JP2012070001A - Reactor and bobbin for reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor excellent in assembly workability and heat dissipation, and a bobbin for the reactor suitable for constructing the reactor.SOLUTION: The bobbin 1 is an insulating member disposed between an annular core having a pair of coil winding parts and a pair of coils disposed in the respective coil winding parts, and includes a pair of frame-like parts 11 and 12 abutted to both ends of the coils and outer shell parts 13 and 14 disposed on the outer peripheries of the respective coil winding parts. The outer shell part 13 is a cylindrical body for which a pair of ]-shaped outer shell pieces 13A and 13B having a through-hole 13h passing through from the outer peripheral surface to the inner peripheral surface are combined and is a molded body integrally molded with the frame-like parts 11 and 12. Coil side faces of the frame-like parts 11 and 12 are tapered along the end face shape of the coils. By the through-hole 13h, a part of the coil winding parts is exposed. Since the frame-like parts and the outer shell parts are integrally molded, then can be disposed on the core simultaneously and the assembly workability is excellent. By exposing a part of the coil winding parts, the heat dissipation is excellent.

Description

  The present invention relates to a reactor used for a component of an in-vehicle DC-DC converter such as a hybrid vehicle, and a bobbin used for the reactor. In particular, the present invention relates to a reactor excellent in assembly workability.

  There is a converter that performs voltage step-up / step-down operation as a vehicle-mounted component such as a hybrid vehicle or an electric vehicle that uses a motor as a drive source or a power source for regeneration.

  As a component of the converter, there is a reactor 100 as shown in FIG. 4 (Patent Documents 1 and 2). Reactor 100 includes a pair of coils 110a and 110b arranged in parallel, an annular magnetic core 120 having a coil winding portion 120c disposed in each of coils 110a and 110b, and between coils 110a and 110b and magnetic core 120. And a bobbin 130 disposed on the surface. The magnetic core 120 is formed in an annular shape by a pair of coil winding portions 120c and a pair of end cores 120e arranged so as to sandwich the parallel coil winding portions 120c. The bobbin 130 includes a cylindrical portion 130t that covers the outer periphery of the coil winding portion 120c, and a pair of frame-shaped portions 130f that are in contact with the end surfaces of the coils 110a and 110b. The cylindrical portion 130t is formed into a cylindrical shape by combining a pair of] -shaped pieces. FIG. 4B schematically shows a state where the coils 110a and 110b and a part of the cylindrical portion 130t are cut out.

  Reactor 100 is assembled in the following procedure. (1) A cylindrical portion 130t is formed by arranging a piece on the outer periphery of the coil winding portion 120c. (2) The coils 110a and 110b are arranged on the outer periphery of the cylindrical portion 130t. (3) The frame portion 130f and the end core 120e are arranged so that the end surfaces of the coils 110a and 110b are sandwiched between the frame portion 130f and the end core 120e. (4) The end core 120e and the coil winding part 120c are joined.

JP 2008-028290 A JP 2007-116066

  In the above-described conventional bobbin, the cylindrical portion and the frame-like portion are separate members (FIG. 4 of Patent Document 1 and FIG. 8 of Patent Document 2), so each needs to be disposed on the magnetic core 120 for assembly. It takes time and there are many parts. In addition, when the cylindrical part is an assembly of pieces, it tends to fall apart during assembly and difficult to assemble. When a bobbin is configured by directly attaching a plurality of plate pieces to the coil winding part (Patent Document 2), each plate piece must be attached to the coil winding part, which takes time and further increases the number of parts. Many.

  In addition, the bobbin may be made of a resin having excellent insulation but low heat dissipation. Then, in the structure which covers the outer periphery of a coil winding part completely like the cylindrical part of the conventional bobbin, it is hard to discharge | release the heat of a core outside and is inferior to heat dissipation.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor having excellent assembly workability and heat dissipation. Another object of the present invention is to provide a reactor bobbin suitable for constructing the reactor.

  This invention achieves said objective by devising the shape of the part arrange | positioned especially in the outer periphery of a coil winding part among bobbins.

