JP2009246221A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve assembly operability by eliminating the need for an adhesive. <P>SOLUTION: The reactor includes a core having a gap material interposed between a plurality of core pieces, a coil disposed at a circumference of the core, and a pair of frame-shaped members 4 disposed on both sides of the coil. Further, the reactor includes a gap definition portion 6 which is interposed between the core pieces to define the thickness of the gap material, a holding portion 5 holding the gap definition portion 6 and core pieces, and a resin coating portion covering an outer circumference of an assembly of the core, coil, frame-shaped members 4, and holding portion 5. The gap definition portion 6 and core pieces are united by the resin coating portion without using an adhesive. The reactor requires no adhesive to fix the gap material, and is superior in assemble operability. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor used for a component of a DC-DC converter mounted on a vehicle such as a hybrid vehicle or an electric vehicle.

  Conventionally, as shown in FIG. 7, a reactor 100 including an O-shaped core 110 made of a magnetic material and a coil 120 disposed on the core 110 is known (Patent Document 1). The core 110 is formed by combining a plurality of core pieces, for example, a rectangular parallelepiped piece 111 and a U-shaped piece 112. A gap material g made of an alumina plate is interposed between the core pieces in order to maintain a predetermined gap distance. The gap distance (the thickness of the gap material g) is appropriately set according to the desired inductance. In addition, a cylindrical inner bobbin (not shown in FIG. 7) made of an insulating material is arranged on the outer periphery of the place where the coil is arranged in the core 110 (FIG. 8 of Patent Document 1, FIG. 8 of Patent Document 2). Four). The inner bobbin insulates between the coil 120 and the core 110 and is used for positioning the core 110 with respect to the coil 120. A pair of frame-shaped outer bobbins made of an insulating material are disposed at both ends of the coil 120, and the coil 120 is sandwiched between the outer bobbins (FIGS. 3 and 4 of Patent Document 2).

  The conventional reactor 100 is assembled in the following procedure. A gap piece g is sandwiched between the rectangular parallelepiped pieces 111 and joined with an adhesive to produce a core piece, and an inner bobbin is disposed on the outer periphery of the core piece. Prepare a pair of core pieces including the inner bobbin, insert the core pieces into the coils, respectively, pair a pair of outer bobbins so as to sandwich the end surface of the core piece, and a pair of pairs so as to sandwich the outer bobbin. The U-shaped piece 112 is disposed, and the end surface of the core piece body and the U-shaped piece 112 are joined with an adhesive. The assembled reactor 100 is housed in a case, filled with potting resin, and used in a state of being sealed with resin (FIG. 7 of Patent Document 1).

JP 2007-116066 JP 2008-028290 A

  Conventional reactors have a problem in that assembly workability is poor because the core piece and the gap material are joined using an adhesive. In particular, a location where the coil is arranged in the core may have a plurality of gaps for adjusting the inductance. Then, the joining work by the adhesive is increased, and the assembling workability is further deteriorated.

  In addition, when the gap material is fixed to the core piece with an adhesive, the inductance varies due to variations in the thickness of the adhesive, that is, variations in the gap distance, and the inductance is difficult to stabilize.

  Accordingly, one of the objects of the present invention is to provide a reactor having excellent assembly workability. Another object of the present invention is to provide a reactor in which an inductance change is less likely to occur due to variations in the thickness of the adhesive.

  The present invention is configured so that a desired gap distance can be maintained without using an adhesive. Specifically, a member that defines the gap distance and a core piece are made of a resin that integrally covers the core and the coil. By adopting a fixed configuration, the above object is achieved.

  The present invention provides a core having a gap material interposed between a plurality of core pieces, a coil disposed on the outer periphery of the core, a pair of frames into which the core is inserted and abutted on both ends of the coil. The present invention relates to a reactor including a member. The reactor further includes a gap defining portion, a holding portion, and a resin coating portion. The gap defining portion is interposed between the core pieces and defines the thickness of the gap material. The holding portion is a member that holds the core piece and the gap defining portion, and is connected to the frame-shaped member. The resin coating portion covers the outer periphery of the combination of the core, coil, frame member, and holding portion. And in this reactor, positioning of the inner core piece held | maintained by the holding | maintenance part among the said cores, and the outer core piece arrange | positioned on the outer side of each frame-shaped member is a frame-shaped member. Do. In the reactor, the gap defining portion and the core piece are integrated with the resin coating portion without an adhesive.

  According to this configuration, the core piece and the gap defining portion are held by the holding portion, the holding portion is connected to the frame-like member, and the coil is disposed on the outer periphery of the core piece held by the holding portion. The In this configuration, since the gap defining portion that maintains the set gap distance (gap material thickness) is fixed to the core piece by the resin coating portion, it is not necessary to fix the gap material to the core piece with an adhesive. . Therefore, compared with the conventional reactor which uses an adhesive agent for fixing the gap material, the reactor of the present invention is easy to assemble and has excellent assembling workability. In particular, according to this configuration, even when the core has a plurality of gaps, the gap defining portions that maintain the gap distances do not have to be fixed to the core piece with an adhesive, so that assembly is easy. is there. Further, according to this configuration, the core, the coil, the frame-shaped member, and the holding portion can be handled integrally before the resin coating portion is formed, and the handling property is excellent. Further, according to this configuration, since the core / coil / frame member / holding portion assembly is covered with the resin coating portion and the mutual position thereof is fixed, the gap distance can be reliably maintained. Therefore, the reactor of the present invention has a stable inductance characteristic in which an inductance change is hardly caused due to a variation in the thickness of the adhesive unlike a conventional reactor using an adhesive.

