JP2010165800A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor for achieving both of heat radiation properties and reduction in vibration. <P>SOLUTION: The reactor includes: E and I type cores 11, 12 stored in a box-like casing 31 and formed from a magnetic material; a coil 21 wound around the E, I type cores 11, 12; and a mold resin 22 housing the coil 21. The mold resin 22 includes an overhang section 23 formed while projecting to an inner-wall surface 35 of the casing 31 with respect to a side 11a of the E type core 11. The overhang section 23 is brought into face contact with a pair of mutually facing inner-wall surfaces 35 of the casing 31. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor, and more particularly to a reactor that includes a core and a coil wound around the core and is accommodated in a box-shaped housing.

  Conventionally, a magnetic component in which a bobbinless air-core coil is fixed to a holder made of a separate insulating resin and combined with a magnetic core has been proposed (for example, see Patent Document 1). Also, a reactor device has been proposed that includes a reactor and a case that can accommodate the reactor, and a potting resin solidified after filling is interposed between the inner surface of the case and the reactor (see, for example, Patent Document 2). ). In addition, a reactor having a coil, a core made of a magnetic powder mixed resin filled inside and around the coil, and a case for housing the core inside has been proposed (see, for example, Patent Document 3).

JP-A-9-232154 JP 2006-351653 A JP 2008-42094 A

  When the reactor is operated by energizing the coil, Joule heat is generated from the coil, and vibration is generated due to deformation of the core. Therefore, in the conventional reactor, it is important to efficiently dissipate the generated heat to the outside and not transmit the vibration to the outside. In the above-mentioned Patent Document 2, a technique for suppressing noise transmitted around the reactor as much as possible is proposed, and in Patent Document 3, a reactor having excellent heat dissipation is proposed, but the heat dissipation and vibration reduction are proposed. However, it is not always sufficient in terms of compatibility, and there is room for further improvement.

  This invention is made | formed in view of said problem, The main objective is to provide the reactor which balances heat dissipation and reduction of a vibration.

  The reactor which concerns on this invention is a reactor accommodated in the box-shaped housing | casing, Comprising: The core formed from the magnetic material, the coil wound around the core, and the mold resin which encloses a coil are provided. The mold resin has an overhang portion formed so as to protrude from the side surface of the core to the inner wall surface of the housing. The overhang portion is in surface contact with a pair of inner wall surfaces facing each other of the housing.

  In the reactor, the pair of surfaces of the overhang portion that are in surface contact with the inner wall surface may be inclined so that the distance between the surfaces decreases from the upper side to the lower side of the reactor.

  In the reactor, an air gap may be formed between the core and the bottom of the housing. In addition, a gap may be formed between the core and the inner wall surface of the housing.

  In the reactor, the core may be formed of a dust core.

  According to the reactor of the present invention, heat generated in the coil can be efficiently released to the housing, and transmission of core vibration to the housing can be suppressed.

It is a figure which shows roughly an example of the structure of the drive unit containing the cooling structure of the reactor which concerns on one embodiment of this invention. It is a circuit diagram which shows the structure of the principal part of PCU. It is a perspective view of a reactor. It is a top view of a reactor. It is a rear view of a reactor. It is a perspective view which shows the resin structure which includes a coil. It is a disassembled perspective view of a reactor. It is a disassembled perspective view which shows the holding structure of a reactor. It is sectional drawing which shows the holding structure of a reactor.

  Embodiments of the present invention will be described below with reference to the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and description thereof will not be repeated.

  In the embodiments described below, each component is not necessarily essential for the present invention unless otherwise specified. In the following embodiments, when referring to the number, amount, etc., unless otherwise specified, the above number is an example, and the scope of the present invention is not necessarily limited to the number, amount, etc.

  FIG. 1 is a diagram schematically showing an example of the structure of a drive unit including a reactor cooling structure according to an embodiment of the present invention. In the example shown in FIG. 1, the drive unit 1 is a drive unit mounted on a hybrid vehicle, and includes a motor generator 100, a housing 200, a speed reduction mechanism 300, a differential mechanism 400, a drive shaft receiving portion 500, And a terminal block 600.

