JP2009231390A - Reactor and coil for reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor having a reduced projection area, and to provide a coil used for the reactor. <P>SOLUTION: The reactor includes a pair of coils 10A and 10B constituted of a series of winding wires and arranged in parallel through a connection part 13, and an annular coil 20 whose one part is fitted to both coils 10A and 10B and residual part is exposed from both coils 10A and 10B. In the reactor 100, the connection part 13 is projected on the outer side of a turn part more than a turn-forming surface (upper turn forming surface 15U) formed of the turn part of both coils 10A and 10B arranged in parallel. Then, of core surfaces practically in parallel relation with the installation surface of the reactor, an exposed surface (upper exposed surface 22U) exposed from the coil 10 is projected toward at least one of the side of the connection part 13 more than a cover surface (upper cover surface 21U) covered with the coil 10 and the side opposite from the side of the connection part 13. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor used for components such as a converter and a coil used for the reactor.

  2. Description of the Related Art In recent years, converters that perform voltage step-up / step-down are used in hybrid vehicles that are becoming popular, and a reactor described in Patent Document 1 is known as one of the components of the converter.

This reactor includes a ring-shaped core made of a magnetic material and a pair of coils formed on a part of the outer periphery of the core as main constituent members. Such a reactor is configured as follows, for example. A pair of coils are formed in advance by edgewise winding a series of rectangular wires. Both coils are arranged in parallel with each other via a connecting portion obtained by bending a part of a flat wire into a hairpin shape. This connecting portion is formed flush with the upper surface of the turn portion of the coil and is formed so as to protrude in the axial direction of the turn portion. Then, a plurality of intermediate core pieces made of a magnetic material are fitted into the inner periphery of each coil, the intermediate core pieces are bonded to each other through a gap plate between the intermediate core pieces, and the ends of the intermediate core piece group are further connected to each other. Are connected by end core pieces to form an annular core. As a result, a part of the core is covered with the coil, the remaining part is exposed from the coil, and the connecting part is arranged on the exposed upper surface side of the core with a very small gap.
JP 2008-28290 A FIG. 3 and FIG. 4

  However, in the above configuration, the connecting portion of the coil is flush with the turn portion and protrudes from the turn portion in the axial direction of the coil, so that there is a problem that the projected area of the reactor is increased.

  That is, since the connecting portion of the coil is flush with the turn portion, the covering surface covered with the coil and the exposed surface exposed from the coil must be flush with each other on the upper surface of the core. As a result, in order to secure the volume necessary for the core, the portion that extends from the coil in the axial direction of the core and is exposed from the coil must be taken large.

  On the other hand, the core / coil assembly as described above is usually stored in a container-like case and mounted on a cooling base through which a refrigerant flows or mounted on a cooling base without being stored in the case. The In order to fix the core to the installation surface (the bottom surface of the case or the cooling base) of the reactor, for example, the core is pressed against the installation surface side with an attachment member such as a gate type. However, in that case, since the gap between the exposed surface of the core and the connecting portion is very small, the mounting member can only be pressed in parallel with the connecting portion to press the exposed surface of the core. This requires an area that allows the mounting members to be arranged in parallel. As a result, the core is further increased in size in the coil axis direction, and there is a problem that the projected area when the reactor is viewed from above must be increased.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor capable of reducing the projected area and a coil used for the reactor.

  The reactor of the present invention includes a pair of coils that are configured by a series of windings and are arranged in parallel via a connecting portion, and an annular core that is partially fitted into both coils and the remaining portion is exposed from both coils. . In this reactor, the connecting portion of the coil protrudes outside the turn portion from the turn forming surface formed by the turn portions of the two coils arranged in parallel. Of the core surfaces that are substantially in parallel with the installation surface of the reactor, the exposed surface exposed from the coil is at least one of the connecting portion side and the connecting portion side opposite to the covering surface covered with the coil. It is protruded.

  According to this configuration, since the connecting portion that connects the pair of coils protrudes outside the turn forming surface of the coil, the exposed surface exposed from the coil and the covering surface covered by the coil are flush with each other on the core surface. You don't have to. As a result, when the core has the same volume as the conventional reactor, the height of the core portion exposed from the coil is made larger than that of the conventional reactor, and the exposed width of the core portion (the length in the coil axis direction) is increased. By reducing it, the projected area of the reactor can be reduced.

  The reactor of this invention WHEREIN: It is preferable that the exposed surface is protruded in the said connection part side rather than the coating | coated surface among the said cores.