  In the present invention, the gap defining portion is, for example, a separate member different from the holding portion, and is configured to be held by the holding portion while being sandwiched between the core pieces, or a configuration that is integrally formed of the same material as the holding portion. Is mentioned. Moreover, as long as the gap defining portion has a size capable of maintaining a predetermined gap distance, the shape and size can be selected as appropriate. For example, the contact location with the end face of the core piece in the gap defining portion may be the same shape as the end face of the core piece, or may be smaller than the end face of the core piece. In the former case, at least a part of the gap material is composed of a gap defining portion. In particular, when the gap material is composed of a gap defining portion, the gap distance can be reliably maintained and the inductance can be stabilized. In the latter case, the gap material is composed of a resin constituting the resin coating portion and a gap defining portion.

  In order to fix the gap defining portion and the core piece without using an adhesive, positioning of the gap defining portion and the core piece is important before the resin coating portion is formed. In the reactor of the present invention, the inner core in which the coil is arranged on the outer periphery and the outer core in which the coil is not arranged are positioned via the frame-shaped member. In particular, the holding portion that holds the core piece constituting the inner core and the gap defining portion is connected to the frame-like member, so that the positioning of the core piece and the gap defining portion is further ensured. By forming the resin coating portion in this state, the reactor of the present invention can fix the gap defining portion and the core piece by the resin coating portion, and can secure a desired gap distance.

  As one form of this invention, the form by which the holding | maintenance part was integrally formed in at least one of a pair of frame-shaped member is mentioned.

  According to this configuration, since the holding portion and the frame-shaped member are integrally formed, it is not necessary to combine the both, and the assembly workability is excellent. When the holding part is formed integrally with one of the frame-like members, the core piece can be easily arranged and the assembly workability is excellent. When the holding part is integrally formed with both frame-shaped members, the core piece is easily held by the holding part before the resin coating part is formed.

  As one form of this invention, the holding | maintenance part and the frame-shaped member have the engaging part which mutually engages, and the form with which both are connected by this engaging part is mentioned.

  According to this structure, a core piece can be easily arrange | positioned to a holding | maintenance part because a holding | maintenance part and a frame-shaped member are separate members. Moreover, since both the above are separate members, the manufacture of each member is facilitated and the dimensional accuracy is improved.

  As one form of this invention, the form which has an engaging part which a holding | maintenance part and a gap prescription | regulation part mutually engage is mentioned.

  According to this configuration, since the gap defining portion and the holding portion are separate members, the constituent material of the gap defining portion can be arbitrarily selected. By configuring the gap defining portion with a material that can easily maintain the gap distance, it is easy to stabilize the inductance. Specific examples of the material include ceramics such as alumina which is a nonmagnetic material having high heat resistance and rigidity. In addition, according to this configuration, the holding portion and the gap defining portion are integrated by the engaging portion, so that the holding portion sufficiently holds the gap defining portion without using an adhesive for the assembly of both. Can be assembled and has excellent assembly workability. This engagement only needs to be maintained to the extent that both do not fall off until the resin coating portion is formed.

  As one form of this invention, the holding | maintenance part and the gap prescription | regulation part are integrally formed with the same kind of material, and the form comprised by resin and the gap prescription | regulation part which comprise the resin coating | coated part is mentioned.

  According to this configuration, since the gap defining portion is integrally formed with the holding portion, the work of arranging the gap defining portion on the holding portion is unnecessary, and the assembly workability is excellent.

  As one form of this invention, the form whose core piece is a compacting body is mentioned.

  A laminated core made by laminating electromagnetic steel sheets has a constant magnetic direction, whereas a compacted body has excellent magnetic properties such as a large degree of freedom in the magnetic direction. Moreover, the compacting body can manufacture the core piece of a complicated solid shape easily.

  Since the reactor of the present invention is assembled without using an adhesive, it is excellent in assembling workability. Further, in the reactor of the present invention, since no adhesive is present in the gap between the core pieces, the inductance is not substantially changed due to the presence of the adhesive.

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

(Embodiment 1)
FIG. 1 (I) is a perspective view of the reactor of the present invention, FIG. 1 (II) is a perspective view of a combination of a core, a coil, a frame-like member, and a holding portion in a state without a resin coating portion, FIG. FIG. 2 (I) is a perspective view, FIG. 2 (II) is a front view, and FIG. 3 is a gap defining portion / frame-like member / holding portion provided in the reactor of the present invention. 3 (I) is a perspective view showing a state in which one frame-shaped member is provided, FIG. 3 (II) is a plan view, FIG. 3 (III) is a front view, and FIG. 3 (IV) is a pair of frame shapes. FIG. 4 is an exploded front view for explaining the assembly state of the assembly. In the drawings, the same reference numerals indicate the same items. In FIGS. 3 (II) and (III), the frame-like member is omitted.