  The reactor bobbin of the present invention is arranged between a ring-shaped core having a pair of coil winding portions and a pair of coils which are formed by winding a winding in a spiral shape and arranged in each coil winding portion. It comprises a pair of frame-like portions that are in contact with both ends of the coil, and an outer portion that is disposed on the outer periphery of the coil winding portion. The outer portion and at least one frame-like portion are integrally formed molded bodies. And the said outer part has an exposure formation location exposed without covering a part of said coil winding part. Moreover, the coil side surface with which the end surface of the said coil each contact | abuts in each said frame-shaped part is made into the taper shape from which thickness differed partially so that it might become a shape along the end surface shape of the said coil. The reactor bobbin according to the present invention is used in the case where the coil is formed by spirally winding a winding having a rectangular wire in an edgewise manner.

  The reactor of the present invention includes an annular core having a pair of coil winding parts, a pair of coils arranged in each coil winding part, and a bobbin arranged between the core and the coil. Have. Each of the above coils is formed by spirally winding a winding having a rectangular wire. And this invention reactor is provided with the bobbin for reactors of the said this invention as said bobbin. Specifically, each of the bobbins includes a pair of frame-shaped portions that are in contact with both ends of the coil, and an outer portion that is disposed on the outer periphery of the coil winding portion. The outer portion and at least one frame-like portion are integrally formed molded bodies. The coil side surfaces with which the end surfaces of the coils abut in the respective frame-shaped portions have a tapered shape in which the thicknesses are partially different so as to have a shape along the end surface shape of the coils. The outer portion has an exposed portion that is exposed without covering a part of the coil winding portion.

  According to the configuration of the present invention, since the outer shell portion and the frame-shaped portion are a molded body integrally formed, both can be arranged on the core at a time. Therefore, as compared with the conventional bobbin in which the cylindrical portion and the frame-like portion are separate members, the configuration of the present invention can shorten the assembly time of the reactor, and is excellent in assembling workability. In addition, since the outer portion and the frame-shaped portion are integrally formed, the outer portion does not fall apart during assembly. From this point, the configuration of the present invention is excellent in assembling workability and the number of parts is also increased. Few. And according to the structure of this invention, since a part of coil winding part is exposed because an outer part has an exposure formation location, even if an outer part is comprised with the insulating material inferior to heat dissipation, a coil Compared to a conventional cylindrical portion covering the entire circumference of the winding portion, the heat of the core is easily released to the outside, and the heat dissipation is excellent. Further, since the outer portion has the exposed portion, the constituent material of the outer portion can be reduced, and the material cost can be reduced. Furthermore, according to the structure of this invention, a part of coil winding part is exposed by the exposure formation location of an outer shell part, and it is set as the structure which covers a remainder with an outer shell part, and can insulate a core and a coil. . In addition, since the coil side surface of the frame-shaped portion is tapered along the end face shape of the coil, the coil and the frame-shaped portion can be in surface contact, and when the coil is compressed, the stress applied to the frame-shaped portion is wide. The thickness of the frame-like portion can be reduced because it is received in a distributed manner. Hereinafter, the configuration of the present invention will be described in more detail.

  Each frame-like portion is a frame-like body provided with two core holes penetrating from the front surface to the back surface of the plate-like material so that the end face of each coil winding portion is exposed on the plate-like material. An end core is usually joined to the exposed end surface of the coil winding portion.

  The outer portion may be a single member or a combination member formed by combining a plurality of outer pieces. In any form, the outer portion is formed integrally with the frame-like portion.

  In the case of the former single member, examples of the outer portion include a cylindrical body having a through hole penetrating from the outer peripheral surface of the outer shell portion to the inner peripheral surface and a C-shaped cylindrical body having a notch. An exposed portion is formed by the through hole or notch.

  In the case of the latter combination member, a configuration in which all the outer pieces are integrally formed in one of the frame-shaped parts, or a part of the outer piece is integrally formed in one of the frame-shaped parts, and the remaining outer piece is the other frame. It is set as the structure integrally molded by the shape part. That is, as an aspect of the present invention, the outer shell portion includes a first outer shell piece integrally formed with one frame-shaped portion and a second outer shell piece integrally formed with the other frame-shaped portion. be able to.