  According to this configuration, the height of the core portion exposed from the coil can be protruded upward, for example, upward, so that the exposed width of the core portion can be narrowed, and the projected area of the reactor can be reduced.

  The reactor of this invention WHEREIN: It is preferable that the attachment member for fixing a core to the installation surface of a reactor is interposed between the said connection part and an exposed surface.

  According to this structure, a connection part and an attachment member can be arranged in piles, and it is not necessary to arrange both side by side. Therefore, the exposed width of the core portion exposed from the coil can be narrowed, which can contribute to the reduction in the projected area of the reactor.

  The reactor of this invention WHEREIN: It is preferable that the said exposed surface protrudes on the opposite side to the said connection part side rather than the coating | coated surface.

  According to this configuration, the height of the core portion exposed from the coil protrudes on the opposite side, for example, downward, so that the exposed width of the core portion can be reduced, and the projected area of the reactor can be reduced. . In particular, even when the coated surface on the upper side of the core and the exposed surface are flush with each other, the exposed surface on the lower side of the core can protrude beyond the coated surface, contributing to a reduction in the projected area of the reactor. it can.

  The reactor of this invention WHEREIN: It is preferable that the said connection part is formed so that it may overlap on the turn formation surface of a coil.

  According to this configuration, since the connecting portion overlaps the turn forming surface of the coil, the connecting portion does not protrude in the axial direction of the turn portion, and the height of the core portion exposed from the coil is arbitrarily selected. Can do. Accordingly, the exposed width of the core portion exposed from the coil can be reduced with a wide degree of freedom, and the projected area of the reactor can be reduced.

  On the other hand, the reactor coil according to the present invention includes a pair of coils that are constituted by a series of windings and are arranged in parallel via a connecting portion. And the said connection part protrudes on the outer side of a turn part rather than the turn formation surface formed by the turn part of the said both coils arranged in parallel, It is characterized by the above-mentioned.

  According to this configuration, since the connecting portion that connects the pair of coils protrudes outside the turn forming surface of the coil, the exposed surface exposed from the coil and the covering surface covered by the coil are flush with each other on the core surface. There is no need to As a result, when the core has the same volume as the conventional reactor, the height of the core portion exposed from the coil is made larger than that of the conventional reactor, and the exposed width of the core portion (the length in the coil axis direction) is increased. By reducing it, the projected area of the reactor can be reduced.

  According to the reactor of the present invention, the projected area of the reactor can be further reduced, and the occupied area required for installing the reactor can be reduced.

  Moreover, according to the coil for reactors of this invention, a reactor with a small projection area can be comprised.

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

  A coil according to an embodiment of the present invention will be described with reference to FIG. 1, and a reactor using the coil of FIG. 1 will be described with reference to FIG.

<Coil>
First, as shown in FIG. 1, the coil 10 is formed by spirally edgewise winding a rectangular copper wire (winding) having an insulating coating, and is arranged in parallel in a direction orthogonal to the axial direction. It is composed of a pair of 10A and a second coil 10B. The first and second coils 10A and 10B are coils having the same number of turns and a substantially rectangular shape when viewed from the axial direction. Further, both the coils 10A and 10B are constituted by a single winding without a joint. That is, on one end side of the coil 10, the start end 11 and the end end 12 of the winding are drawn upward, and on the other end side of the coil 10, the first coil 10A and the first coil 10A are connected via the connecting portion 13 bent in a hairpin shape. The second coil 10B is connected. The connecting portion 13 extends the winding in a direction away from the second coil 10B by bending edge-wise the end portion of the first coil 10A rising upward along the winding direction of the coil 10A. The winding is formed by flatwise bending, folding it back to the second coil 10B side, and drawing it to the side of the first coil 10A. The winding drawn to the side of the first coil 10A is connected to the second coil 10B by being edgewise bent downward. With this configuration, the winding directions of the first coil 10A and the second coil 10B are the same.

  Here, as shown in FIG. 1 (B), a portion other than the connecting portion 13 in the coil, that is, a portion where a turn is formed by winding a winding is defined as a turn portion 14, and the turns of both the coils 10A and 10B are turned on. A plane including the upper surface of the portion 14 is defined as an upper turn forming surface 15U, and a plane including the lower surface of the turn portion 14 opposed thereto is defined as a lower turn forming surface 15L. In the coil of this example, the connecting portion 13 protrudes above the upper turn forming surface 15U. More specifically, the connecting portion 13 protrudes upward from the upper turn forming surface 15U by about half the width of the flat copper wire. With this configuration, compared to the conventional coil in which the connecting portion 13 is formed flush with the upper turn forming surface 15U, an extra portion corresponding to a height of about half the width of the flat copper wire is provided below the connecting portion 13. A space is formed.

