JP2010192798A - Reactor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reactor which is compact and can be fixed tightly to a cooling base. <P>SOLUTION: The reactor 1 includes a covered assembly 14 having an assembly having a coil formed by winding a winding 12w around an outer periphery of a magnetic core and an outer resin part 13 covering an outer periphery of the assembly, and a metallic fixing member 15 having a bolt hole 15h (fitting part) for a bolt 300 for fixing the covered assembly 14 to a cooling base 200. The outer resin part 13 has an inclined part 13s, formed in a spreading shape, on the side of the cooling base 200. When the bolt 300 is clamped, the inclined part 13s is pressed toward the cooling base 200 by a pressing inclined part provided on an inner peripheral side of the fixing member 15 to be fixed tightly to the cooling base 200. The bolt 300 is not clamped directly to the outer resin part 13 and stress due to vibrations etc., is received by a base surface 13d of the inclined part 13s, thus the outer resin part 13 hardly cracks in spite of vibrations, so that the reactor 1 can be held in the fixed state for a long period. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a reactor used for a component part of an in-vehicle DC-DC converter such as a hybrid vehicle. In particular, the present invention relates to a reactor that is small and can be firmly fixed to a fixed object such as a cooling base for a long time.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. For example, Patent Documents 1 and 2 disclose a reactor used for circuit components of a converter mounted on a vehicle such as a hybrid vehicle. The reactor includes an annular magnetic core, a coil having a pair of coil elements arranged side by side on the outer periphery of the core, a case for housing a combination of the magnetic core and the coil, and a case. And a resin that is filled to seal the combination. The reactor is used by fixing the case to a metal cooling base (cooler) made of metal such as aluminum so that a coil or the like that generates heat upon energization can be cooled. A bolt is generally used for fixing, and a bolt hole to which the bolt is attached is provided in the case (FIG. 7 of Patent Document 2).

JP 2006-351675 A JP 2007-116066

However, further miniaturization is difficult with a conventional reactor having a case.
Recently, in-vehicle components such as hybrid vehicles are desired to be smaller and lighter. Therefore, it is conceivable to omit the case, but if the case is omitted, the magnetic core and coil will be exposed, so it is desirable to protect from the external environment such as dust and corrosion and mechanical protection. .

  As a configuration satisfying the above requirements, the outer periphery of a combination (not shown) of a magnetic core and a coil is covered with a resin 130 as in the reactor 100 shown in FIG. 7, and further, the resin 130 is fixed to the cooling base 200. The structure which provided the bolt hole 130h where the bolt 300 for this was attached was examined. However, in this configuration, when the reactor 100 is used, a crack (crack) 400 enters in the vicinity of the location where the bolt hole 130h is formed in the resin 130, and the crack 400 develops, and in the worst case, the bolt hole 130h There is a risk that the vicinity of the formation will fall out of the association.

  For example, like the reactor 100 shown in FIG. 7, by providing the resin 130 in a rectangular parallelepiped shape so as to cover almost the entire combination of the magnetic core and the coil, the size can be reduced. Further, if the flange 130f protruding outward is provided around the cooling base side in the rectangular resin 130, and the bolt hole 130h is formed in the flange 130f, the amount of resin used can be reduced. In addition, it can be reduced that the outer periphery of the combined body is excessively covered with the resin and the heat dissipation is reduced. Further, by forming the bolt holes 130h at the four corners of the rectangular frame-shaped flange 130f, the screwing process is reduced, and the reactor 100 can be stably fixed to the cooling base 200.

  However, in the above configuration, since the thermal expansion coefficient of the resin 130 and the thermal expansion coefficient of the cooling base 200 are different, the stress due to thermal expansion and thermal contraction during use of the reactor 100 and the stress due to vibration are the bolts in the resin 130. It concentrates on the place screwed by 300, that is, in the vicinity of the place where the bolt hole 130h is formed in the flange 130f. That is, the vicinity of the place where the bolt hole 130h is formed is particularly supported by the bolt 300, and the other part of the flange 130f is not sufficiently supported by the bolt 300, so that the crack 400 may occur as described above. If the number of bolts 300 is increased so that they are sufficiently supported by the bolts 300, the number of screwing steps increases, resulting in a decrease in workability.

  Accordingly, an object of the present invention is to provide a reactor that is small in size and can be firmly fixed to a cooling base.

  The present invention has a configuration that does not include a case, covers the assembly with a resin, and reduces the amount of resin used and the screwing process as much as possible. Propose a configuration.