  The reactor 1 includes a core 2 having a gap material (gap defining portion 6, FIG. 3), a coil 3 disposed on the outer periphery of the core 2, and a pair of frame-like members 4 that are in contact with both ends of the coil 3. A holding part 5 (FIG. 3) that holds a part of the core 2 and the gap defining part 6, and a resin coating part 7 that covers the outer periphery of the assembly 10 of the core 2, the coil 3, the frame-like member 4, and the holding part 5. Is a main component. The reactor 1 is mounted and used on a cooling base B (FIG. 2) having a refrigerant circulation path (not shown) therein. Hereinafter, each component will be described in detail.

  As shown in FIG. 2, the core 2 has a pair of coil winding portions 2c facing each other, is an annular member formed in a closed loop shape, and includes a magnetic body portion 2m and a gap material. In this example, the magnetic body portion 2m is configured by combining a plurality of rectangular parallelepiped core pieces made of a soft magnetic powder compact. Specifically, the core 2 includes an inner piece 2i that constitutes the coil winding portion 2c, and an outer piece 2o that is exposed without the coil 3 being disposed.

  Each coil winding portion 2c has a plurality of gaps 2g. The gap 2g is a gap provided between the inner pieces 2i for adjusting the inductance, and a gap material is disposed therein. The gap member is interposed between the inner pieces 2i (see FIG. 4), and is configured by a gap defining portion 6 that defines the thickness (gap distance) thereof. In this example, the gap defining portion 6 is made of an alumina plate having substantially the same area as the end face of the inner piece 2i and having a thickness corresponding to a desired gap distance. In this example, each coil winding portion 2c is composed of three inner pieces 2i and two gaps 2g (gap material (gap defining portion 6)). Note that the number of divisions of the core pieces and the number of gaps can be appropriately selected so as to obtain a desired inductance.

  The core 2 is H-shaped when viewed from the front as shown in FIG. 2 (II). That is, the outer piece 2o is thicker than the inner piece 2i (the length in the direction perpendicular to the surface of the cooling base B when the reactor is placed on the cooling base B (mounted state)). More specifically, the thickness of the inner piece 2i and the outer piece 2o is adjusted so that the outer peripheral surface of the outer piece 2o and the turn forming surface of the coil 3 are flush with each other in the mounted state. Further, the outer piece 2o includes a through hole 2h through which a bolt (not shown) for fixing the reactor 1 to the cooling base B is penetrated.

  The coil 3 includes a pair of coils arranged in parallel, and is an integrated body in which one end portions of both coils are connected by TIG welding or the like. The other end of both coils is used as a terminal to which power supply wiring is connected. In this example, both coils are formed by edgewise winding a winding having an enamel coating on the surface of a flat copper wire. In one coil, the winding connected to the end portion on the connection side is bent to connect both coils so that both ends of both coils are aligned. With this configuration, the axial length of the coil 3 can be shortened.

  Each frame-like member 4 has a rectangular shape including a pair of openings 4o into which a part of the inner piece 2i (FIG. 2) of the core is inserted, as shown in FIGS. 3 (I) and (IV). It is a frame body. The pair of frame-like members 4 are arranged at both ends of the coil 3 so as to sandwich the coil 3 (FIG. 1), and the core outer piece 2o (FIG. 2) is arranged so as to sandwich this pair of frame-like members 4. The That is, one surface of each frame-like member 4 is in contact with each end surface of the coil 3 (surface in which the turn appears to be annular), and the other surface is in contact with the outer piece 2o. The inner piece 2i inserted through the coil 3 is a core piece (inner core) sandwiched between the frame-like members 4A and 4B, and the outer piece 2o is a core disposed outside each of the frame-like members 4A and 4B. It is a piece (outer core).

  The frame-like member 4 positions the inner piece 2i (FIG. 2) and the outer piece 2o (FIG. 2) of the core. In this example, positioning is performed using the opening 4o of the frame-like member 4 and the outer shape of the frame-like member 4. The position of the inner piece 2i with respect to the frame-shaped member 4 is determined by being inserted into the opening 4o. On the other hand, since the frame-shaped member 4 has the same outer shape (contour shape) as the end face of the outer piece 2o (FIG. 1), the outer piece 2o is arranged along the outer shape of the frame-shaped member 4 to form a frame shape. The position with respect to the member 4 is determined. In this way, the inner piece 2i and the outer piece 2o are positioned via the frame-like member 4. Note that, in this example, all the contour lines that describe the outer shape of the frame-like member 4 are used for positioning the outer piece 2o, but a configuration in which a part of the contour lines is used may also be used. For example, when the outer shape of the frame-shaped member is a rectangular shape, it is only necessary that two sides forming one corner portion of the outline match the outer piece 2o.

  The holding portion 5 is a member in the shape of a front view formed integrally with a plate-like flat portion 5f and a pair of side wall portions 5s erected from the flat portion 5f (FIG. 3 (III)). The inner piece 2i (FIG. 2) and the gap defining portion 6 are held. Unlike the conventional inner bobbin, the holding portion 5 does not position the core with respect to the coil, and mainly holds the core piece and the gap defining portion 6 before the resin coating portion is formed.

