assembly facing surface. In the invention described in this claim, a concave portion or a convex portion capable of positioning and holding the spacer is provided on one or both of the assembling facing surfaces of the block. In particular, in the core formed by compacting, the concave portion and the convex portion can be formed very easily.

  By providing the concave portion or the convex portion, the spacer is held at a predetermined position between the blocks, so that the assembling workability is improved. Further, since the spacer can be positioned and held at a predetermined position, it is possible to assemble the block without using an adhesive. Therefore, it is possible to reduce the manufacturing cost.

  The form of the said recessed part and a convex part will not be limited if a spacer can be positioned in a predetermined position. Moreover, the recessed part or convex part corresponding to the whole shape of a spacer can also be provided, and the recessed part or convex part corresponding to a partial shape of a spacer can also be provided.

  For example, when a disc-shaped spacer is employed, a circular concave portion having a depth corresponding to the shape of the disc and capable of being positioned can be provided, and a predetermined thickness of the spacer can be embedded. Further, for example, a convex portion that restrains three or more points around the disk can be provided on the block side to be positioned and held.

  According to a third aspect of the present invention, a positioning recess or a positioning protrusion is provided in the spacer, and a protrusion or a recess that engages with the positioning recess or the positioning protrusion on one or both of the assembly facing surfaces of the block. Is provided. The invention described in this claim does not form a concave or convex portion corresponding to the entire shape of the spacer on the core side, but provides a concave or convex portion for positioning on both the spacer and the core. The spacers are positioned by fitting them together.

  For example, when a disc-shaped spacer is employed, when the entire disc-shaped spacer is embedded, the spacer material in the portion to be embedded increases. On the other hand, in the invention described in this claim, a positioning convex portion can be provided on a part of a disk having a thickness corresponding to a gap between blocks, and a concave portion for accommodating the positioning convex portion can be provided on the block side. . By adopting this configuration, the material for manufacturing the spacer can be reduced.

  In addition, when the core and the spacer are formed by compacting, the concave and convex portions can be easily formed. Moreover, the freedom degree of a shape is high. In addition, a recessed part or a convex part can also be provided in one of the assembly | attachment opposing surfaces, and can also be provided in both of assembly | attachment opposing surfaces.

  The invention described in claim 4 is provided with a bobbin disposed on the outer peripheral portion of the annular core, and the spacer is positioned and held via the bobbin.

  Since the bobbin is formed by resin molding, the design freedom is high. In addition, the manufacturing cost is lower than that of the core or spacer. According to the present invention, the spacer is held at a predetermined position by using the bobbin.

  For example, as in the invention described in claim 5, the spacer may be provided with an extending portion extending from the outer peripheral surface of the core, and the spacer may be positioned and held on the bobbin via the extending portion. it can. For example, an extension portion extending from the assembly facing surface where the spacer is inserted to the outside of the core is integrally formed, and a recess or the like that can lock or hold the extension portion can be provided on the bobbin.

  Further, as in the invention described in claim 6, the bobbin can be provided with an extending portion that extends into a gap in which the spacer is inserted, and the spacer can be positioned and held via the extending portion. . For example, when a disc-shaped spacer is disposed at the center of the assembly facing surface, an extension portion that contacts the peripheral edge of the disc and can position the disk-shaped spacer at the center of the assembly facing surface is provided. Can be provided. Since the spacer can be held at a predetermined position using the bobbin, an adhesive is not necessary, and the manufacturing cost can be reduced.

  Note that the extending portion and the extending portion need not be integrally formed with the spacer and the bobbin. A positioning member for connecting and positioning the bobbin and the spacer may be provided as an extending portion or an extending portion.

  FIG. 1 shows an external view in which a part is broken so that the internal structure of the reactor can be understood. The reactor 1 includes a core 2, a coil 3 wound around the core 2 in an annular shape, a bobbin 4 interposed between the core 2 and the coil 3, and a case 5 for housing these members. It is configured with.

  As shown in FIG. 2, the core 2 is formed by assembling a plurality of blocks. In the embodiment, a rectangular parallelepiped block 6a disposed in the longitudinal linear portion of the core 2 and a C-shaped block 6b in plan view disposed at both ends in the longitudinal direction are assembled into a track shape. Yes. Spacers 7 a are arranged between the blocks, and the blocks 6 a and 6 b are assembled with a predetermined gap 9. The spacer 7a can be formed by sintering a nonmagnetic material such as alumina powder.

  2 and 3 show a first embodiment. FIG. 2 is an exploded perspective view of the core 2, and FIG. 3 is a cross-sectional view of the core 2 cut at a spacer arrangement position. In the first embodiment, by providing four rectangular plate-like spacers 7a between the blocks, a predetermined gap 9 is secured between the blocks. As is apparent from these drawings, the spacers 7a are disposed at the four corners of the rectangular gap 9 between the assembling facing surfaces, and the central portion of the assembling facing surface 8 is opposed to the adjacent block through a space. It has been.

  By adopting the above configuration, less powder material is required to manufacture the spacer 7a than a conventional spacer formed so as to fill all the gaps 9 between the assembling facing surfaces. For this reason, the manufacturing cost of a spacer can be reduced. Further, the bonding area for bonding the spacer 7a to the assembly facing surface 8 is reduced, and the amount of adhesive used is also reduced. For this reason, the manufacturing cost of a reactor can also be reduced.

  The form and arrangement of the spacer are not limited. For example, as in the second embodiment shown in FIG. 4, a substantially square plate-like spacer 7b can be employed. Further, as in the third embodiment shown in FIG. 5, a disk-like spacer 7c can be arranged at the center of the opposing surface.

