JP2009218292A - Reactor and assembling method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a compact reactor in which the number of components is reduced and manufacturing steps are simplified. <P>SOLUTION: The reactor 1 is provided with a core 2 having a pair of coil winding portions, coils 31, 32 wound around the coil winding portion, and a terminal block 4 connected to the coils 31, 32 so as to be connected to an external device. The terminal block 4 is integrally molded using a resin material 5 together with the core 2 and the coils 31, 32. According to such configuration, since the reactor is entirely molded by the resin material 5, the reactor 1 can be obtained having excellent shock resistance and corrosion resistance. Thus, a fixing member is not required for fixing the terminal block 4. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a reactor mounted on a vehicle or the like and a method for assembling the reactor, and more particularly, to a compact reactor and a method for assembling the same with a reduced number of parts and a simplified manufacturing process.

  A reactor mounted on a vehicle such as an electric vehicle or a hybrid vehicle includes a core and a coil wound around the core, and the core and the coil are usually a pedestal or container-shaped protective case made of a plate-like member or the like. Fixed inside. In such a reactor, the entire core and coil are often molded with a resin material mainly for protection from the external environment.

  For example, a portion of the core around which the coil is wound, a portion facing the coil of the fixing member for fixing the core to the pedestal, and a portion of the pedestal facing the coil are molded integrally with a resin material. There has been proposed a reactor apparatus and a manufacturing method thereof (for example, refer to Patent Document 1). The fixing member has a terminal block connected to an external device mounted on four legs standing in a fixed state on the pedestal, and a coil arranged between the terminal block and the pedestal. Both sides are covered with a resin material. That is, the terminal block is molded separately from the coating of the resin material on both sides of the coil.

JP 2004-95570 A

  However, in the reactor or the like described in Patent Document 1, since the terminal block and the fixing member on which the terminal block is mounted are separate members, the number of parts is large, and the four legs of the fixing member are connected with screws. Since a process of fixing to the pedestal is required, the number of work steps is large, and there is a concern that the cost will be increased as a whole. In addition, there is a problem that the overall configuration is complicated and bulky.

  The present invention has been made in view of such circumstances, and an object of the present invention is to provide a compact reactor and an assembling method thereof in which the number of parts is reduced and the manufacturing process is simplified.

  The reactor of the present invention includes a core having a pair of coil winding portions, a coil wound around the coil winding portion, and a terminal block connected to the coil for connection to an external device. Reactor related. In this reactor, together with the core and the coil, the terminal block is integrally sealed or molded with a first resin material.

  According to such a configuration, since the entire reactor is molded together with the terminal block by the first resin material, a reactor having excellent impact resistance and corrosion resistance can be obtained. Therefore, a fixing member for fixing the terminal block to the core or the coil side becomes unnecessary, and the number of parts can be reduced. Thereby, compactness and weight reduction are realizable. Further, it is not necessary to fix the terminal block separately to the core or coil. Accordingly, the cost can be reduced in combination with the reduction in the number of parts.

  In such a reactor, it is preferable to provide a bus bar having one end connected to the end of the coil and the other end facing the position where the terminal block is formed.

  In this way, the bus bar can be integrated with the coil or core with the resin material, and there is no need to separately fix the bus bar to the coil or core. Further, by using the bus bar, it is possible to improve the formability of the reactor that ensures the degree of freedom of the position of the terminal connected to the end of the coil and the external device.

  In addition, a relay part in which the bus bar is insert-molded with a second resin material in a state where the other end of the bus bar whose one end is connected to the end of the coil faces the position where the terminal block is formed. May be formed.

  In particular, when the reactor is housed in a protective case, it is difficult to assemble a mold on the upper part of the protective case. Therefore, if a relay part in which a bus bar is insert-molded is formed in advance, it is integrally formed with the first resin material. Since a mold is sometimes unnecessary, there is an advantage that it is easy to manufacture a reactor.