  The planar portion 5f is a plan view of one inner piece 2i (FIG. 2 (II)) constituting the coil winding portion 2c (FIG. 2) and the two gap defining portions 6 sandwiching the inner piece 2i. The total area is larger than the total area when the three inner pieces 2i and the two gap defining portions 6 are viewed in plan. The side wall portion 5s has a plate-like shape having a width smaller than that of the flat surface portion 5f (length when viewed in plan) and a height in the standing direction lower than that of the inner piece 2i and the gap defining portion 6. Stands at the center of the edge. Therefore, when the inner piece 2i and the gap defining portion 6 are arranged on the flat surface portion 5f, a part of the side surface of the inner piece 2i and the gap defining portion 6 is covered with the side wall portion 5s, and the remaining portion of the side surface is exposed. (Figure 3 (IV) etc.).

  One end of the holding portion 5 is integrally formed with the opening 4o of one frame-like member 4A and is connected to the frame-like member 4A. The other frame-like member 4B and the holding portion 5 are separate members that can be separated. The other end of the holding part 5 is inserted into the opening 4o of the frame-like member 4B and connected to the frame-like member 4B. That is, the peripheral edge on the other end side of the holding portion 5 and the opening 4o of the frame-like member 4B constitute an engaging portion that engages with each other. By this connection, the frame-like members 4A and 4B and the holding portion 5 are positioned.

  Insulating materials such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE), and liquid crystal polymer (LCP) can be used as the constituent material of the frame-like member 4 and the holding portion 5.

  As shown in FIG. 1 (I), the resin coating portion 7 is formed along the outer shape of the combined body 10 of the core 2, the coil 3, the frame-like member 4, and the holding portion 5 (FIG. 3). In both the outer piece 2o of the core 2 and the coil 3, the surface disposed on the cooling base side is not covered with the resin coating portion 7, but is exposed. In addition, both end portions of the winding forming the coil 3 (one end portion to be welded and the vicinity thereof, the other end portion serving as a terminal) are also exposed. In addition, through holes 7h communicating with the through holes 2h of the core 2 are provided at the four corners of the resin coating portion 7, respectively. Insulating resin, specifically epoxy resin, urethane resin, polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene (ABS) resin, etc. Is available. In this example, an epoxy resin is used. The thickness of the resin coating portion 7 is preferably about 1 to 2 mm in consideration of moldability.

  In the reactor 1 having the above-described configuration, first, the assembly 10 of the core 2, the coil 3, the frame-like member 4, and the holding portion 5 (FIG. 3) is manufactured, and the resin coating portion 7 is formed on the outer periphery of the combination 10. Can be manufactured.

  The combined body 10 is produced as follows. As shown in FIG. 4, the two gap defining portions 6 and the three core pieces (inner pieces 2i) are alternately arranged and placed on the holding portion 5. At this time, the inner piece 2i is fitted into the opening of the frame-like member 4A so that one surface of the frame-like member 4A (contact surface with the outer piece 2o) and the end face of the inner piece 2i are flush with each other. Then, the inner piece 2i is held by the holding portion 5 and the frame-like member 4A. Further, the flat portion 5f of the holding portion 5 is larger than the total area of the one inner piece 2i and the two gap defining portions 6 as described above, and one end of the flat portion 5f is integrally formed with the frame-like member 4. Therefore, it is possible to reliably support these five members, particularly the inner piece 2i located in the middle portion and the gap defining portions 6 located on both sides thereof.

  Next, a coil (not shown in FIG. 4) is arranged on the outer periphery of the inner piece 2i, the frame-like member 4A, the holding portion 5 and the gap defining portion 6 and the pair of frame-like members 4A and 4B The frame-like member 4B is arranged so as to sandwich the gap. At this time, in addition to the inner piece 2i and the holding portion 5 in the opening of the frame-like member 4B, one surface of the frame-like member 4B (contact surface with the outer piece 2o) and the end face of the inner piece 2i are flush with each other. Fit the end.

  Further, a pair of outer pieces 2o are arranged so as to sandwich the pair of frame-like members 4A and 4B and along the outer shape of the frame-like member 4. By this step, a combination of the core 2, the coil, the frame-like member 4 and the holding part 5 is obtained. Further, the inner piece 2i and the outer piece 2o are positioned by the frame-like member 4. No adhesive is used in the processes so far.

  After the assembly is placed in a mold (not shown), the resin constituting the resin coating portion 7 (FIG. 1 (I)) is filled into the mold. As shown in FIG. 1, the assembly 10 is configured such that the outer piece 2o of the assembly 10 is molded with a mold so that the coil 3 is covered with the resin coating portion 7 in a state where the coil 3 is compressed (no gap between turns). Fill with resin while pressing. By this pressing, the coil 3 comes into contact with the frame-like member 4, whereby the coil 3 is positioned with respect to the frame-like member 4. As described above, since the frame-shaped member 4 positions the core 2, the core 2 is positioned with respect to the coil 3 as a result. Further, since the gap defining portion 6 (FIG. 3) existing in the gap 2g (FIG. 2) is excellent in rigidity, it is difficult to be deformed by pressing and can maintain a predetermined gap distance. Further, the resin does not flow between the gap defining portion 6 and the core piece (inner piece 2i) due to the pressing. Accordingly, the obtained reactor 1 has a gap distance defined only by the gap defining portion 6. The side surface of the inner piece 2i exposed from the side wall portion 5s (FIG. 3) of the holding portion and the side surface of the gap defining portion 6 can sufficiently contact the resin, and the gap defining portion 6 and the core piece are integrated by this resin. can do. In this manner, the adhesive is used by forming the resin coating portion while pressing with the mold while holding the core, the coil, and the gap defining portion 6 using the frame-shaped member 4 and the holding portion 5. In addition, the positions of the core and the gap can be determined with high accuracy.