  Specifically, the present invention relates to a reactor in which a coil formed by spirally winding a winding is disposed on the outer periphery of a magnetic core, and the reactor includes the magnetic core and the coil. An outer resin portion covering the outer periphery of the combined body and a metal fixing member for fixing the covering combined body having the combined body and the outer resin portion to the cooling base are provided. The outer resin portion includes a base surface that contacts the cooling base. In addition, the outer resin portion includes an inclined portion that is widened so that the cross-sectional area increases toward the base surface side. The fixing member includes a pressing inclined portion and an attaching portion. The said press inclination part is a part which contacts the inclination part of the said outer side resin part, and presses the said coating assembly to the said cooling base side in the state in which the said reactor was fixed to the said cooling base. The attachment portion is a portion to which a fastening member for fixing the covering combination to the cooling base is attached.

  The reactor according to the present invention is not configured to directly attach a fastening member such as a bolt to the outer resin portion, but to a fastening member attached to a fixing member that is a separate member, and the fixing member is made of a metal that is stronger than resin. To do. And this invention reactor provides an inclination part in the outer side resin part of a covering combination, and this inclination part is pressed against the cooling base side by a press inclination part of a fixing member, and a covering combination is passed through this fixing member. This configuration is fixed to the cooling base. With the above configuration, in the reactor of the present invention, even if heat from a coil or the like is transmitted to the fixing member, it is indirectly transmitted through the outer resin portion, and the heat dissipation is excellent because the fixing member is made of metal. Therefore, expansion and contraction due to heat of the coil or the like is difficult to occur. In addition, with the above-described configuration, the reactor according to the present invention supports the covering assembly on the entire base surface of the outer resin portion even when stress associated with the cooling cycle during use or stress due to vibration is applied to the outer resin portion. Can do. With such a configuration, it is possible to prevent a crack from being substantially generated in the vicinity of the attachment portion of the fastening member in the fixing member and to prevent the outer resin portion from being cracked. For this reason, the reactor of the present invention can firmly fix the covering assembly to the cooling base side, and also prevents the occurrence of cracks as described above, so that the fixing state of the covering combination by the fastening member can be maintained for a long time. It can be maintained stably. Furthermore, since the reactor according to the present invention includes an attachment portion on the fixing member, the magnetic characteristics cannot be deteriorated as in the case where the magnetic core is fixed with a bolt hole. The reactor of the present invention can be reduced in size and weight by omitting the case, and can be protected from the external environment and mechanical protection of the assembly because it includes the outer resin portion. .

  As one form of this invention reactor, the said coil has the form used as the molded object provided with the inner side resin part hold | maintained in the state compressed rather than the free length of the said coil.

  When the reactor is assembled using the molded body, the coil does not expand and contract during assembly, so that the coil is easy to handle and the reactor is easy to assemble.

  Examples of the magnetic core provided in the reactor of the present invention include a coil winding portion in which the coil is disposed and an exposed portion in which the coil is not disposed and exposed. At this time, both the cooling base side surface of the coil (hereinafter referred to as the coil base surface) and the cooling base side surface of the exposed portion of the magnetic core (hereinafter referred to as the core base surface) are both the outer resin portion. The coil base surface, the core base surface, and the base surface of the outer resin portion are flush with each other.

  As in the magnetic core shown in FIG. 3 of Patent Document 1 and FIG. 1 of Patent Document 2, when the outer peripheral surface of the exposed portion and the outer peripheral surface of the coil winding portion are flush with each other, the outer peripheral surface of the coil It protrudes from the outer peripheral surface of. On the other hand, when the shape of the exposed portion is changed so that the core base surface and the coil base surface of the exposed portion are flush without changing the volume of the exposed portion, the axial length of the coil in the reactor The length can be shortened. Therefore, since the installation area of the reactor with respect to a cooling base can be made small, a reactor can be reduced in size. In addition, since the core base surface and the coil base surface are flush with the base surface of the outer resin portion, when the covering assembly is placed on the cooling base, the core base surface, the coil base surface, and the outer resin portion base The surface can contact the cooling base. Therefore, when the reactor is used, the heat of the coil and the magnetic core can be directly discharged to the cooling base, and this reactor is excellent in heat dissipation. In this configuration, since the magnetic core and the coil are directly supported by the cooling base, the covering assembly can be stably fixed to the cooling base. Even in the case where the coil is the molded body, heat radiation can be improved by exposing the cooling base side surface of the molded body from the outer resin portion.

  Examples of the constituent metal of the fixing member provided in the reactor of the present invention include stainless steel, aluminum, and aluminum alloy. In particular, stainless steel is preferable because of its strength and corrosion resistance, and aluminum and its alloys are lightweight. In addition, when the fixing member is a frame-like body disposed along the outer periphery of the covering assembly, the fixing member is present on the entire periphery of the covering combination, thereby fixing the covering assembly more stably. In addition, since only one fixing member is required, the number of parts can be reduced. On the other hand, when the fixing member is an assembly composed of a plurality of divided pieces, the fixing member can be reduced in size.