<Reactor>
Next, based on FIG. 2, the reactor 100 which concerns on the Example of this invention which combined the core with the said coil is demonstrated.

  The core 20 is formed in an annular shape by combining a plurality of intermediate core pieces 21 fitted in the coils 10A and 10B and a pair of end core pieces 22 exposed at the ends of the coils 10A and 10B. Yes. For example, three intermediate core pieces 21 are fitted into one coil, and the end portions of the intermediate core pieces 21 located in both the coils 10A and 10B are connected by the end core pieces 22. The intermediate core piece 21 is made of a magnetic material and is a block having a cross section that can be accommodated in each of the coils 10A and 10B. The end core piece 22 is also made of a magnetic material so as to substantially cover the ends of both the coils 10A and 10B. It is a flat block with a wide area. Any of the core pieces 21 and 22 can be formed of a magnetic powder compact or an electromagnetic laminated steel sheet. Generally, a gap plate (not shown) made of a nonmagnetic material such as alumina is interposed between the core pieces 21 and 22 in order to adjust the inductance of the reactor. The number of divisions of the core pieces 21, 22 and the number of gap plates or the shapes of these members are not particularly limited. Each of the core pieces 21 and 22 and the gap plate are joined with an appropriate adhesive.

Here, as shown in FIG. 2B, of the core 20, the upper surface of the end core piece 22 is the upper exposed surface 22U, the lower surface is the lower exposed surface 22L, and the upper surface of the intermediate core piece 21 is the upper covering surface 21U. The lower surface is a lower covering surface 21L. The upper covering surface 21U and the lower covering surface 21L are surfaces that are substantially in parallel with the installation surface of the reactor (not shown on the bottom surface of the case or the cooling base surface). The reactor 100 of this example is a rectangular copper wire between the lower surface of the connecting portion 13 and the upper covering surface 21U, compared to a conventional reactor using a coil whose connecting portion is flush with the upper turn forming surface. An extra space corresponding to a height of about half the width is formed. Therefore, the upper exposed surface 22U and the upper coated surface 21U do not need to be flush with each other, and the upper exposed surface 22U is made higher than the upper coated surface 21U, and the end core piece is within a range corresponding to the above-mentioned space. The height of 22 can be increased. Accordingly, since the width W ₂₂ of the end core piece 22 can be reduced, the projected area when the reactor 100 is viewed from above can be reduced while securing the same volume as the core of the conventional reactor. it can.

  In the reactor 100 of the present example, the lower exposed surface 22L of the core protrudes below the lower covering surface 21L, and the lower exposed surface 22L protrudes below the lower turn forming surface 15L of the coil. Therefore, when fixing the core 20 to the installation surface of the reactor 100, the lower exposed surface 22L can be brought into surface contact with the installation surface, and the heat of the coil 10 is installed via the intermediate core piece 21 and the end core piece 22. The heat can be efficiently radiated to the side. Furthermore, if a heat dissipation plate (not shown) with high thermal conductivity such as silicon nitride is interposed between the installation surface and the lower turn forming surface 15L, and the lower exposed surface 22L and the lower surface of the heat dissipation plate are flush with each other, The heat can be radiated from the lower turn forming surface 15L to the installation surface via the heat radiating plate, and the heat dissipation of the reactor 100 can be further enhanced. Of course, the lower exposed surface 22L and the lower turn forming surface 15L may be flush with each other so that both surfaces are in surface contact with the installation surface of the reactor 100.

  The merits of the reactor of the present invention will be described more specifically based on the schematic diagram of FIG.

In the conventional reactor, as shown in FIG. 3A, the upper turn forming surface 15U of the coil 10 and the connecting portion 13 are flush with each other. Therefore, the upper covering surface 21U and the upper exposed surface 22U of the core 20 must be flush with each other. As a result, in order for the core 20 to secure a predetermined volume, the width of the end core 22 must be increased, and the projected area of the reactor is increased. That is, the reactor width W _LC becomes wide.