  Furthermore, by pressing the coil with a mold, the spring back of the coil can be suppressed during resin filling. The holding portion 5 can be prevented from being applied with a pressing force by being inserted into the opening 4o so as not to be flush with one surface of the frame-like member 4. Therefore, it is possible to prevent the holding portion 5 made of resin from being damaged by pressing the mold.

  The reactor 1 having the above configuration can be easily assembled and excellent in assembling workability because the core piece and the gap defining portion 6 can be integrated without using an adhesive. Further, in the reactor 1, no adhesive is interposed in the gap 2g, and no resin of the resin coating portion 7 is interposed between the core piece and the gap defining portion 6, and only the gap defining portion 6 exists in the gap 2g. It is a configuration. Therefore, since the reactor 1 is maintained with the gap distance only by the gap defining portion 6, there is substantially no change in inductance due to variations in the thickness of the adhesive or deformation of the resin. It can be ensured reliably and can have a stable inductance.

  Further, the reactor 1 can sufficiently join the core piece and the gap defining portion 6 without using the adhesive since the resin constituting the resin coating portion 7 sufficiently wraps around the assembly 10.

  Furthermore, the reactor 1 has a structure that does not have a case, but by providing the resin coating portion 7, (1) the reactor 1 can be handled integrally, (2) the core 2 can be reinforced, and (3) the outside Various effects such as protection of the core 2 and the coil 3 from the environment and (4) insulation between the coil 3 and surrounding members can be achieved. Further, the reactor 1 can be made smaller by omitting the case.

  In addition, since the core 2 is configured so that a part of the outer peripheral surface of the core 2 and a part of the outer peripheral surface of the coil 3 are flush with each other, the core 2 and the coil 3 are provided with the cooling base B. Can contact directly. Therefore, the reactor 1 can efficiently transfer the heat of the core 2 and the coil 3 to the cooling base B and has excellent heat dissipation, and can be stably placed on the cooling base B. Further, since the thickness of the outer piece 2o of the core 2 is thicker than the coil winding portion 2c (inner piece 2i), the installation area of the reactor 1 can be reduced.

  At least one of the following configurations can be added to or replaced with the reactor according to the first embodiment and other embodiments described later.

(End face shape of frame-shaped member)
If the contact surface in contact with each end surface of the coil in the frame-shaped member has an inclined surface corresponding to the form of the coil end portion, the contact area between the coil and the frame-shaped member is large, and the coil can be securely held. Further, a projecting frame may be provided on the contact surface. Examples of the projecting frame include a shape in which the inner peripheral surface is along the outer peripheral surface of the inner piece and the outer peripheral surface is along the inner peripheral surface of the coil. By providing such a protruding frame, the position of the inner piece relative to the frame-like member can be determined more reliably, and the frame-like member can also hold the inner piece.

(Positioning by frame-like member)
In the first embodiment, the positioning of the inner piece and the outer piece of the core is performed by inserting the inner piece into the opening of the frame-like member and arranging the outer piece along the outer shape of the frame-like member. . In addition, a configuration in which a part of the outer piece is inserted into the opening of the frame-shaped member and the inner piece is disposed on the end surface of the inserted outer piece, or both pieces are inserted into the opening of the frame-shaped member, The structure which abuts both pieces within a frame-shaped member may be sufficient. At this time, the outer piece has a shape that can be inserted into the opening of the frame-shaped member, for example, a U-shape. Alternatively, a frame-shaped member positioning groove or the like is provided in the mold or the case, and the frame-shaped member is sized and shaped to be fitted in the groove. By arranging a frame-shaped member having an inner piece and an outer piece in such a mold or case, the inner piece and the outer piece may be automatically positioned.

(Connection structure of frame-shaped member and holding part)
The holding portion can be configured to be formed integrally with not only one frame-shaped member but also both frame-shaped members. At this time, among the alternately arranged bodies of the plurality of inner pieces and the gap defining portion, the one located in the intermediate portion can be inserted from the space sandwiched between the frame-shaped members and arranged in the holding portion. Of the alternating array, the core pieces (inner pieces) located at both ends can be inserted and arranged from the opening of the frame-shaped member. The coil is formed by winding a winding around the outer periphery of the core piece held by the holding portion.

  In the first embodiment, the opening portion of the frame-like member and the edge portion of the holding portion are used as the engaging portions. In addition, a convex portion may be provided on one of the frame-shaped member and the holding portion, and a concave portion that engages with the convex portion may be provided on the other, and both may be coupled by the engaging portion.