  The degree of inclination of the inclined portion of the outer resin portion can be selected as appropriate. In particular, the angle θ formed by the outer peripheral surface of the inclined portion and the base surface is preferably 30 ° or more and less than 90 °. The larger the angle θ, the higher the strength of the inclined portion, which is preferable because it can sufficiently withstand the pressing force by the pressing inclined portion of the fixing member. More preferably, it is not less than 50 ° and not more than 70 °.

  The reactor according to the present invention is small because the case is omitted, and can be firmly fixed to a fixed object such as a cooling base.

FIG. 1 (A) is a schematic perspective view showing a state in which the reactor of Embodiment 1 is fixed to a cooling base, and FIG. 1 (B) is a schematic side view of a covering combination provided in the reactor. FIG. 2 is a schematic perspective view of an assembly provided in the reactor of the first embodiment. FIG. 3 is an exploded perspective view for explaining a procedure for fixing the reactor of the first embodiment to the cooling base. FIG. 4 is a schematic perspective view of the fixing member provided in the reactor according to the first embodiment by XX cutting. FIG. 5 is a schematic perspective view of a coil molded body included in the reactor of the second embodiment. FIG. 6 is an exploded perspective view for explaining an assembly procedure of a combination of a magnetic core and a coil molded body, which is provided in the reactor of the second embodiment. FIG. 7 is a schematic perspective view of a reactor having no case.

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

(Embodiment 1)
Hereinafter, the reactor 1 according to the first embodiment will be described with reference to FIGS. In the drawings, the same reference numerals indicate the same items. The reactor 1 is used by being directly attached to a cooling base 200 made of metal (typically made of aluminum) having a refrigerant circulation path (not shown) and the like inside, and an annular magnetic core 11 ( An assembly 10 (FIG. 2) having a coil 12 (FIG. 2) disposed on the outer periphery of FIG. 2) is provided. A feature of the reactor 1 is that the outer resin part 13 covering the outer periphery of the combined body 10 is provided, and the combined body 10 covered by the outer resin part 13 (hereinafter referred to as a coated combined body 14). The fixing member 15 for fixing to the cooling base 200 is provided. Hereinafter, each configuration will be described in more detail.

<Coating association>
[Magnetic core]
The magnetic core 11 will be described with reference to FIG. The magnetic core 11 includes a pair of rectangular parallelepiped coil winding portions 11c (FIG. 6) in which the coil 12 is disposed and a pair of end cores 11e (exposed portions) that are exposed without the coil 12 being disposed. The end core 11e is disposed so as to sandwich the coil winding portion 11c that is disposed and spaced apart, and is formed in a closed loop shape (annular shape). The coil winding portion 11c is formed by alternately laminating core pieces 11m (Fig. 6) made of a soft magnetic material containing iron such as iron or steel and gap members 11g (Fig. 6) made of a non-magnetic material such as alumina. The end core 11e is a core piece made of the soft magnetic material. Each core piece can be a soft magnetic powder compact or a laminate of a plurality of electromagnetic steel plates. The gap material 11g is a plate-like material disposed in a gap provided between the core pieces 11m for adjusting the inductance (it may be an air gap). The core piece and the gap material are integrally joined with an adhesive or the like. The number of core pieces and gap members can be appropriately selected so that the reactor 1 has a desired inductance. Moreover, the shape of a core piece or a gap material can be selected suitably.

  The outer peripheral surface of the coil winding portion 11c and the outer peripheral surface of the end core 11e are not flush with each other, but the surface on the cooling base side of the end core 11e (hereinafter referred to as the core base surface; the lower side in FIGS. ) Projecting from the coil winding portion 11c. The end core 11e has a core base surface that is flush with a cooling base side surface (hereinafter referred to as a coil base surface in FIG. 2) of the coil 12, which will be described later. 11e height (the length in the direction perpendicular to the surface of the cooling base 200 (here, the direction equal to the direction perpendicular to the axial direction of the coil 12) in a state where the reactor 1 is fixed to the cooling base 200). It is adjusted. Note that the outer peripheral surface of the coil winding portion and the outer peripheral surface of the end core may be flush with each other.