  The motor generator 100 is a rotating electric machine having a function as an electric motor or a generator. The motor generator 100 is a rotary shaft 110 that is rotatably attached to the housing 200 via a bearing 120, a rotor 130 that is attached to the rotary shaft 110, and a stator. 140.

  The rotor 130 includes, for example, a rotor core configured by laminating plate-like magnetic bodies such as iron or an iron alloy, and a permanent magnet embedded in the rotor core. For example, the permanent magnets are arranged at substantially equal intervals in the vicinity of the outer periphery of the rotor core. In addition, you may comprise a rotor core with a powder magnetic core.

  The stator 140 includes a ring-shaped stator core 141, a stator coil 142 wound around the stator core 141, and a bus bar 143 connected to the stator coil 142. The bus bar 143 is connected to a PCU (Power Control Unit) 700 through a terminal block 600 provided in the housing 200 and a power supply cable 700A. PCU 700 is connected to battery 800 via power supply cable 800A. Thereby, battery 800 and stator coil 142 are electrically connected.

  The stator core 141 is configured by, for example, laminating plate-like magnetic bodies such as iron or iron alloy. A plurality of teeth portions (not shown) and slot portions (not shown) as recesses formed between the teeth portions are formed on the inner peripheral surface of the stator core 141. The slot portion is provided so as to open to the inner peripheral side of the stator core 141. In addition, you may comprise the stator core 141 by a dust core.

  Stator coil 142 including three winding phases, U-phase, V-phase, and W-phase, is wound around the tooth portion so as to fit into the slot portion. The U phase, V phase, and W phase of the stator coil 142 are wound so as to deviate from each other on the circumference. Bus bar 143 includes a U phase, a V phase, and a W phase corresponding to the U phase, V phase, and W phase of stator coil 142, respectively.

  The feeding cable 700A is a three-phase cable including a U-phase cable, a V-phase cable, and a W-phase cable. U-phase, V-phase, and W-phase of bus bar 143 are connected to U-phase cable, V-phase cable, and W-phase cable in power supply cable 700A, respectively.

  The power output from the motor generator 100 is transmitted from the speed reduction mechanism 300 to the drive shaft receiving portion 500 via the differential mechanism 400. The driving force transmitted to the drive shaft receiving portion 500 is transmitted as a rotational force to a wheel (not shown) via a drive shaft (not shown), thereby causing the vehicle to travel.

  On the other hand, during regenerative braking of the hybrid vehicle, the wheels are rotated by the inertial force of the vehicle body. Motor generator 100 is driven via drive shaft receiving portion 500, differential mechanism 400 and reduction mechanism 300 by the rotational force from the wheels. At this time, the motor generator 100 operates as a generator. Electric power generated by motor generator 100 is stored in battery 800 via an inverter in PCU 700.

  The drive unit 1 is provided with a resolver (not shown) having a resolver rotor and a resolver stator. The resolver rotor is connected to the rotating shaft 110 of the motor generator 100. The resolver stator has a resolver stator core and a resolver stator coil wound around the core. The rotational angle of the rotor 130 of the motor generator 100 is detected by the resolver. The detected rotation angle is transmitted to the PCU 700. PCU 700 generates a drive signal for driving motor generator 100 using the detected rotation angle of rotor 130 and a torque command value from an external ECU (Electrical Control Unit), and uses the generated drive signal as a motor. Output to the generator 100.

  FIG. 2 is a circuit diagram showing a configuration of a main part of PCU 700. Referring to FIG. 2, PCU 700 includes a converter 710, an inverter 720, a control device 730, capacitors C1 and C2, power supply lines PL1 to PL3, and output lines 740U, 740V, and 740W. Converter 710 is connected between battery 800 and inverter 720, and inverter 720 is connected to motor generator 100 via output lines 740U, 740V, and 740W.