  According to the above aspect, when the coil is arranged on the outer periphery of the coil winding part in the assembly of the reactor, the outer piece integrally formed with one frame-like part is arranged in the coil winding part, and at the same time, one frame-like part Is disposed on one end side of the coil winding portion, the one frame-shaped portion can be used for stopping the coil, and the coil is easily clamped on the coil winding portion. Next, when the other frame-shaped portion is arranged on the other end side of the coil winding portion, the outer piece integral with the one frame-shaped portion already exists between the coil winding portion and the coil, so that the coil A gap is provided between at least a part on the other end side of the winding portion and the coil. By inserting the outer shell piece integral with the other frame-like portion into this gap, the other frame-like portion can be easily placed at an appropriate position with respect to the coil winding portion. For this reason, the assembly workability of the reactor is excellent.

  For example, by arranging the respective outer pieces at intervals, an exposed portion can be formed by a gap provided between the outer pieces. Alternatively, at least one of the outer shell pieces may have a through-hole penetrating from the outer peripheral surface to the inner peripheral surface. In this case, an exposed formation location is formed by the through hole. The outer shell piece having the through hole can increase the mechanical strength of the outer shell portion by relatively increasing the constituent material of the outer shell piece.

  As one form of this invention, an outer shell part is comprised by the some rod-shaped outer shell piece, and each outer shell piece can be set as the structure arrange | positioned with the clearance gap. At this time, an exposed portion is formed by the gap.

  According to this configuration, compared to the case where the through hole is provided, the constituent material of the outer portion is reduced and the exposed portion is easily enlarged. Therefore, the heat dissipation is easily improved and the material cost is easily reduced. In particular, when the coil winding part has a rectangular parallelepiped shape, each rod-shaped outer piece may be arranged at the center of the four surfaces constituting the outer periphery of the coil winding part. There is a risk that the coil contacts the corner of the turning part. Therefore, it is preferable that the rod-shaped outer pieces are arranged at the four corners of the coil winding portion. According to this configuration, the coil does not contact the corner of the coil winding portion, and the coil and the core can be reliably separated from each other, so that the insulation between the coil and the core can be reliably obtained. Moreover, according to this structure, since the position of the coil winding part with respect to an outer shell part is decided reliably, the position of the coil winding part with respect to the coil arrange | positioned on the outer periphery of an outer shell part can also be positioned reliably.

  As one form of this invention, it can be set as the structure provided with the resin part which covers the assembly of a core, a coil, and a bobbin. At this time, in the coil winding portion, the portion exposed from the exposed portion of the outer shell portion is in contact with the resin portion.

  According to the said structure, by providing a resin part, the mechanical protection of the said assembly and protection from external environments, such as corrosion and dust, can be aimed at. And since a coil winding part and a resin part can contact directly, it is excellent in adhesiveness of both. In particular, if the resin constituting the resin part is excellent in heat dissipation, it is easy to effectively release heat from the core and coil, and the heat of the core can be directly transferred to the resin part due to the presence of the exposed formation location. Therefore, the heat of the core can be effectively released.

  As one aspect of the present invention, the pair of coils is formed by one continuous winding and is connected by a winding portion formed by a part of the winding. One frame-like portion can be configured to have a flange portion on which the winding portion is disposed.

  The said form can also insulate reliably between a winding | wrapping part and a core by providing a flange part.

  As one form of this invention, each said frame-shaped part can be set as the structure provided with the protruding item | line which protrudes in the said coil side surface and is arrange | positioned between the said both coils.

  The said form can hold | maintain the space | interval of both coils by arrange | positioning a protruding item | line between both coils, and can also prevent that coils contact.

  The reactor of the present invention can be suitably used for a converter, and examples of the converter of the present invention include those having the reactor of the present invention.

  The reactor of the present invention using the reactor bobbin of the present invention is excellent in assembling workability and heat dissipation.