[coil]
The coil 12 (FIG. 2) includes a pair of coil elements 12a and 12b formed by spirally winding one continuous winding 12w. Both coil elements 12a and 12b are formed side by side so that their axial directions are parallel to each other. The winding 12w is preferably a coated wire having an insulating coating layer on the outer periphery of the conductor. Here, a coated rectangular wire is used in which the conductor is made of a copper rectangular wire and the insulating coating layer is made of enamel. Both coil elements 12a and 12b are formed by edgewise winding the covered rectangular wire, and are connected by a winding portion 12r. The windings can be used in various shapes such as a circular shape and a polygonal shape in addition to the conductor made of a flat wire. Alternatively, each coil element may be manufactured separately, and the ends of the windings forming each coil element may be joined by welding or the like to form an integral coil.

  Both ends of the winding 12w forming the coil 12 are appropriately extended from the turn forming portion and pulled out of the outer resin portion 13, and the conductive portion is exposed to the conductive portion exposed by peeling off the insulating coating layer. A terminal member (not shown) is connected. An external device (not shown) such as a power source for supplying power is connected to the coil 12 through this terminal member. For connection between the conductor portion of the winding 12w and the terminal member, welding such as TIG welding or crimping can be used.

[Insulator]
The combined body 10 including the magnetic core 11 and the coil 12 is also provided with an insulator 16 (FIG. 2). The insulator 16 includes a cylindrical bobbin (not shown) that covers the outer periphery of the coil winding portion 11c, and a pair of flange portions 16f that come into contact with the end face of the coil 12. If the bobbin is configured to engage half-cut square tube pieces as shown in FIG. 8 of Patent Document 2, the outer periphery of the coil winding portion 11c can be easily covered. Each flange 16f is a rectangular frame disposed at one end of the bobbin. For the insulator, an insulating resin such as polyphenylene sulfide (PPS) resin, liquid crystal polymer (LCP), polytetrafluoroethylene (PTFE) resin can be used.

[Outside resin part]
The outer periphery of the combined body 10 is covered with the outer resin portion l3 to form a covering combined body 14. Here, the outer resin portion l3 is formed so that the outer appearance of the covering combined body 14 becomes a rectangular parallelepiped shape by casting the epoxy resin after producing the combined body 10. The end of the winding 12w is exposed from the outer resin portion 13 as shown in FIG. Here, in the state in which the covering assembly 14 is placed on the cooling base 200, the surface on the side from which the end of the winding 12w of the rectangular parallelepiped outer side resin portion 13 is drawn is the upper surface, and the cooling surface is the opposite surface. The base side surface (base surface 13d) is referred to as a lower surface, and the four surfaces surrounding the upper surface and the lower surface are referred to as side surfaces. The outer resin portion 13 includes a portion protruding from the outer peripheral surface so as to surround the entire circumference of the portion on the cooling base side (lower side) (see FIG. 3 as appropriate). More specifically, on the four side surfaces of the outer resin part 13, the cross-sectional area is formed so as to continuously increase from the intermediate part toward the cooling base side (lower surface side), so that the cooling is performed. It has a base surface 13d in contact with the base 200. That is, when the coating assembly 14 is viewed from the front or side, as shown in FIG. 1 (B), the cooling base side in the outer resin portion 13 has a trapezoidal shape. This widened portion is referred to as an inclined portion 13s.

  Here, the inclined portion 13s is provided over the entire circumference of the four side surfaces and exists in a rectangular frame shape. In addition, it may be configured such that a part of each side surface is provided with an inclined part, or may be configured such that an inclined part is provided only on two opposing side surfaces among the four side surfaces, It is good also as a structure by which the inclination part was provided only in any one side surface or only in three side surfaces. The more the formation area of the inclined part with respect to the whole of the four side surfaces, the more difficult it is to crack the outer resin part even if stress due to vibration during use of reactor 1 or stress due to thermal expansion / contraction is applied to the outer resin part Can do. Here, when the height of the covering assembly 14 (the length in the direction from the lower surface (base surface 13d) to the upper surface of the outer resin portion 13) is H, the lower surface (base surface 13d) of the outer resin portion 13 is ( An inclined portion 13s is provided in a region up to 1/5) × H. The angle θ formed by the outer peripheral surface (inclined surface) of the inclined portion 13s and the base surface 13d is 60 °.

  In the outer resin portion 13, the average thickness of the portion excluding the formation region of the inclined portion 13s is uniform as 1 to 2 mm, and the thickness of the outer resin portion l3 of the portion and the covering region for the combined body 10 are appropriately selected. can do. For example, a part of the end core 11e and the coil 12 may be exposed without being covered with the constituent resin of the outer resin portion. Further, the core base surface of the end core 11e and the coil base surface of the coil 12 may be covered with the constituent resin of the outer resin portion, and only the end portion of the winding 12w may be exposed from the outer resin portion.