  The reactor assembly method of the present invention includes a core having a pair of coil winding portions, a coil wound around the coil winding portion, a terminal block connected to the coil for connection to an external device, It is related with the assembly method of the reactor provided with. In this assembling method, a step of passing a bus bar to a terminal of the coil and a position where the terminal block is formed, and a step of integrally forming the terminal block together with the core and the coil with a first resin material And comprising.

  According to such a method, since the terminal block is integrally formed with the first resin material together with the core and the coil, a fixing member for fixing the terminal block to the core or the coil becomes unnecessary, and the number of parts can be reduced. It becomes possible. Thereby, compactness and weight reduction are realizable. Further, it is not necessary to fix the terminal block separately to the core or coil. Accordingly, the cost can be reduced in combination with the reduction in the number of parts. The electrical connection work such as welding between the bus bar and the end of the coil may be performed before the integral molding with the first resin material or after that.

  Further, another reactor assembling method of the present invention is connected to the coil having a pair of coil winding portions, a coil wound around the coil winding portion, and an external device. And a reactor assembly method including a terminal block. In this assembling method, the bus bar is insert-molded with a second resin material to form a relay part, and the terminal of the coil and the position where the terminal block is formed are inserted into the relay part. A step of passing a bus bar, and a step of integrally forming the terminal block together with the core and the coil by a first resin material.

  In particular, when the reactor is housed in a protective case, a relay part in which the bus bar is insert-molded with the second resin material is formed in advance, thereby eliminating the troublesome work of assembling the mold on the protective case. The entire reactor can be integrally molded with the first resin material together with the protective case in a state where the relay part is disposed at a predetermined position. Thereby, manufacture of the reactor 1 becomes easy. In this case, if a buried member embedded in the first resin material is formed below the relay part, the stable fixing property of the relay part is improved. The electrical connection work such as welding between the bus bar and the end of the coil may be performed before the integral molding with the first resin material or after that.

  Since the reactor of the present invention is molded together with the terminal block, a fixing member for fixing the terminal block becomes unnecessary, and the number of parts can be reduced.

  In the reactor assembling method of the present invention, since the entire reactor is molded together with the terminal block, the step of fixing the terminal block to the coil or the reactor can be omitted.

  According to another reactor assembling method of the present invention, since the entire reactor including the relay part in which the bus bar is insert-molded in advance is integrally formed, the manufacture when the reactor is housed in the protective case becomes easy.

  Hereinafter, a reactor according to an embodiment of the present invention will be described with reference to the drawings.

  1A is a perspective view of a reactor, FIG. 1B is a perspective view of a reactor before being molded with a resin material, 2A is a perspective view of a bus bar, and FIG. 1B is a perspective view of a coil in a wound state. It is. As shown in these drawings, the reactor 1 is connected to a core 2 having a pair of coil winding portions (not shown), coils 31 and 32 wound around the coil winding portion, and an external device. Therefore, a terminal block 4 connected to the coils 31 and 32 is provided. And the terminal block 4 is integrally formed with the core 2 and the coils 31 and 32 by the resin material 5 (1st resin material). Examples of the resin material 5 include thermosetting materials such as urethane, epoxy, and silicone.

  According to such a configuration, since the entire reactor including the terminal block 4 is molded at once by the resin material 5, it is possible to obtain the reactor 1 having good impact resistance and corrosion resistance by efficient molding. it can. Further, since a fixing member or the like for fixing the terminal block 4 to the core or coil is not necessary, the number of parts can be reduced. As a result, compactness and weight reduction can be realized, and the cost can be reduced.

  More specifically, as shown in FIG. 1 (B) showing the reactor 1 in a state before being integrally molded with the resin material 5, the terminals 31a and 32a of the coils 31 and 32 and the bus bars 61 and 62 are connected to each other. Has been. The bus bars 61 and 62 are formed by bending a sheet metal material as shown in FIG. On the other hand, as shown in FIG. 2 (B), the coils 31 and 32 in a state where the windings are wound are wound around the coil of the core 2 via a bobbin 7 (see FIG. 1 (B)) made of an insulating material. It is wound around the turning part. The above-described bus bars 61 and 62 are connected by welding or the like to the end portions (the other ends) 61b and 62b with holes integrated with the terminal block 4 and the terminals 31a and 32a of the coil 3 with their surfaces exposed. End portions (one end) 61a, 62a. Downward convex portions 61c and 62c that are bent downward are formed between both end portions 61a and 61b and between 62a and 62b. When such three-dimensional bus bars 61 and 62 are molded with the resin material 5, a part of the bus bars 61 and 62 is embedded in the resin material, so that the fixed state is stabilized. Note that the end portions (the other ends) 61b and 62b with holes are terminals to which external devices (not shown) are connected.