  Battery 800 connected to converter 710 is, for example, a secondary battery such as nickel metal hydride or lithium ion. Battery 800 supplies the generated DC voltage to converter 710 and is charged by the DC voltage received from converter 710.

  Converter 710 includes power transistors Q1 and Q2, diodes D1 and D2, and a reactor L. Power transistors Q1, Q2 are connected in series between power supply lines PL2, PL3, and receive a control signal from control device 730 as a base. Diodes D1 and D2 are connected between the collector and emitter of power transistors Q1 and Q2, respectively, so that current flows from the emitter side to the collector side of power transistors Q1 and Q2. Reactor L has one end connected to power supply line PL1 connected to the positive electrode of battery 800, and the other end connected to a connection point between power transistors Q1 and Q2.

  Converter 710 boosts the DC voltage received from battery 800 using reactor L, and supplies the boosted boosted voltage to power supply line PL2. Converter 710 steps down the DC voltage received from inverter 720 and charges battery 800.

  Inverter 720 includes a U-phase arm 750U, a V-phase arm 750V, and a W-phase arm 750W. Each phase arm is connected in parallel between power supply lines PL2 and PL3. U-phase arm 750U includes power transistors Q3 and Q4 connected in series, V-phase arm 750V includes power transistors Q5 and Q6 connected in series, and W-phase arm 750W includes power transistors connected in series. It consists of transistors Q7 and Q8. Diodes D3 to D8 are respectively connected between the collector and emitter of power transistors Q3 to Q8 so that current flows from the emitter side to the collector side of power transistors Q3 to Q8. The connection point of each power transistor in each phase arm is connected to the anti-neutral point side of each phase coil of motor generator 100 via output lines 740U, 740V, and 740W.

  Inverter 720 converts a DC voltage received from power supply line PL <b> 2 into an AC voltage based on a control signal from control device 730, and outputs the AC voltage to motor generator 100. Inverter 720 rectifies the AC voltage generated by motor generator 100 into a DC voltage and supplies it to power supply line PL2.

  Capacitor C1 is connected between power supply lines PL1 and PL3, and smoothes the voltage level of power supply line PL1. Capacitor C2 is connected between power supply lines PL2 and PL3, and smoothes the voltage level of power supply line PL2.

  Control device 730 calculates each phase coil voltage of motor generator 100 based on the rotation angle of the rotor of motor generator 100, the motor torque command value, each phase current value of motor generator 100, and the input voltage of inverter 720, Based on the calculation result, a PWM (Pulse Width Modulation) signal for turning on / off the power transistors Q3 to Q8 is generated and output to the inverter 720.

  Control device 730 calculates the duty ratio of power transistors Q1 and Q2 for optimizing the input voltage of inverter 720 based on the motor torque command value and the motor rotation speed described above, and power based on the calculation result. A PWM signal for turning on / off the transistors Q 1 and Q 2 is generated and output to the converter 710.

  Further, control device 730 controls switching operations of power transistors Q <b> 1 to Q <b> 8 in converter 710 and inverter 720 in order to charge battery 800 by converting AC power generated by motor generator 100 into DC power.

  In PCU 700, converter 710 boosts a DC voltage received from battery 800 based on a control signal from control device 730, and supplies the boosted voltage to power supply line PL2. Inverter 720 receives the DC voltage smoothed by capacitor C <b> 2 from power supply line PL <b> 2, converts the received DC voltage into an AC voltage, and outputs the AC voltage to motor generator 100.

  Inverter 720 converts the AC voltage generated by the regenerative operation of motor generator 100 into a DC voltage and outputs the DC voltage to power supply line PL2. Converter 710 receives the DC voltage smoothed by capacitor C2 from power supply line PL2, and steps down the received DC voltage to charge battery 800.

  Thus, PCU 700 as an electric device unit according to the present embodiment includes inverter 720 and reactor L. Reactor L is provided in the power supply path to inverter 720.