  The lower surface of the outer resin portion 13 is a base surface 13d that comes into contact with the cooling base 200 when the covering assembly 14 is fixed to the cooling base 200. The base surface 13d and the core base of the end core 11e described above The surface and the coil base surface of the coil 12 are flush with each other. Therefore, when the covering combination 14 is fixed to the cooling base 200, the base surface 13d of the outer resin portion 13 of the covering combination 14, the core base surface of the end core 11e, and the coil base surface of the coil 12 are Also contacts the cooling base 200.

  For example, epoxy resin, urethane resin, PPS resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like can be used as the constituent resin of the outer resin portion 13. Further, when the constituent resin is mixed with a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide, heat dissipation can be improved.

<Fixing member>
In order to fix the covering combination 14 to the cooling base 200, a fixing member 15 and a bolt 300 (clamping member) are used. The fixing member 15 is a rectangular frame-shaped member arranged so as to cover the inclined portion 13s of the rectangular frame shape of the covering combination 14 in a state where the covering combination 14 is placed on the cooling base 200. Here, it is made of stainless steel.

  The fixing member 15 is a base surface 15d (FIG. 4) whose one surface is in contact with the cooling base 200. The fixing member 15 is so-called so that the cross-sectional area continuously decreases from the intermediate portion toward the base surface 15d on the cooling base side over the entire circumference of the cooling base side portion on the inner peripheral surface thereof. It has a pressing inclined portion 15s (FIG. 4) formed in a tapered shape. The fixing member 15 is disposed on the covering assembly 14 such that the outer peripheral surface (inclined surface) of the pressing inclined portion 15s contacts the outer peripheral surface (inclined surface) of the inclined portion 13s of the outer resin portion 13 provided in the covering union body 14. Is done. That is, the angle α formed by the outer peripheral surface of the pressing inclined portion 15s and the extended surface of the base surface 15d is equal to the angle θ of the inclined portion 13s.

  Further, the fixing member 15 has bolt holes 15h (attachment portions) through which the bolts 300 are inserted at the four corners. Here, the bolt holes 15h are provided at the four corners of the fixing member 15, respectively. However, for example, the bolt holes may be provided only at the two opposite corners. Here, the bolt hole 15h is a smooth cylindrical hole that is not threaded, and the bolt hole 200h (FIG. 3) provided in the cooling base 200 is a threaded hole that is threaded. The 15 bolt holes may also be screw holes. The fixing member 15 is made of a metal such as stainless steel, so that it can be easily threaded and can sufficiently withstand the tightening force of the bolt 300.

  Here, the fixing member 15 is a rectangular frame-shaped integrally molded product, but can be a set of a plurality of divided pieces. In addition, here, the fixing member 15 is configured to cover the entire circumference of the inclined portion 13s of the outer resin portion 13 provided in the covering assembly 14, but includes a split piece disposed only on a part of the inclined portion 13s. Can be configured. For example, it may be an assembly composed of four divided pieces respectively disposed in and near the four corners of the inclined portion 13s of the outer resin portion 13 included in the covering assembly 14, or two opposite corners of the inclined portion 13s and its It is good also as a braid which consists of two division pieces each arrange | positioned in the vicinity. By making the fixing member an assembly of such divided pieces, the constituent material of the fixing member and the number of bolts can be reduced, which can contribute to weight reduction.

<Reactor assembly procedure and fixing procedure>
Referring mainly to FIG. 3, a procedure for forming reactor 1 having the above-described configuration and a procedure for fixing to cooling base 200 will be described.

  First, the core piece 11m (Fig. 6) and the gap material 11g (Fig. 6) are fixed with an adhesive or the like to form the coil winding portion 11c (Fig. 6), and the bobbin of the insulator 16 (Fig. 2) is formed on the outer periphery. Deploy. Separately, the coil elements 12a and 12b (FIG. 2) of the prepared coil 12 (FIG. 2) are respectively disposed on the coil winding portion 11c where the bobbin is disposed, and both end surfaces of the coil elements 12a and 12b are arranged. The flange portion 16f (FIG. 2) and the end core 11e (FIG. 6) of the insulator 6 are brought into contact with each other, and the flange portion 16f and the end core 11e are disposed so as to sandwich the coil 12, and the end portion is bonded with an adhesive or the like. The core part 11e and the coil winding part 11c are joined. Through this step, the combined body 10 (FIG. 2) of the magnetic core 11 and the coil 12 is obtained.

  In the obtained combined body 10, the outer resin portion 13 is formed so that the core base surface of the end core 11e, the coil base surface of the coil 12, and the end of the winding 12w are exposed. Further, the outer periphery of the combined body 10 is covered with the constituent resin of the outer resin portion 13, and an inclined portion 13s is formed on the cooling base side of the outer resin portion 13. The covering combination 14 is obtained by the above process.