FIG. 2 is a schematic perspective view of a reactor bobbin shown in Embodiment 1, in which (A) shows a state in which the bobbins are combined, and (B) shows a state before the combination. FIG. 6 is a reactor bobbin shown in Embodiment 2, wherein (A) is a schematic perspective view of a state before the bobbin is assembled, and (B) is a schematic explanatory view for explaining an arrangement state of the outer portion of the bobbin. It is a bobbin for a reactor shown in Embodiments 3 to 5, and is a schematic explanatory view for explaining the arrangement state of the outer portion, (A) is Embodiment 3, (B) is Embodiment 4, and (C) is Embodiment 5 is shown. A conventional reactor is shown, (A) is a schematic perspective view, and (B) is an explanatory view for explaining an arrangement state of bobbins.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a reactor bobbin and a reactor according to the present invention will be described based on the drawings. The reactor of the present invention has the main characteristics of the form of the bobbin of the present invention, and the basic configuration of the coil and the core constituting the reactor is the same as the conventional one. To do.

<Embodiment 1>
FIG. 1 is a schematic perspective view of a reactor bobbin according to the present invention, in which (A) shows a combined state and (B) shows a state before combining. The bobbin 1 is an insulating member disposed between the annular core 120 having a pair of coil winding portions 120c and the pair of coils 110a, 110b disposed in each coil winding portion 120c (see FIG. 4). ). First, an outline of the core and the coil will be described, and then the bobbin will be described in detail. Hereinafter, the same reference numerals in the drawings mean the same thing.

[core]
The core has a pair of rectangular parallelepiped coil winding portions where the coils are disposed and a pair of end cores where the coils are not disposed, and the end cores so as to sandwich the coil winding portions disposed apart from each other. Are arranged to form a closed loop (annular). The core is typically composed of a magnetic body portion made of a soft magnetic material containing iron such as iron or steel, and a gap material made of a nonmagnetic material such as alumina and adjusting inductance. . The coil winding portion is typically configured by alternately laminating core pieces and gap materials constituting the magnetic body portion. As the magnetic part, a compact formed of soft magnetic powder or a laminated body in which a plurality of electromagnetic steel sheets are laminated can be used. The surface sandwiching the pair of coil winding portions in each end core may be configured by a single plane (see FIG. 4).

[coil]
In addition to the coiled wire with an enamel coating on the surface of a copper rectangular wire (Fig. 4), the coil has various cross-sectional windings such as a circular shape and a polygonal shape. Those formed by winding can be used. The pair of coils may be formed by one continuous winding, or each coil may be formed by a separate winding. In the former case, both coils are connected by a part of the winding (rewinding portion 110r (FIG. 4 (A) (not shown in FIG. 4 (B))). Both coils are connected by joining one end to each other by welding, etc. Each of the other ends 110e of the windings constituting each coil (FIG. 4 (A) (not shown in FIG. 4 (B))) A terminal member made of a conductive material is joined, and an external device such as a power source for supplying power to the coil is connected via the terminal member.

[Bobbin]
The bobbin 1 includes a pair of frame-like portions 11 and 12 that are in contact with both ends of the coil (the side on which the coil turns appear to be annular), and outer portions 13 and 14 that are disposed on the outer periphery of each coil winding portion. One feature is that it is a molded body in which the frame-shaped portion and the outer portion are integrally formed.

<< Frame-shaped part >>
The frame-shaped part 11 is a frame-shaped member that is interposed between the end face of the coil and the end core, and is provided with a pair of rectangular holes (core holes) 11h penetrating from the front surface to the back surface of the plate-like material. is there. The end surfaces of the coil winding portions are exposed from the rectangular holes 11h. One surface of the frame-shaped portion 11 is a coil side surface on which both ends of the coil are in contact, and the other surface facing the core surface is a core side surface on which the end core is in contact. Examples of the core side surface include a plane formed as shown in FIG. Since the frame-like part 12 also has a pair of rectangular holes 12h and the basic configuration is the same as that of the frame-like part 11, the description thereof is omitted. These frame-shaped portions 11 and 12 are arranged so that the coil side surfaces face each other.

  Note that one frame-like portion 11 shown in this example includes a flange portion 11f protruding from the side surface of the core. A winding portion 110r (FIG. 4) is disposed on the flange portion 11f. In addition, the frame-like parts 11 and 12 respectively have ridges 11p and 12p that protrude from the coil side surfaces. The ridges 11p and 12p are disposed between both coils. Further, the coil side surfaces of the frame-like portions 11 and 12 are each tapered so that the thickness is partially different so as to be a shape along the end face shape of the coil formed by winding the windings in a spiral shape. . You may abbreviate | omit these flange parts, a protruding item | line, and a taper shape.