  FIG. 3 is a perspective view of the reactor L. FIG. FIG. 4 is a plan view of the reactor L. FIG. FIG. 5 is a rear view of the reactor L. FIG. 4 is a view of the reactor L as seen from the direction of the arrow IV shown in FIG. 3, and FIG. 5 is a view of the reactor L as seen from the direction of the arrow V shown in FIG. FIG. 6 is a perspective view showing a resin structure including a coil. FIG. 7 is an exploded perspective view of the reactor L. FIG. The structure of the reactor L is demonstrated with reference to FIGS.

  The reactor L includes a coil 21 that generates magnetic flux when energized, and a core body that has a magnetic material filled inside and outside the coil 21. The coil wire constituting the coil 21 is a flat wire such as an edge width coil. The coil 21 is formed by winding a coil wire having higher rigidity than that of a conventional general coil wire having a circular cross-sectional shape and excellent space factor and heat dissipation.

  The core body is formed by combining a pair of E-type cores 11 and a plurality of I-type cores 12 arranged to face each other. As shown in FIG. 7, a plurality of I-type cores 12 are sequentially stacked between a pair of E-type cores 11 with a nonmagnetic plate 13 typified by a ceramic plate interposed therebetween, thereby forming a core body. . The coil 21 is wound around a core body (iron core) constituting a magnetic circuit.

  The E-type core 11 and the I-type core 12 included in the core body are formed of a dust core having excellent shape flexibility and magnetic isotropy. A pair of E-type cores 11 and a plurality of I-type cores 12 form a closed magnetic circuit. An E-type core 11, an I-type core 12, and a plurality of nonmagnetic plates 13 are bonded and laminated to form a central shaft. A reactor L is formed by the closed magnetic path and the coil 21 wound around the central shaft. The core body is disposed on both the inner side and the outer peripheral side of the coil 21.

  The E-type core 11 is formed with a recess 15 in which a part of the side surface 11a is recessed. As shown in FIG. 4, the recessed part 15 is formed in both of a pair of substantially parallel side surfaces 11a of the E-type core 11 in which the planar shape was formed in the substantially rectangular shape. The recess 15 is formed in both the pair of E-type cores 11. The E-type core 11 is formed with an insertion hole 16 through which a bolt 51 for fixing the reactor L to the casing 31 can be inserted when the reactor L is accommodated in the casing 31 described later.

  In FIG. 6, the coil 21 disposed inside the mold resin 22 is illustrated through the mold resin 22. As shown in FIG. 6, the coil 21 is encapsulated in a mold resin 22 except for a terminal portion 21 a that serves as a connection terminal with an external electronic device. The mold resin 22 is formed in a cylindrical shape having a through hole 25 formed therein. The molding resin 22 and the coil 21 can be arranged around the central axis by inserting the central axis in which the E-type core 11, the I-type core 12 and the nonmagnetic plate 13 are laminated into the through hole 25.

  Since the mold resin 22 covers the coil 21, insulation performance from the outside of the coil 21 is ensured. Since the mold resin 22 integrated with the coil 21 has a bobbin function for electrically insulating the coil 21, it is not necessary to separately provide a coil bobbin for electrically insulating the coil 21 and the core body. That is, since the coil 21 and the mold resin 22 that insulates the coil 21 are integrated, a reduction in the number of parts constituting the reactor L can be realized. In addition, since it is not necessary to perform resin potting to insulate the coil 21 after the reactor L is assembled to the casing 31 described later, the steps required for assembling the reactor L can be reduced. Improvement can be achieved.

  As shown in FIGS. 3 to 5, the mold resin 22 has an overhang portion 23 that protrudes outward with respect to the side surface 11 a of the E-type core 11. As shown in FIG. 4, the mold resin 22 protrudes from the side surface 11a of the E-type core 11 by the distance L2 in the overhang portion 23 on the side where the terminal portion 21a of the coil 21 is exposed to the outside, The hang portion 23 protrudes by a distance L1.