  The obtained covering combination 14 is placed on the cooling base 200 so that the core base surface of the end core 11e and the coil base surface of the coil 12 are on the cooling base side. At this time, the core base surface of the end core 11e, the coil base surface of the coil 12, and the base surface 13d (FIG. 1) of the inclined portion 13s of the outer resin portion 13 contact the cooling base 200. Note that if the adhesive or the like is applied to the core base surface of the end core 11e very thinly (about several tens of μm), the end core 11e and the cooling base 200 are easily brought into close contact with each other.

  The fixing member 15 is placed on the cooling base 200 so as to cover the inclined portion 13s of the outer resin portion 13 of the covering combination 14 placed on the cooling base 200. At this time, the pressing inclined portion 15s of the fixing member 15 contacts the inclined portion 13s of the outer resin portion 13, and the base surface 15d (FIG. 4) of the fixing member 15 contacts the cooling base 200.

  Then, the bolts 300 are fixed to the bolt holes 15h of the fixing member 15 and the bolt holes 200h of the cooling base 200, respectively. At this time, when the bolt 300 is tightened, the pressing inclined portion 15s of the fixing member 15 presses the inclined portion 13s of the outer resin portion 13, whereby the covering assembly 14 is pressed to the cooling base side and firmly fixed. . The cooling base 200 is previously provided with a bolt hole 200h into which the bolt 300 is screwed. The reactor 1 is fixed to the cooling base 200 by the above process.

<Effect>
Reactor 1 having the above configuration is not provided with a case, and is compact and lightweight, but has outer resin portion 13 to protect magnetic core 11 and coil 12 from the external environment and mechanical protection. In addition, it is easy to handle the combined body 10. In addition, the reactor 1 is not configured such that the bolt 300 is directly attached to the outer resin portion 13, but is configured such that the bolt 300 is attached to the metal fixing member 15, so that vibrations, coils, etc. when the reactor 1 is used Even when subjected to stress due to heat expansion and contraction accompanying heat generation, the fixing member 15 has high strength and excellent heat dissipation, so that substantially no cracks are generated in the vicinity of the bolt hole 15h formation portion in the fixing member 15. Further, even if the number of bolts 300 is small, the outer resin portion 13 can receive stress due to the vibration and thermal expansion / contraction on the entire base surface 13d, so that the outer resin portion 13 is hardly cracked. Therefore, the reactor 1 can maintain the state firmly fixed to the cooling base 200 for a long period of time. Furthermore, since the fixing member 15 is made of metal, the covering assembly 14 can be mechanically protected or used as a heat dissipation path.

  Further, the reactor 1 is configured such that the core base surface of the end core 11e and the coil base surface of the coil 12 are exposed from the outer resin portion 13 and are in contact with the cooling base 200, so that the magnetic core 11 and the coil 12 Heat can be directly transferred to the cooling base 200, so heat dissipation is excellent. Furthermore, the reactor 1 has a shape in which the end core 11e protrudes from the coil winding portion 11c, so that when the end core and the coil winding portion have the same volume as the magnetic core, the reactor 1 Since the axial length of the coil 12 in 1 can be shortened, the coil 12 can be made smaller.

(Embodiment 2)
Hereinafter, the reactor of the second embodiment will be described with reference to FIGS. In the first embodiment, the coil 12 provided in the reactor 1 has been described by simply winding the winding in a spiral shape. In addition, as the coil, a coil molded body 22 in which the outer periphery of the coil elements 12a and 12b is covered with resin as shown in FIG. 5 can be used. The reactor of the second embodiment has the same configuration except that the coil 12 of the reactor 1 of the first embodiment is changed to the coil molded body 22. For this reason, the coil molded body 22 and the combined body 20 including the molded body 22 will be mainly described here, and the description of other configurations will be omitted.

<Coil molding>
The coil molded body 22 includes an inner resin portion 22c on the outer periphery of the coil 12 described in the first embodiment so as to hold the coil elements 12a and 12b in a compressed state. Here, the inner resin portion 22c covers the entire outer periphery of the coil 12 along the shape of the coil 12 except for both ends of the winding 12w. In the inner resin portion 22c, the thickness of the portion covering the turn forming portions of the coil elements 12a and 12b is substantially uniform, and the portion covering the winding-back portion 12r has a shape protruding in the axial direction of the coil.