On the other hand, in the reactor of the present invention, as shown in FIG. 3 (B), the connecting portion 13 protrudes above the upper turn forming surface 15U of the coil 10. This figure shows the coil 10 in which the connecting portion 13 is made higher than the upper turn forming surface 15U by a height corresponding to the width of the winding in order to further clarify the merit of reducing the size of the reactor. In this case, the upper covering surface 21U and the upper exposed surface 22U of the core 20 do not need to be flush with each other. Therefore, the upper exposed surface 22U protrudes above the upper covering surface 21U, and the height of the end core 22 is increased. Can be taken high. Therefore, in order to secure the same core volume as that of the conventional reactor, the width of the end core 22, that is, the width of the upper exposed surface 22U can be reduced. As a result, the width W _{LI of the} reactor of the present invention <the width W _{LC of the} conventional reactor can be obtained, and the projected area of the reactor can be reduced.

<Other configurations>
At least one of the following configurations can be further added to the reactor according to the above embodiment.

(Bobbin)
Usually, a cylindrical bobbin made of an insulating material is interposed between the core and the coil, that is, between the intermediate core piece and the coil. For example, by combining a pair of [molded plastic moldings into a square pipe shape, a portion of the core covered with a coil is covered with a cylindrical bobbin. The cylindrical bobbin mainly functions to align the core and the coil in a coaxial manner and to ensure insulation between the core and the coil. Furthermore, a frame-shaped bobbin that is fitted on the outer side of the intermediate core piece and interposed between the end core piece and the coil end may be used. The frame bobbin presses the end of the coil and contributes to securing insulation between the coil and the end core piece.

(Case)
The case houses the above-described core and coil assembly, and dissipates heat from the assembly through the case. This case is usually a container having a front, back, left, and right side surfaces and a bottom surface, and an open top. As a constituent material of the case, a metal material with high heat dissipation such as aluminum or aluminum alloy can be preferably used. However, in the reactor of the present invention, the assembly of the core and the coil may be used as it is as a reactor without being housed in the case, or may be housed in the case. If the case is not used, the reactor can be downsized. On the other hand, when the case is used, it is easy to mechanically protect the core and coil assembly. Usually, the sealing material described below is filled between the assembly and the case.

(Encapsulant)
The encapsulant covers the periphery of the coil and core assembly and provides mechanical protection for the assembly. In addition, the functions of the sealing material include absorbing vibration generated when the reactor is excited, and mechanically and electrically protecting the coil by covering it. In addition, when a case is used, the function of further increasing the insulation between the coil and the case, the function of holding the components such as the core and the coil housed in the case, or the heat of the coil is conducted to the case. It also has a function to make it. Of course, when the case is not used, the assembly of the coil and the core may be covered with a sealing material. As this sealing material, an insulating material that does not soften at the maximum temperature reached by the core or coil can be suitably used. For example, an epoxy resin, a urethane resin, etc. are mentioned.

  Next, the reactor which concerns on the Example of this invention using the attachment member for fixing a core to the installation surface of a reactor is demonstrated based on FIG.

  The reactor 100 of this example forms a space between the connecting portion 13 and the upper covering surface 21U by projecting the connecting portion 13 above the upper turn forming surface 15U, and the mounting member 30 is placed in the space. Intervene. As the attachment member 30, for example, a gate-shaped metal fitting can be used. More specifically, it includes a pressing piece 31 facing the upper exposed surface 22U of the core, and a leg piece 32 extending downward from both sides of the pressing piece 31 with the end core 22 interposed therebetween, and a reactor at the tip of the leg piece 32 One in which an attachment portion 33 facing the installation surface is formed. Bolt holes are formed in the mounting portion 33, and bolts are inserted therein to fix the mounting portion 33 to the installation surface of the reactor.

  According to the reactor 100 of the present example, the connecting portion 13 and the attachment member 30 can be arranged in an overlapping state, and it is not necessary to arrange them in parallel. Therefore, by projecting the upper exposed surface 22U of the end core 22 above the upper turn forming surface 21U and reducing the width of the end core 22, the projected area of the reactor 100 can be reduced.

  As a modification of this example, the upper exposed surface 22U may be flush with the upper covering surface 21U. For example, the upper exposed surface 22U of the end core does not protrude upward from the upper covering surface 21U, and only the attachment member 30 is interposed between the connecting portion 13 and the upper exposed surface 22U. In this case, the upper exposed surface 22U of the end coil 22 cannot protrude upward, but the lower exposed surface 22L protrudes downward to reduce the width of the end core 22, and the projected area of the reactor 100. Can be reduced.