  The surface of the overhang portion 23 protruding from the side surface 11 a of the E-type core 11 forms a tapered surface 24 that is inclined with respect to the side surface 11 a of the E-type core 11. As shown in FIG. 5, the taper surface 24 decreases from the upper side to the lower side of the E-type core 11 so that the separation distance between the taper surface 24 and the side surface 11 a of the E-type core 11 decreases. It is inclined with respect to the side surface 11a. When the reactor L is viewed from the side, the tapered surface 24 is formed to be inclined with respect to the vertical direction so that the distance between the pair of tapered surfaces 24 decreases from the upper end to the lower end of the tapered surface 24.

  A holding structure for holding the reactor L having the above configuration inside the housing 31 will be described. FIG. 8 is an exploded perspective view showing the holding structure of the reactor L. FIG. FIG. 9 is a cross-sectional view showing a structure for holding the reactor L. As shown in FIG. As shown in FIGS. 8 and 9, the reactor L including the E-type core 11, the I-type core 12, the coil 21, and the mold resin 22 includes a box-shaped housing 31 having an upper opening, and an opening of the housing 31. It arrange | positions in the space enclosed by the lid | cover 32 which closes.

  The housing 31 has a column 52 extending upward from the bottom 36. Inside the support column 52, a screw hole is formed along the extending direction of the support column 52 from the upper end of the support column 52. Bolt 51 penetrates lid 32 from the outside, and bolt 51 is screwed into a screw hole formed in support column 52, so that casing 31 and lid 32 are integrated. At this time, the bolt 51 passes through the insertion hole 16 formed in the E-type core 11, and is further inserted through the central shaft in which the I-type core 12 and the nonmagnetic plate 13 are laminated. L is assembled.

  The lid 32 is formed with a convex portion 33 that protrudes toward the bottom 36 of the housing 31. The convex portion 33 is formed to protrude toward the coil 21 so as to reduce the distance between the coil 21 of the reactor L and the lid 32. The convex portion 33 is formed in a shape that can be fitted into the concave portion 15 formed in the E-type core 11. The lid 32 is also formed with two holes 34 through which the terminal portion 21a of the coil 21 can pass. Since the terminal portion 21a passes through the lid 32 and is disposed outside the housing 31, it is possible to supply power to the coil 21 through the terminal portion 21a.

  The housing 31 includes a bottom portion 36 and a rectangular wall portion standing from the bottom portion 36. The surface of the wall portion facing the internal space of the housing 31 forms an inner wall surface 35. In a state where the reactor L is assembled inside the casing 31, the overhang portion 23 of the mold resin 22 is formed so as to protrude to the inner wall surface 35 of the casing 31.

  As shown in FIG. 9, the overhang portion 23 protrudes toward the inner wall surface 35 with respect to the side surface 11 a of the E-type core 11, and the tapered surface 24 is in surface contact with the inner wall surface 35. The inner wall surface 35 is in surface contact with the tapered surface 24 of the overhang portion 23 of the mold resin 22. By having the overhang portion 23 formed so that the mold resin 22 protrudes from the E-type core 11, the contact between the mold resin 22 and the housing 31 is ensured.

  The inner wall surface 35 that is in surface contact with the tapered surface 24 is formed to be inclined with respect to the vertical direction. The inner wall surface 35 that is in surface contact with the tapered surface 24 is inclined from the bottom 36 of the housing 31 toward the lid 32 so that the passing dimension increases. In addition, the passing dimension of the inner wall surface 35 means a distance connecting two intersections of the straight line parallel to the bottom portion 36 and the pair of inner wall surfaces 35 in the cross-sectional view shown in FIG.

  Further, as described above, the pair of tapered surfaces 24 of the overhang portion 23 that are in surface contact with the inner wall surface 35 are inclined so that the distance between the tapered surfaces 24 decreases from the upper side to the lower side of the reactor L. Yes. In a state where the reactor L shown in FIG. 9 is housed in the housing 31, the tapered surface 24 is inclined so that the distance between the tapered surfaces 24 increases from the bottom 36 of the housing 31 toward the lid 32. is doing.