(Holding part shape)
A holding part can be made into the form comprised in a cylinder shape combining the split piece of a half crack. According to this structure, the insulation between a coil and a core can be ensured because a holding part is cylindrical. Moreover, the arrangement | positioning to the outer periphery of a core is also easy.

(Core shape)
Arbitrary shapes can be utilized for the core piece. In particular, it is easy to position the core pieces if they have engaging portions that engage with each other at the place where the core pieces contact each other. Also, the outer piece 2o is made thicker than the inner piece 2i so that the surface on the cooling base B side of the outer piece 2o protrudes from the surface on the cooling base B side of the coil 3, and the cooling base B and the coil 3 If it is set as the structure which has arrange | positioned the heat sink in the space between, heat dissipation is improved. As the heat radiating plate, a heat radiating plate made of a material having excellent heat radiating properties and electrical insulating properties such as ceramics such as silicon nitride, alumina, aluminum nitride, boron nitride and silicon carbide can be used. The surface of the coil 3 on the cooling base side is preferably brought into contact with the heat sink. Alternatively, the core pieces may all have the same thickness.

(Embodiment 2)
In the first embodiment, the configuration in which the frame-like member 4 and the holding portion 5 are integrated has been described. In addition, the frame-like member 4 and the holding portion 5 may be configured to be separable. FIG. 5 shows a holding part and a gap defining part, (I) is a perspective view, (II) is a plan view, (III) is a front view, and (IV) is a state further comprising a core piece and a frame-like member. It is a perspective view. The main difference between the second embodiment and the first embodiment is the shape of the frame-like member 4 and the holding part 5. Therefore, this point will be mainly described, and description of other points will be omitted.

  The holding part 5C is a member in the form of a flat part 5f and a pair of side wall parts 5s provided upright from the flat part 5f. The flat surface portion 5f is a plate having a size substantially equal to the total area when the three inner pieces 2i and the two gap defining portions 6 are viewed in plan. Further, the flat portion 5f is integrally formed with a small protrusion 5e at the center. The protrusion 5e is such that it is crushed by the core piece by the pressing force when forming the resin coating portion. The side wall portion 5s has the same width as the flat surface portion 5f and the height in the standing direction is equal to the gap defining portion 6 disposed in the flat surface portion 5f. Therefore, since three surfaces of the outer peripheral surfaces of the inner pieces 2i are surrounded by the holding portions 5C, the holding portions 5C can easily hold the inner pieces 2i before the resin covering portion is formed.

  The gap defining portion 6 is an alumina plate as in the first embodiment, and is slightly smaller than the end face of the rectangular parallelepiped space created by the holding portion 5C. The gap defining portion 6 is disposed on the protrusion 5e provided on the flat portion 5f. Therefore, when the gap defining portion 6 is arranged in the holding portion 5C, as shown in FIGS. 5 (II) and (III), the gap defining portion 6 is formed between the peripheral surface and the flat surface portion 5f, the same peripheral surface, and the side wall portion. There is a gap between 5s. In this way, the gap defining portion 6 is in a state of floating in the space in the holding portion 5, and when forming the resin coating portion on the core / coil / frame-like member 4 / holding portion 5C assembly, a pressing force is applied to the assembly. Add. At this time, the gap defining portion 6 held by the holding portion 5C can move slightly in the pressing direction by being pressed by the core piece (inner piece 2i) and crushing the protrusion 5e. For this reason, the core piece and the gap defining portion 6 can sufficiently come into contact with each other by pressing. Moreover, by having the said clearance gap, the resin which comprises a resin coating part is easy to wrap around, and is fully filled. Therefore, the gap defining portion 6 and the inner piece 2i can be securely fixed by the resin. In the second embodiment, the gap material is composed of the gap defining portion 6 and the resin of the resin coating portion. The upper surface of the side wall portion 5s, the upper surface of the gap defining portion 6, and the upper surface of the inner piece 2i are flush with each other (FIG. 5 (IV)).

  Further, the holding portion 5C is configured to be assembled integrally with the frame-shaped member 4 by inserting both ends into the opening 4o of the frame-shaped member 4 (FIG. 5 (IV)). That is, the vicinity of the periphery of both ends of the holding portion 5 and the opening 4o of the frame-like member 4 constitute an engaging portion that engages with each other. By inserting the holding portion 5C into the opening 4o of the frame-like member 4, the holding portion 5C is connected to the frame-like member 4, and the core piece (inner piece 2i) is positioned with respect to the frame-like member 4. As in the first embodiment, the inner piece 2i and the outer piece 2o are positioned through the frame-shaped member 4 by arranging the outer piece 2o (FIG. 1) of the core along the outer shape of the frame-shaped member 4. The The holding portion 5C is inserted so that one surface of the frame-like member 4 (the surface that contacts the outer piece of the core) protrudes beyond the end surface of the holding portion 5C. With this configuration, when the resin-coated portion is formed, when pressing the combination of the core, the coil, the frame-like member 4 and the holding portion 5 with a mold, no pressing force is applied to the holding portion 5C. Damage can be prevented. The inner piece 2i is inserted into the opening 4o of the frame-like member 4 so as to be flush with one surface of the frame-like member 4, and can contact the outer piece 2o.