  One terminal 31b on the rear side in the figure of the coils 31, 32 shown in FIG. 2 (B) is raised upward, and the other terminal 32b is bent to the left in the figure, on the front side of the one terminal 31b. The two terminals 31b and 32b are connected to each other by overlap welding or the like. Then, the end portions 61b and 62b with holes of the bus bars 61 and 62 are arranged at positions where the terminal block 4 is formed on the connecting portion between the terminals 31b and 32b. In such a state, a mold is applied so that the entire reactor is covered with the resin material 5, and the reactor 1 as shown in FIG. 1A is formed. Prior to such molding, an insulating heat absorbing material such as a ceramic thin plate (alumina, aluminum nitride, silicon nitride, etc.) or a silicone resin sheet is interposed in the gap 8 between the coils 31, 32. preferable. In this way, heat generated from the coils 31 and 32 can be effectively absorbed.

  In the molded state, the terminal block 4 is integrated with the upper surface of the reactor 1, and the connection portions between the terminals 31 a and 32 a of the coils 31 and 32 and the end portions 61 a and 62 a of the bus bars 61 and 62 are connected to the terminal block. 4 protrudes from a plane that is one step lower than 4. Thus, by exposing the connection part to the outside, the heat dissipation from the connection part can be improved. In addition, bolt holes (not shown) through which bolts 9 for fixing to a cooling base (not shown) through which the refrigerant is circulated are formed at the four corners of the core 2.

  Moreover, although the reactor 1 shown to FIG. 1 (A) does not require the base provided in the lower part of the core 2, and the protective case which covers the core 2 and the coils 31 and 32, this invention is limited to this. Alternatively, a pedestal or a protective case may be provided. Even in that case, the plate-like pedestal and the container-like protective case can be integrated simultaneously by the molding of the resin material 5. For example, when using a protective case, first, the core 2 and the coils 31 and 32 are accommodated in the protective case, and the bus bars 61 and 62 are welded to the terminals 31a and 32a of the coils 31 and 32 in this state. Then, when filling the resin material into the protective case, the terminal block 4 may be formed by insert molding the bus bars 61 and 62 at the same time.

  When a pedestal or protective case (not shown) is provided, insulation between the coils 31 and 32 and the bottom plate of the pedestal or protective case, such as a ceramic thin plate (alumina, aluminum nitride, silicon nitride, etc.) or a silicone resin sheet, etc. A heat-absorbing material may be interposed, and a paste-like resin may be applied to the base plate or the coil. In this way, the insulation between the pedestal or the protective case and the coils 31 and 32 can be improved, and the heat generated by the coils 31 and 32 can be efficiently absorbed by the insulating heat-absorbing material or the like, thereby improving the heat dissipation. To do. Moreover, in this Embodiment, although the terminal block 4 is arrange | positioned on the upper surface of the reactor 1, although illustration is abbreviate | omitted, this invention does not specify the arrangement position of the terminal block 4, but the terminal block For example, 4 may be provided on the side surface of the reactor 1.

  Such an assembly method of the reactor 1 is formed as follows. First, the ends 31a and 62a of the bus bars 61 and 62 are connected to the terminals 31a and 32a of the coils 31 and 32 by welding or the like, and the other ends 61b and 62b face the position where the terminal block 4 is formed. Then, the terminal block 4 is formed by integral molding of the resin material 5 together with the core 2 and the coils 31 and 32. The electrical connection by welding or the like between the terminals 31 a and 32 a of the coils 31 and 32 and the one ends 61 a and 62 a of the bus bars 61 and 62 may be performed after the resin material 5 is integrally formed. In that case, the bus bars 61 and 62 may be held at predetermined positions by a mold during molding with the resin material 5.