  By making the inclination angle of the taper surface 24 with respect to the vertical direction equal to the inclination angle of the inner wall surface 35 with respect to the vertical direction, the taper surface 24 and the inner wall surface 35 can be brought into surface contact with each other. When the reactor L is moved from the outside to the inside of the housing 31 through the opening of the housing 31, the pair of tapered surfaces 24 of the overhang portion 23 come into surface contact with the pair of inner wall surfaces 35 facing each other. Is held inside the housing 31. When the lid 32 is fixed to the casing 31 using the bolts 51, the convex portion 33 formed on the lid 32 presses the mold resin 22 toward the bottom portion 36 from above. Thereby, a load in the direction toward the bottom portion 36 is applied to the reactor L, and the taper surface 24 and the inner wall surface 35 are surely brought into surface contact by taper fitting so that the adhesiveness between the mold resin 22 and the housing 31 is improved. It is a configuration that can be secured.

  The mold resin 22 that encloses the coil 21 is in surface contact with the housing 31, and no gap is generated between the tapered surface 24 and the inner wall surface 35. Therefore, the heat generated by the coil 21 is easily transmitted to the casing 31 through the mold resin 22, and heat dissipation of the heat generated by the coil 21 is promoted. That is, by stably securing the surface contact state between the mold resin 22 and the housing 31, the heat generated in the coil 21 can be efficiently radiated to the housing 31 via the mold resin 22. The temperature rise of the coil 21 can be suppressed. Therefore, the high heat dissipation performance of the coil 21 can be ensured, and the coil 21 can be prevented from overheating and the stability of the operation of the reactor L being lowered.

  The casing 31 and the lid 32 can be formed of a material excellent in heat dissipation represented by a metal material. For example, the casing 31 and the lid 32 can be formed by aluminum die casting. Further, by forming the mold resin 22 from a resin having excellent thermal conductivity such as an epoxy resin, higher heat dissipation can be expected. If an oil and fat material having a high thermal conductivity represented by silicon grease is applied in advance to the tapered surface 24 and the inner wall surface 35 where the mold resin 22 and the casing 31 are in surface contact, the taper surface 24 and the inner wall surface 35 are in close contact with each other. Therefore, heat dissipation can be further improved.

  As described above, the lid 32 is formed with the convex portion 33 that protrudes toward the coil 21. Since the convex portion 33 is formed, the mold resin 22 is pressed toward the bottom portion 36 and pressed against the housing 31 when the reactor L is assembled. In addition, the convex portion 33 has a function of shortening the distance between the coil 21 and the lid 32. As a result, the heat generated in the coil 21 is transmitted to the convex portion 33 and is easily radiated through the lid 32. Therefore, the heat dissipation of the coil 21 can be further improved by arranging the convex portion 33 in the vicinity of the coil 21.

  Next, the vibrations of the E-type core 11 and the I-type core 12 that occur when the reactor L is energized will be described. As described with reference to FIG. 7, the nonmagnetic plate 13 is filled between the E-type core 11 and the I-type core 12. Gaps are formed between the E-type core 11 and the I-type core 12 and between the plurality of I-type cores 12, and the predetermined magnetic performance of the reactor L can be ensured.

  When the magnetic flux passes through the magnetic bodies (E-type core 11 and I-type core 12) that are separated from each other in this way, an electromagnetic attractive force is generated in an attempt to reduce the magnetic resistance of the magnetic circuit. Due to the influence of the electromagnetic attractive force acting on the magnetic gap, the E-type core 11 and the I-type core 12 are deformed, and the E-type core 11 and the I-type core 12 are in the direction in which the electromagnetic attractive force acts (that is, the E-type core). 11 and the I-type core 12 in the stacking direction (vertical direction shown in FIG. 9). When the E-type core 11 directly contacts the casing 31 or the lid 32, the vibration generated in the E-type core 11 is transmitted to the casing 31, and a problem that the vibration is transmitted to devices arranged around the reactor L occurs. .