《Outer part》
The outer portion 13 is formed in a cylindrical shape by combining a pair of] -shaped outer pieces 13A and 13B, and one outer piece 13A (first outer piece) is integrally formed with one frame-like portion 11, and the other outer portion 13 is formed. A piece 13B (second outer piece) is integrally formed with the other frame-like portion 12. More specifically, the outer piece 13A (13B) is provided so as to protrude from the peripheral edge of the rectangular hole 11h (12h) of the frame-like portion 11 (12) to the coil side surface. In the outer portion 14, one outer piece 14A (first outer piece) is integrally formed with one frame-like portion 11, and the other outer piece 14B (second outer piece) is integrally formed with the other frame-like portion 12. Since the basic configuration is the same as that of the outer shell 13, the description thereof is omitted. The thickness of the outer shell portions 13 and 14 can be set as appropriate so that a predetermined interval (interval desired for insulation) can be secured between the core and the coil.

Outer pieces 13A has a plate-like piece 13a _A projecting from the edge of the rectangular hole 11h to the coil side from the center portion of both edges of the plate-like pieces 13a _A, a pair of projecting so as to be perpendicular to the plate-like pieces 13a _A It has a strip 13b _A. The plate-like piece 13a _A has a through hole 13h extending from the outer peripheral surface to the inner peripheral surface, and a part of the coil winding portion is exposed from the through hole 13h. The width of the strip 13b _A (the protruding direction of the plate 13a _A (the length in the longitudinal direction of the coil winding portion (the axial direction of the coil)) is shorter than the width of the plate 13a _A. The other outer pieces 13B, 14A, 14B also include plate-like pieces 13a _B , 14a _A , 14a _B having through holes 13h, 14h, and strip-like pieces 13b _B , 14b _A , 14b _B. Since the general configuration is the same, the description is omitted. Due to the short width of the strips 13b _A , 13b _B , 14b _A , 14b _B , the strips 13b _A , 13b _B and both sides of the strips 14b _A , 14b _B , from the outer peripheral surface to the inner peripheral surface A hole is provided. The coil winding part is also exposed from these holes. One of the features of the bobbin 1 is that these holes and the through holes 13h and 14h form exposed formation portions that are exposed without covering a part of the coil winding portion.

The width of the plate-like pieces 13a _A , 13a _B , 14a _A , 14a _B shown in this example is substantially equal to the length in the longitudinal direction of the coil winding part, and a pair of plate-like pieces arranged oppositely ( 13a _A , 13a _B ) and (14a _A , 14a _B ) cover two opposing surfaces of the coil winding portion. Also, the outer pieces 13A, 13B, 14A, and 14B are all formed in a shape so that the four corners of the coil winding portion can be covered. Furthermore, the pair of strips (13b _A , 13b _B ) and (14b _A , 14b _B ) arranged opposite to each other have engaging portions that engage with each other on the peripheral edge opposite to the side connected to the plate-like pieces. Prepare.

<Constituent materials of bobbins>
As the constituent material of the bobbin 1, an insulating material is used. Specific examples include those used for insulators such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, and liquid crystal polymer (LCP).

[Assembly of the reactor]
The reactor including the reactor bobbin 1 having the above-described configuration can be formed as follows.

First, the core piece and the gap material are fixed with an adhesive or the like to form a coil winding portion, and is inserted into the rectangular hole 11h of one frame-like portion 11. At this time, a part of the outer periphery of the coil winding portion is covered with outer pieces 13A, 14A integrally formed with the frame-like portion 11. In addition, the positions where the through holes 13h and 14h of the plate-like pieces 13a _A and 14a _A are arranged in the coil winding portion and both sides of the strip-like pieces 13b _A and 14b _A are exposed.

  Coils are inserted into the outer periphery of the coil winding part and the outer pieces 13A and 14A, respectively. At this time, the coil is configured such that the coil winding portion 110r (FIG. 4) is placed on the flange portion 11f, and one end face of the coil winding portion is exposed from the rectangular hole 11h of the frame-shaped portion 11. To do. At this time, the end surface of the coil can be brought into contact with the coil side surface of the frame-shaped portion 11 so that the frame-shaped portion 11 can stop.