  Next, a coil having a configuration different from that of the first embodiment will be described with reference to FIG. This coil 10 is different from the coil shown in FIG. 1 in that the connecting portion 13 of the coil is configured to overlap the turn portion. Since the other configuration is the same as that of the coil of FIG. 1, the following description will focus on the differences.

  The connecting portion 13 of the coil of this example is configured as follows. First, the end portion of the first coil 10A that rises upward is flatwise bent almost at right angles so as to overlap the turn portion of the coil 10A, and is extended to one end side (starting end side) of the coil. The wire is edgewise bent almost at right angles and extended toward the second coil 10B. Further, the winding is edgewise bent at a substantially right angle and extended toward the other end of the coil, and then the winding is flatwise bent at a substantially right angle and extended downward. The winding extending downward forms the second coil 10B. According to this configuration, when the reactor is viewed in plan (when viewed from a direction orthogonal to the upper turn forming surface 15U), the connecting portion 13 is positioned so as to overlap with the upper portions of both the coils 10A and 10B with a space therebetween. The two coils 10A and 10B are not projected in the axial direction. Therefore, the upper exposed surface of the end core is not interfered with by the connecting portion 13 and can be set to an arbitrary height.

  That is, even with the coil of this example, it is not necessary to make the upper covering surface and the upper exposed surface of the core flush with each other as in the first and second embodiments. Therefore, the upper exposed surface can be protruded upward from the upper covering surface, and the height of the end core can be increased, so that a reactor having a small projected area can be configured. Of course, the lower exposed surface of the core may protrude downward from the lower covering surface.

  Further, according to the coil 10 of this example, since the width direction of the flat copper wire constituting the connecting portion 13 is along the upper turn forming surface 15U, the height of the connecting portion 13 protruding on the upper turn forming surface 15U Can be kept small.

  Each of the above-described embodiments can be appropriately changed without departing from the gist of the present invention, and is not limited to the above-described configuration. For example, the winding of the coil is not limited to a rectangular wire, and may be a wire having a circular or polygonal cross section. Further, the connecting portion in FIG. 2 may be positioned further upward, and the upper exposed surface of the core may be flush with the upper turn forming surface of the coil.

  The coil of the present invention can be used as a component of a reactor, and the reactor of the present invention can be used as a component such as a converter. In particular, it can be suitably used as a reactor for automobiles such as hybrid cars and electric cars.

The coil of this invention which concerns on Example 1 is shown, (A) is a perspective view, (B) is a side view. The reactor of this invention which concerns on Example 1 is shown, (A) is a perspective view, (B) is a side view. The reactor which concerns on an Example, and the conventional reactor are shown by contrast, (A) is a schematic explanatory drawing of a conventional reactor, (B) is a schematic explanatory drawing of the reactor which concerns on an Example. It is a side view of the present invention reactor concerning Example 2. FIG. It is a perspective view of the coil of the present invention concerning Example 3.

Explanation of symbols

100 reactors
10 coils
10A 1st coil 10B 2nd coil
11 Start 12 End 12 Connection 14 Turn
15U Upper turn forming surface 15L Lower turn forming surface
20 cores
21 Intermediate core piece 22 End core piece
21U Upper coated surface 21L Lower coated surface 22U Upper exposed surface 22L Lower exposed surface
30 Mounting member
31 Pressing piece 32 Leg piece 33 Mounting part

Claims (6)

A reactor comprising a pair of coils composed of a series of windings and arranged in parallel via a connecting part, and an annular core partly fitted into both coils and the remaining part exposed from both coils,
The connecting portion of the coil protrudes outside the turn portion from the turn forming surface formed by the turn portions of the two coils arranged in parallel,
Of the core surface that is substantially in parallel with the reactor installation surface, the exposed surface exposed from the coil projects to at least one of the connecting portion side and the opposite side of the connecting portion side from the covering surface covered by the coil. A reactor characterized by   The reactor according to claim 1, wherein the exposed surface protrudes closer to the connecting portion than the covering surface.   The reactor according to claim 1, wherein an attachment member for fixing the core to the installation surface of the reactor is interposed between the connecting portion and the exposed surface.   The reactor according to claim 3, wherein the exposed surface is protruded on the opposite side of the connecting surface from the covering surface.   The reactor according to any one of claims 1 to 4, wherein the connecting portion is formed so as to overlap a turn forming surface of the coil. A reactor coil comprising a pair of coils that are configured from a series of windings and are arranged in parallel via a connecting portion,
The reactor coil, wherein the connecting portion protrudes outward from a turn forming surface formed by turn portions of the two coils arranged in parallel.

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