  As shown in FIG. 9, in the reactor L disposed inside the housing 31, a gap 38 corresponding to a distance L3 is formed between the E-type core 11 and the bottom portion 36 of the housing 31. Further, the casing 31 and the reactor L are formed so that a gap is also formed between the side surfaces 11a and 11b (see FIGS. 3 to 5) of the E-type core 11 and the inner wall surface 35 of the casing 31. Yes. That is, only the mold resin 22 holding the coil 21 in the reactor L is in contact with the casing 31, and no reactor L other than the mold resin 22 is in contact with the casing 31, and the reactor L is accommodated inside the casing 31. Has been.

  The reactor L is accommodated in the casing 31 in a state where the E-type core 11 and the I-type core 12 that generate vibration when the reactor L is energized are not in contact with the casing 31 and the lid 32. On the other hand, the mold resin 22 that does not generate vibration comes into contact with the casing 31, and the reactor L is held with respect to the casing 31. When vibration occurs in the E-type core 11 and the I-type core 12, there is no contact with the E-type core 11 and the I-type core 12 that are vibration sources, and the E-type core 11 and the I-type core 12 31 is held in a floating state. Therefore, the vibration generated in the E-type core 11 and the I-type core 12 can be prevented from being directly transmitted to the casing 31 or the lid 32, and the transmission of the vibration to the outside of the casing 31 can be suppressed.

  The core body formed by the E-type core 11, the I-type core 12 and the nonmagnetic plate 13 and the resin molded body formed by the coil 21 and the mold resin 22 are formed as separate bodies. The resin molded body is not fixed to each other, and the core body can freely move relative to the resin molded body. Therefore, when vibration occurs in the E-type core 11 and the I-type core 12, it is possible to suppress the mold resin 22 from vibrating in conjunction with the vibration of the core body. Therefore, the vibration generated in the E-type core 11 and the I-type core 12 can be more effectively suppressed from being transmitted to the casing 31 or the lid 32 via the mold resin 22. Transmission of vibration to the outside can be more effectively suppressed.

  In the vibration direction of the E-type core 11 and the I-type core 12, a gap 38 is formed between the E-type core 11 and the bottom portion 36 of the housing 31. A gap 38 is formed between the mold resin 22 serving as a main path of vibration transmission from the core body to the housing 31 and the bottom portion 36 of the housing 31, and the mold resin 22 and the housing 31 are not in contact with each other. The effect of suppressing vibration transmission from the core body to the housing 31 is great. In addition, since an air gap is also formed between the inner wall surface 35 forming the surface of the wall portion of the housing 31 and the E-type core 11, vibration transmission from the core body to the housing 31 can be more effectively performed. Can be suppressed.

  The tapered surface 24 and the inner wall surface 35 are formed along the vibration direction of the E-type core 11 and the I-type core 12. That is, the normal direction to the surface where the mold resin 22 and the housing 31 are in surface contact is substantially orthogonal to the vibration directions of the E-type core 11 and the I-type core 12. Since the contact direction of the mold resin 22 and the housing 31 is substantially orthogonal to the vibration direction of the core body, the vibration of the core body is not easily transmitted to the housing 31. That is, the vibration of the core body is suppressed from being transmitted to the casing 31 through the mold resin 22, and the vibration transmission to the casing 31 can be further effectively suppressed.

  Although there are portions that partially overlap with the above description, the characteristic configurations of the present embodiment are listed below. The reactor L of the present embodiment includes a mold resin 22 that encloses the coil 21. The mold resin 22 has an overhang portion 23 formed so as to protrude from the side wall 11 a of the E-type core 11 to the inner wall surface 35 of the housing 31. The overhang portion 23 is in surface contact with the mutually opposing inner wall surfaces 35 of the housing 31.