  In particular, when the reactor 1 is stored in a protective case (not shown), the molding may be performed in two stages as follows. For example, before integral molding with the resin material 5, for example, bus bars 61 and 62 molded as shown in FIG. 2A are insert-molded into a substantially terminal block shape with the second resin material and relay parts (not shown) ). Next, after this relay part is disposed at a predetermined position, the entire reactor including the relay part may be molded with the first resin material (resin material 5). When the relay parts are integrated, the downward convex portions 61c, 62c of the bus bars 61, 62 protrude downward from the relay parts and are embedded in the first resin material, so that the first resin material of the relay parts is obtained. Can be stably fixed. In addition to the downward projecting portions 61c and 62c, an embedded member (made of a metal material, a resin material, or the like) for embedding in the first resin material may be protruded below the relay component. Good. This embedded member may be formed of a part of the second resin material.

  The integral molding of the reactor 1 through such a relay component eliminates the troublesome work process of assembling the mold on the protective case, and thus has an advantage that the reactor 1 can be easily manufactured. In addition, even if a portion having a complicated shape exists in the vicinity of the bus bars 61 and 62 in the relay component, there is an advantage that the second resin material can be reliably filled in advance in that portion. The second resin material may be the same resin material as the first resin material (resin material 5) or a different resin material. Also in this case, electrical connection by welding or the like between the terminals 31a and 32a of the coils 31 and 32 and the one ends 61a and 62a of the bus bars 61 and 62 is performed before the first molding of the first resin material. You may go to or later.

  It should be noted that the present invention is not limited to the embodiment, and can be freely improved, changed, etc. as necessary without departing from the gist of the invention.

  Since the reactor of the present invention is formed at a low cost, lightweight and compact, it can be suitably applied to, for example, a vehicle. In addition, the reactor assembling method of the present invention can be reduced in weight and size in a small number of steps, and thus can be suitably applied to the reactor manufacturing stage. Furthermore, another reactor assembling method of the present invention can be suitably applied to the production stage of the reactor because the mold is not required when the reactor is housed in the protective case, and the production becomes easy.

(A) is a perspective view of the reactor which concerns on embodiment of this invention, (B) is a perspective view before the mold of the reactor. (A) is a perspective view of a bus bar, (B) is a perspective view of a coil in a wound state.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reactor 2 Core 31, 32 Coil 31a, 32a, 31b, 32b Terminal 4 Terminal block 5 Resin material 61, 62 Bus bar 61a, 62a One end 61b, 62b The other end 61c, 62c Convex part 7 Bobbin 8 Gap 9 Bolt

Claims (5)

A reactor comprising a core having a pair of coil winding portions, a coil wound around the coil winding portion, and a terminal block connected to the coil for connection to an external device,
The reactor, wherein the core and the coil, and the terminal block are integrally sealed or molded with a first resin material. The reactor according to claim 1, further comprising a bus bar having one end connected to a terminal of the coil and the other end facing a position where the terminal block is formed. A relay part is formed by insert-molding the bus bar with a second resin material with the other end of the bus bar having one end connected to the end of the coil facing the position where the terminal block is formed. The reactor according to claim 1. A reactor assembly method comprising: a core having a pair of coil winding portions; a coil wound around the coil winding portion; and a terminal block connected to the coil for connection to an external device. And
Passing the bus bar to the terminal of the coil and the position where the terminal block is formed;
And a step of integrally forming the terminal block together with the core and the coil with a first resin material. A reactor assembly method comprising: a core having a pair of coil winding portions; a coil wound around the coil winding portion; and a terminal block connected to the coil for connection to an external device. And
Forming a relay part by insert molding a bus bar with a second resin material;
Passing the bus bar inserted into the relay part to the terminal of the coil and the position where the terminal block is formed;
And a step of integrally forming the terminal block together with the core and the coil with a first resin material.

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