  The inner periphery of each coil element 12a, 12b is also covered with the constituent resin of the inner resin portion 22c, and has a hollow hole 22h formed of this constituent resin. A coil winding portion 11c (FIG. 6) of the magnetic core 11 (FIG. 6) is inserted and disposed in each hollow hole 22h. The thickness of the constituent resin of the inner resin portion 22c is adjusted so that each coil winding portion 11c is disposed at an appropriate position on the inner circumference of the coil elements 12a and 12b, and the shape of the hollow hole 22h is coiled. The outer shape of the turning portion 11c (here, a rectangular parallelepiped shape) is used. Therefore, the constituent resin of the inner resin portion 22c existing on the inner periphery of each coil element 12a, 12b functions as a positioning portion for the coil winding portion 11c.

  Here, the entire inner circumference of each of the coil elements 12a and 12b is covered with the constituent resin, but the insulation distance between the magnetic core 11 and the coil 12 can be secured and positioned as described above. If the constituent resin is present, the entire inner circumference of each of the coil elements 12a and 12b may not be covered, and a part of the inner peripheral surface of the coil elements 12a and 12b is exposed from the constituent resin of the inner resin portion 22c. May be.

  The resin of the inner resin part 22c has heat resistance that does not soften against the maximum temperature of the coil or magnetic core when a reactor including the coil molded body 22 is used, and transfer molding and injection molding are possible. Possible materials can be suitably used. In particular, a material having excellent insulating properties is preferable. Specifically, a thermosetting resin such as epoxy, or a thermoplastic resin such as PPS resin or LCP can be suitably used. Here, an epoxy resin is used. The constituent resin of the inner resin portion 22c may be the same as or different from the constituent resin of the outer resin portion 13. Moreover, heat dissipation can be improved by mixing the above-described ceramic filler with the constituent resin of the inner resin portion 22c.

<Manufacture of coil molding>
The coil molded body 22 can be manufactured using a molding die as described below. As the molding die, one constituted by a pair of first and second molds that can be opened and closed can be used. The first mold includes an end plate positioned on one end side of the coil 12 (the side from which the end of the winding 12w is pulled out in FIG. 5), and a core inserted into the inner circumference of each of the coil elements 12a and 12b. The second mold includes an end plate located on the other end side of the coil (on the winding portion 12r side in FIG. 5) and a peripheral side wall covering the periphery of the coil 12. The first mold and the second mold include a plurality of rod-shaped bodies that can be moved back and forth inside the mold by a drive mechanism, and the end surfaces of the coil elements 12a and 12b (turn forming portions are annularly formed) by these rod-shaped bodies. The coil elements 12a and 12b are compressed by appropriately pressing the visible surface). The rod-shaped body has sufficient strength against compression of the coil 12 and heat resistance against heat during molding of the inner resin portion 22c, and reduces the number of portions of the coil 12 that are not covered with the inner resin portion 22c. Furthermore, it is preferable to make it as thin as possible.

  The coil 12 is arranged in the molding die so that a certain gap is formed between the surface of the molding die and the coil 12. At this time, the coil 12 is not yet compressed.

  Next, the molding die is closed, and the core of the first die is inserted into the inner periphery of each coil element 12a, 12b. At this time, the interval between the inner periphery of the core and the coil elements 12a and 12b is made substantially uniform over the entire periphery of the core.

  Subsequently, the rod-shaped body is advanced into the molding die to compress the coil elements 12a and 12b. By this compression, a gap between adjacent turns constituting each coil element 12a, 12b is reduced.

  Thereafter, the resin is injected into the molding die from the resin inlet and solidified, and then the molding die is opened, and the coil molded body 22 holding the coil 12 in a compressed state is taken out. Note that the plurality of small holes formed in the portion pressed by the rod-like body are filled with the outer resin portion 13, and may be left as they are, or may be filled with an appropriate insulating material or the like.

<Assembly procedure for union>
The assembly procedure of the combined body 20 including the coil molded body 22 will be mainly described with reference to FIG. First, the coil molded body 22 is prepared as described above. Also, the coil winding part 11c is prepared by fixing the core piece 11m and the gap material 11g with an adhesive or the like. Then, the coil winding portion 11c is inserted and disposed in the hollow hole 22h of the coil molded body 22. Since the hollow hole 22h is formed to a predetermined thickness by the constituent resin of the inner resin part 22c of the coil molded body 22 as described above, each coil winding part 11c inserted into the hollow hole 22h is respectively The coil elements 12a and 12b (FIG. 5) are arranged at appropriate positions. Next, the end core 11e is arranged so that both end faces of the coil molded body 22 are sandwiched between the pair of end cores 11e, and the end core 11e and the coil winding portion 11c are joined with an adhesive or the like. By this process, the combined body 20 is obtained. In the obtained combined body 20, the core base surface of the end core 11e is flush with the surface on the cooling base side (hereinafter referred to as a coil base surface) in the coil molded body 22. Here, the coil base surface of the coil molded body is made of the constituent resin of the inner resin portion. However, one surface of the coil element may be exposed from the inner resin portion, and the coil element may be exposed.