  In this way, since the overhang portion 23 and the inner wall surface 35 are in surface contact, the heat generated in the coil 21 is efficiently transmitted to the housing 31 via the mold resin 22. Therefore, the heat dissipation of the coil 21 can be improved. On the other hand, the reactor L is held with respect to the casing 31 by the mold resin 22 being in surface contact with the inner wall surface 35 of the casing 31, and the E-type core 11 and the I-type core 12 are not in contact with the casing 31. Has been. Therefore, vibration generated in the E-type core 11 and the I-type core 12 is not directly transmitted to the casing 31, and transmission of vibration to the casing 31 can be suppressed.

  In addition, the pair of tapered surfaces 24 of the overhang portion 23 that are in surface contact with the inner wall surface 35 are inclined so that the distance between the tapered surfaces 24 decreases from the upper side to the lower side of the reactor L. In this way, the taper surface 24 and the inner wall surface 35 can be reliably brought into surface contact with each other, so that high adhesion between the mold resin 22 and the housing 31 can be stably ensured. Therefore, the heat dissipation of the coil 21 can be further improved, and vibration transmission to the housing 31 can be more effectively suppressed.

  In addition, a gap 38 is formed between the E-type core 11 and the bottom portion 36 of the housing 31. In this way, since the non-contact state between the E-type core 11 and the housing 31 in the vibration direction of the E-type core 11 can be secured, vibration transmission to the housing 31 can be more effectively suppressed. .

  Further, a gap is formed between the E-type core 11 and the inner wall surface 35 of the housing 31. In addition to the air gap 38, the air gap is also formed between the inner wall surface 35 that forms the surface of the wall portion of the housing 31 and the E-type core 11, so that vibration can be more effectively transmitted to the housing 31. Can be suppressed.

  Further, the E-type core 11 and the I-type core 12 are formed from a dust core. A powder magnetic core made by pressing and compacting magnetic powder has a small Young's modulus (that is, low rigidity), and therefore is easily deformed when a magnetic flux passes through it. Along with this deformation, vibration tends to increase in the powder magnetic core. By adopting the configuration of the present embodiment, it is possible to effectively suppress the vibration generated in the core from being transmitted to the casing 31, so that the vibration is caused by the reactor L using the core made of the dust core. It is possible to effectively suppress the occurrence of problems associated with.

  Although the embodiment of the present invention has been described as above, the embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The reactor of the present invention can be applied particularly advantageously to a reactor for boosting the voltage of a drive unit mounted on a hybrid vehicle.

  DESCRIPTION OF SYMBOLS 1 Drive unit, 11 E type core, 11a, 11b Side surface, 12 I type core, 13 Nonmagnetic board, 15 Recessed part, 16 Insertion hole, 21 Coil, 21a Terminal part, 22 Mold resin, 23 Overhang part, 24 Tapered surface , 25 through-hole, 31 housing, 32 lid, 33 convex portion, 34 hole portion, 35 inner wall surface, 36 bottom portion, 38 gap, 51 bolt, 52 strut, L reactor.

Claims (5)

A reactor housed in a box-shaped housing,
A core formed from a magnetic material;
A coil wound around the core;
A mold resin containing the coil,
The mold resin has an overhang portion formed to protrude to the inner wall surface of the housing with respect to the side surface of the core,
The overhang portion is a reactor in surface contact with a pair of the inner wall surfaces facing each other of the casing.   The pair of surfaces of the overhang portion that are in surface contact with the inner wall surface are inclined so that the distance between the surfaces decreases from the upper side to the lower side of the reactor. Reactor.   The reactor of Claim 1 or Claim 2 with which the space | gap is formed between the said core and the bottom part of the said housing | casing.   The reactor according to claim 3, wherein a gap is formed between the core and the inner wall surface of the casing.   The reactor according to any one of claims 1 to 4, wherein the core is formed of a dust core.

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