  6 and 7 show a fourth embodiment. In this embodiment, a recess 10 capable of embedding and accommodating a spacer 7d at a predetermined depth is provided on an assembly facing surface 8 of a block 6a formed by compacting magnetic powder. FIG. 7 is a cross-sectional view showing a state in which the spacer 7d is embedded and held in the recess 10d. As shown in this figure, by providing the recess 10d, the spacer 7d can be positioned and held at a predetermined position. For this reason, assembly workability improves markedly. Further, the spacer 7d can be held at a predetermined position without using an adhesive. For this reason, the manufacturing cost of the reactor 1 can be reduced.

  Even in the case where a recess is provided on the assembly facing surface 8 of the block 6a, the form, the number and the form of the recess of the spacer are not limited. Moreover, the arrangement position of the spacer is not limited. For example, as in the fifth embodiment shown in FIG. 8, the spherical spacer 7e is adopted, and the concave portion 10d in which a part of the spherical spacer 7d can be embedded and held is formed on the assembly facing surface 8 of the block 6a. be able to.

  In the fourth and fifth embodiments, the recesses are provided on both the assembling facing surfaces 8. However, the recesses may be provided only on one of the facing surfaces 8 and 8.

  FIG. 9 shows a sixth embodiment. In this embodiment, an extension portion 11 extending outward from a gap 9 formed between the assembling facing surfaces from the edge portion of the spacer 7f is integrally formed, and the extension portion 11 is formed on the bobbin. 4 is positioned and held in the engagement concave portion 12 provided in FIG. Since the bobbin 4 is formed of a resin material, the extension portion 12 can be elastically held. Therefore, the spacer can be reliably held at a predetermined position without using an adhesive.

  FIG. 10 shows a seventh embodiment. In this embodiment, an extending portion 13 is provided on the inner peripheral portion of the bobbin 4 so as to extend into the gap 9 between the assembly facing surfaces of the block 6, and the spacer 7 g arranged at the center of the gap 9 is inserted into the gap 9. It is comprised so that positioning and holding | maintenance can be carried out in the center part.

  By adopting the above configuration, it is possible to hold the spacer 7g without using an adhesive as in the sixth embodiment, and the manufacturing cost can be reduced.

  11 and 12 show an eighth embodiment. In this embodiment, a positioning convex portion 10f is provided on the opposing surface 8a of one adjacent block 6a, and a positioning concave portion 10g is provided on the opposing surface 8b of the other block 6b, and between the opposing surfaces 8a and 8b, The spacer 7h provided with the positioning convex part 10f and the concave part 14 and the convex part 15 which fit into the positioning concave part 10g is arranged.

  By adopting the above configuration, it is possible to hold each block and the spacer sandwiched between them without using an adhesive, thereby reducing the manufacturing cost. In addition, the assembly workability of the core is improved.

  It is also possible to provide positioning recesses on both side surfaces of the spacer, and to provide positioning projections that fit into the positioning recesses on both opposing surfaces of the block. When this configuration is adopted, it is possible to reduce the material for forming the spacer by providing the concave portion in the spacer.

  The present invention is not limited to the above embodiments. In the embodiment, the core and the spacer are provided with projections and recesses that fit each other, but the block may be provided with a projection that can be positioned and held in contact with the outer periphery of the spacer.

  In the sixth embodiment, the extending portion 11 is provided in the spacer, and in the seventh embodiment, the extending portion is provided in the bobbin. However, the extending portion or the extending portion can be formed by a separate member. In particular, each spacer can be positioned and held at a predetermined position, and an assembly member capable of integrally assembling a plurality of spacers is provided, and the assembly workability can be improved by positioning the assembly member with a bobbin. .

It is the whole reactor perspective view which fractured | ruptured and represented the internal structure. It is a disassembled perspective view which shows the assembly | attachment structure of the spacer which concerns on a 1st Example. It is sectional drawing which shows the assembly | attachment state of the spacer shown in FIG. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on a 2nd Example. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on a 3rd Example. It is a disassembled perspective view which shows the assembly structure of the core and spacer which concern on a 4th Example. It is sectional drawing which shows the assembly | attachment state of the spacer shown in FIG. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on a 5th Example. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on a 6th Example. It is sectional drawing which shows the assembly | attachment state of the spacer which concerns on a 7th Example. It is a figure which shows the assembly structure of the core and spacer which concern on an 8th Example, and is an exploded perspective view equivalent to FIG. It is sectional drawing which shows the assembly | attachment state of the spacer shown in FIG.

Explanation of symbols

2 Core 6a Block 6b Block 7a Spacer 9 Clearance

Claims (6)

A reactor comprising an annular core configured by assembling a plurality of blocks, a spacer for setting a predetermined gap between the blocks, and a coil provided on the outer periphery of the core,
While some or all of the plurality of blocks are molded using magnetic powder,
Each of the blocks is a reactor that is held via one or more spacers arranged in a part of the gap.   The reactor of Claim 1 which provided the recessed part or convex part which can position-hold the said spacer in one or both of the assembly | attachment opposing surfaces of the said block. While providing a positioning recess or positioning protrusion on the spacer,
The reactor of Claim 2 which provided the convex part or recessed part engaged with the said positioning recessed part or a positioning convex part in one or both of the assembly | attachment opposing surfaces of the said block. While having a bobbin disposed on the outer periphery of the annular core,
The reactor according to claim 1, wherein the spacer is positioned and held via the bobbin. The spacer is provided with an extending portion extending from the outer peripheral surface of the core,
The reactor according to claim 4, wherein the spacer is positioned and held on the bobbin via the extending portion. The bobbin is provided with an extending portion that extends into the gap,
The reactor according to claim 4, wherein the spacer is positioned and held via the extending portion.

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