  According to the reactor including the holding portion 5C, the frame-like member 4 and the holding portion 5 are separate members, so that the core piece and the gap defining portion 6 can be easily arranged on the holding portion 5 and the assembly workability is good.

(Modification)
One side wall 5s may be provided for the holding part 5C to form an L-shaped holding part. At this time, if the size of the holding portion 5C is adjusted so that the corner portion of the L-shape matches the corner portion of the opening 4o of the frame-like member 4, the positioning of the frame-like member 4 and the holding portion can be performed easily. In this configuration, the resin covering portion constituting the gap material has more resin than the holding portion 5C of the second embodiment, so that the fixing strength between the core piece (inner piece) and the gap defining portion can be increased.

(Embodiment 3)
In the third embodiment, a configuration having an engaging portion in which the holding portion 5D and the gap defining portion 6 are engaged with each other will be described. FIG. 6 shows another form of holding part, (I) is a perspective view with a gap defining part, (II) is a perspective view, (III) is a plan view, and (IV) is a front view. . Since this holding portion 5D is the same as the holding portion 5C of Embodiment 2 except that it has an engaging portion with the gap defining portion 6, the description will focus on the engaging portion, and the other points will be described. Omitted.

  The holding portion 5D is a member having a shape in which a flat portion 5f and a pair of side wall portions 5s provided upright from the flat portion 5f are integrally formed. The flat surface portion 5f has a plurality of protrusions 5d protruding inward. Each projection 5d has a rectangular parallelepiped shape, and the three projections 5d are arranged in a row in a state of being separated according to the thickness of the gap defining portion 6 so that the two gap defining portions 6 can be sandwiched (see FIG. 6 (III)). This row of protrusions 5d is provided at the center of the flat surface portion 5f. Similarly, the side wall portion 5s is provided with two rows of protrusions 5d on the inner side thereof in a state of being separated in the standing direction of the side wall portion 5s (FIG. 6 (II)). The holding portion 5D includes the two rows of protrusions 5d, so that the gap defining portion 6 can be easily held before the resin coating portion is formed.

  The gap defining portion 6 is an alumina plate as in the first embodiment. When the gap defining portion 6 is inserted between the protrusions 5d of the holding portion 5D and disposed in the holding portion 5D, as shown in FIG. 6 (III), the peripheral surface of the gap defining portion 6, the plane portion 5f, and the side wall portion 5s It is the structure which touches. That is, the periphery of the gap defining portion 6 constitutes an engaging portion, and the protrusion 5d of the holding portion 5D constitutes an engaging portion. Note that the upper surface of the side wall portion 5s protrudes from the upper surface of the gap defining portion 6. Accordingly, the space surrounded by the side wall portion 5s and the upper surface of the gap defining portion 6 is filled with the resin of the resin coating portion. That is, also in the third embodiment, the gap material is composed of the gap defining portion 6 and the resin coating portion resin.

  According to the reactor including the holding portion 5D, the gap defining portion 6 can be positioned by only being inserted into the holding portion 5D, and the gap defining portion 6 can be held by the holding portion 5D. Therefore, in the process of assembling the holding member 5D with the gap defining part 6 and the core piece arranged on the frame-like member 4, the gap defining part 6 and the core piece are unlikely to fall off the holding part 5D.

(Embodiment 4)
In the first to third embodiments, the form in which the gap defining portion is formed of a single plate material has been described. In addition, the gap defining portion may have a curved body shape such as a cylindrical shape, an elliptical column shape, a polygonal column shape, or a hemispherical shape. In addition, when the holding portion is in the shape of a letter or an L shape, the gap defining portion may be arranged on at least one of the plane portion and the side wall portion. At this time, the size of the gap defining portion (the length of the gap defining portion in the standing direction) may be equal to or shorter than the size of the inner piece. A plurality of such gap defining portions may be provided for one gap. In the fourth embodiment including such a gap defining portion, the gap material is composed of the resin of the gap defining portion and the resin coating portion.

  According to the fourth embodiment, by providing the gap defining portion made up of the position forming member and the separate member, a desired gap distance can be maintained, and a part of the gap material is configured by the resin of the resin coating portion. The fixing strength between the gap defining portion and the core piece can be increased.

(Embodiment 5)
In the first to fourth embodiments, the configuration in which the gap defining portion and the holding portion are separate members has been described. The gap defining portion and the holding portion may be integrally formed of the same kind of material. For the shape and size of the gap defining portion, the configurations of the above-described first to fourth embodiments can be used as appropriate. The constituent material of the gap material varies depending on the shape and size of the gap defining portion. That is, in this embodiment 5, the gap material is composed of a gap defining portion formed of the same type of material as the holding portion and a resin of the resin coating portion, or a gap defining portion formed of the same type of material as the holding portion. Composed.

  According to the fifth embodiment, since the gap defining portion is integrally formed with the holding portion, it is not necessary to engage the gap defining portion and the holding portion, and the assembly workability is excellent.