  When the combined body 20 is obtained, the outer periphery of the combined body 20 is exposed to the reactor of the first embodiment so that the end of the winding 12w, the core base surface of the end core 11e, and the coil base surface of the coil molded body 22 are exposed. In the same manner as 1, the outer resin part is coated with the constituent resin to form a coating assembly. In addition, an inclined portion is provided on the cooling base side of the covering assembly in the same manner as the reactor 1 of the first embodiment. And the reactor of Embodiment 2 can be used by arrange | positioning this fixing | fixed assembly and the fixing member demonstrated in Embodiment 1 to a cooling base in order, and fixing to a cooling base using a volt | bolt.

<Effect>
The reactor according to the second embodiment, in which the outer resin portion of the covering assembly is provided with an inclined portion and having a fixing member, is similar to the reactor 1 of the first embodiment, while being small and light, the magnetic core 11 and The coil 12 can be protected from the external environment and mechanically protected. And since this reactor is hard to produce a crack in a fixing member or an outer side resin part by the stress accompanying the vibration at the time of use or thermal expansion-contraction, it can maintain a strong fixed state over a long period of time.

  In particular, the reactor according to the second embodiment including the coil molded body 22 maintains the compressed state of the coil 12 by the inner resin portion 22c. Therefore, when assembling the reactor, the coil 12 is easy to handle and has excellent workability. The coil molded body 22 also covers the inner periphery of each of the coil elements 12a, 12b with the constituent resin of the inner resin portion 22c, and the magnetic core 11 (coil winding portion) by making the constituent resin into a predetermined thickness and shape. 11c) can be used for positioning. Therefore, by using the coil molded body 22, the magnetic core 11 can be easily positioned without the need for a magnetic core positioning member, and the number of parts and work processes can be reduced. Furthermore, since the constituent resin of the inner resin portion 22c is an insulating resin, the magnetic core 11 and the coil 12 can be insulated by the constituent resin that covers the inner periphery of the coil elements 12a and 12b. Therefore, the number of parts and work processes can be reduced. In addition, this reactor is excellent in heat dissipation as the reactor 1 of the first embodiment because the core base surface of the end core 11e and the coil base surface of the coil molded body 22 are exposed from the outer resin portion.

  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.

  The reactor of this invention can be utilized suitably for the components of vehicle-mounted components, such as a vehicle-mounted converter mounted in vehicles, such as a hybrid vehicle, an electric vehicle, and a fuel cell vehicle, for example.

1 Reactor 10,20 Combined body 11 Magnetic core 11e End core 11c Coil winding part
11m core piece 11g gap material 12 coil 12a, 12b coil element 12r winding part
12w Winding 13 Outer resin part 13s Inclined part 13d Base surface 14 Covering assembly
15 Fixing member 15s Pressing slope 15d Base surface 15h Bolt hole
16 Insulator 16f Buttocks
22 Coil molded body 22c Inner resin part 22h Hollow hole
100 Reactor 130 Resin 130h Bolt hole 130f Flange
200 Cooling base 200h Bolt hole 300 Bolt 400 Crack

Claims (5)

A reactor in which a coil formed by spirally winding a winding is disposed on the outer periphery of a magnetic core,
An outer resin portion covering the outer periphery of the combined body having the magnetic core and the coil;
A metal fixing member for fixing a covering combination having the combination and the outer resin portion to a cooling base;
The outer resin portion is
A base surface in contact with the cooling base, and an inclined portion widened so that a cross-sectional area increases toward the base surface side;
The fixing member is
In a state where the reactor is fixed to the cooling base, a pressing inclined portion that contacts the inclined portion and presses the covering combination toward the cooling base, and a tightening for fixing the covering combination to the cooling base. A reactor comprising an attachment portion to which an attachment member is attached.   2. The reactor according to claim 1, wherein the coil is a molded body including an inner resin portion that is held in a compressed state with respect to a free length of the coil. The magnetic core includes a coil winding portion where the coil is disposed and an exposed portion where the coil is not disposed and exposed,
Both the cooling base side surface of the coil and the cooling base side surface of the exposed portion of the magnetic core are exposed from the outer resin portion and are flush with the base surface of the outer resin portion. The reactor according to claim 1 or 2, wherein   4. The reactor according to any one of claims 1 to 3, wherein the fixing member is a frame-like body arranged along an outer periphery of the covering combination.   The reactor according to any one of claims 1 to 4, wherein an angle θ formed by an outer peripheral surface of the inclined portion and the base surface is 30 ° or more and less than 90 °.

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