(Embodiment 6)
In the first to fifth embodiments, the configuration in which the case is omitted has been described. The assembly of the core / coil / frame member / holding portion may be housed in a case made of aluminum or aluminum alloy, filled with potting resin, and sealed with resin. At this time, since the resin coating portion is made of potting resin, it is not necessary to form the resin coating portion by filling the resin after the assembly is stored in the mold as in the first to fifth embodiments. As the potting resin, urethane resin or epoxy resin can be used.

  In the sixth embodiment, mechanical protection can be sufficiently performed by storing the assembly in a case (not shown). This case can be configured to have a through hole through which a bolt for fixing the case to the cooling base passes, and the core does not have to be provided with a through hole.

  The above-described embodiment can be appropriately changed without departing from the gist of the present invention, and is not limited to the above-described configuration. For example, it can be changed to the following form.

  In the coil, one end and the other end of the winding may protrude in different directions. In the form having no case, the degree of freedom in the winding direction of the winding is large. In addition to the rectangular wire, various windings having a circular cross section and a polygonal shape can be used. Furthermore, it is also possible to use a configuration in which a pair of coils is composed of a series of windings. This form is excellent in assembling workability because the welding work of the pair of coils is unnecessary.

  The resin coating portion can be in a form in which a part of the core and a part of the coil turn forming part are exposed. This form is excellent in heat dissipation because part of the core and coil is exposed from the resin coating.

  For fixing the reactor to the cooling base, a fixing member can be used separately. The fixing member has a pair of leg portions each having a through hole through which a fixing bolt passes, and a connecting portion that connects the leg portions and presses the coil or the core against the cooling base side. Is mentioned. Or the structure which provides a through-hole only in a resin coating part can be utilized. In these forms, it is not necessary to provide a through hole in the core, and the core can be easily manufactured.

  The reactor of this invention can be utilized suitably for the component of vehicle-mounted components, such as a vehicle-mounted converter arrange | positioned at vehicles, such as a hybrid vehicle and an electric vehicle, for example.

(I) is a perspective view of the reactor according to the first embodiment, and (II) is a perspective view of a combination of a core, a coil, a frame-shaped member, and a holding portion in a state where no resin coating portion is provided. FIG. 2 shows a core provided in the reactor of Embodiment 1, wherein (I) is a perspective view and (II) is a front view. FIG. 3 shows a gap defining portion, a frame-shaped member, and a holding portion provided in the reactor of Embodiment 1, (I) is a perspective view of a state including one frame-shaped member, and (II) is a plan view (top view) (frame) (III) is a front view (frame member is omitted), and (IV) is a perspective view in a state including a pair of frame members. FIG. 3 is an exploded front view illustrating an assembly state of an assembly of a core, a coil, a frame-like member, and a holding unit provided in the reactor according to the first embodiment. The gap defining part and the holding part provided in the reactor of Embodiment 2 are shown, (I) is a perspective view, (II) is a plan view (top view), (III) is a front view, (IV) is a core piece and It is a perspective view of the state which provided the frame-shaped member. FIG. 6 shows a holding portion provided in the reactor of Embodiment 3, wherein (I) is a perspective view of a state having a gap defining portion, (II) is a perspective view, (III) is a plan view (top view), and (IV) is a perspective view. It is a front view. It is a perspective view of the conventional reactor.

Explanation of symbols

1 Reactor 10 Core / coil / frame member / holding unit
2 Core 2m Magnetic body 2g Gap 2c Coil winding 2i Inner piece
2o Outer piece 2h, 7h Through hole 3 Coil 4, 4A, 4B Frame member 4o Opening
5,5C, 5D Holding part 5f Flat part 5s Side wall part 5d, 5e Projection
6 Gap defining part 7 Resin coating part
100 reactor 110 core 111 rectangular parallelepiped piece 112 U-shaped piece 120 coil
g Gap material B Cooling base

Claims (8)

A core having a gap material interposed between a plurality of core pieces, a coil disposed in the core, and a pair of frame-like members into which the core is inserted and in contact with both ends of the coil A reactor
A gap defining portion interposed between the core pieces and defining the thickness of the gap material;
Holding the core piece and the gap defining portion, and holding portion connected to the frame-shaped member;
A resin coating covering the outer periphery of the core, the coil, the frame-shaped member, and the holder assembly;
The frame-shaped member is positioned by the inner core held by the holding portion of the core and sandwiched between the pair of frame-shaped members, and the outer core disposed outside each frame-shaped member,
The reactor, wherein the gap defining portion and the core piece are integrated by the resin coating portion without using an adhesive.   2. The reactor according to claim 1, wherein at least a part of the gap material includes a gap defining portion.   3. The reactor according to claim 1, wherein the gap material includes a gap defining portion.   4. The reactor according to claim 1, wherein the holding portion is formed integrally with at least one of the pair of frame-shaped members.   The said holding | maintenance part and the said frame-shaped member have an engaging part which mutually engages, It is connected by this engaging part, The Claim 1 characterized by the above-mentioned. Reactor.   6. The reactor according to claim 1, wherein the holding portion and the gap defining portion have an engaging portion that engages with each other. The holding portion and the gap defining portion are integrally formed of the same kind of material,
2. The reactor according to claim 1, wherein the gap material includes a resin constituting the resin coating portion and the gap defining portion.   The reactor according to any one of claims 1 to 7, wherein the core is a green compact.

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