  The outer pieces 13B, 14B formed integrally with the other frame-like portion 12 are arranged between the coil winding portion and the coil so that the outer pieces 13B, 14B are arranged on the outer periphery of the coil winding portion, and The frame-shaped part 12 is arranged so that the other end face of the coil winding part is exposed from the rectangular hole 12h of the frame-shaped part 12. Furthermore, one end core is disposed on the core side surface of one frame-shaped portion 11, and the other end core is disposed on the core side surface of the other frame-shaped portion 12, and the frame-shaped portions 11, 12 and the coil are arranged at both end cores. The end face of the coil winding part exposed from the rectangular holes 11h and 12h of the frame-like parts 11 and 12 and the end core are joined with the winding part and the coil interposed therebetween. With the above configuration, a reactor (an assembly of the core, the coil, and the bobbin 1) in which the core, the coil, and the bobbin 1 are combined is formed.

[Resin part]
Although the said reactor may be the said combination body, the resin part can be provided so that the outer periphery of a combination body may be covered. As this resin portion, for example, epoxy resin, urethane resin, polyphenylene sulfide (PPS) resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like can be used.

  Or it can be set as the structure which accommodated the assembly in the case. In this case, the resin portion can be formed by the resin filled in the case. For this resin portion, a resin used as a potting resin, for example, a urethane resin, an epoxy resin, or a silicone resin can be used. In addition, the edge part of the coil | winding to which a terminal member is connected is exposed from resin.

[effect]
The reactor bobbin 1 having the above-described configuration is a molded body in which the frame-shaped portions 11 and 12 and the outer shell portions 13 and 14 are integrally molded. Therefore, the frame-shaped portions 11 and 12 and the outer shell portions 13 and 14 are simultaneously formed. It can arrange | position in a coil winding part, and while being able to improve the assembly workability | operativity of a reactor, a number of parts can be reduced. In addition, the bobbin 1 has a configuration in which a part of the coil winding part is exposed by the exposed formation portion, so that the heat dissipation of the reactor is improved as compared with the conventional bobbin in which the coil winding part is not substantially exposed. It is done. For example, the bobbin 1 is made of a resin having a relatively low thermal conductivity (PPS: 0.26 W / m ・ K), and the core / coil / bobbin combination is a resin having a relatively high thermal conductivity (epoxy resin: 2 W / m ・ K), it is easy to transfer the heat of the core to the coating resin with high thermal conductivity because there are few places covered with the bobbin 1 (outer portions 11 and 12) with low thermal conductivity in the coil winding part. . At this time, since the portions exposed from the outer shell portions 13 and 14 in the coil winding portion can directly contact the coating resin, the heat of the core is easily transmitted by the coating resin. Further, by having the exposed formation portion, the constituent material of the bobbin 1 can be reduced, and the material cost can be reduced.

In particular, the bobbin 1 has the outer portions 13 and 14 over the entire outer periphery of the coil winding portion, so that the core and the coil are not substantially in contact with each other, and the core and the coil are reliably insulated. be able to. In addition, the bobbin 1 has through holes 13h and 14h, and is provided with narrow strips 13b _A , 13b _B , 14b _A , and 14b _B , so that a large exposed formation location can be obtained, and heat dissipation is achieved. Improvement can be effectively achieved. Further, since the bobbin 1 has the outer pieces 13A, 13B, 14A, 14B], the connection area with the frame-like portions 11, 12 is large, and the mechanical strength is also high. In addition, the bobbin 1 is provided with an engaging portion on the periphery of the strips 13b _A , 13b _B , 14b _A , 14b _B , and when assembling the reactor, the pair of strips (13b _A , 13b _B ), ( 14b _A , 14b _B ) can be combined with high accuracy. Further, the bobbin 1 has the outer portions 13 and 14 arranged so as to cover the four corners of the coil winding portion, so that the coil winding portion is appropriately positioned with respect to the outer portions 13 and 14, and pulling the outer portion The core is appropriately positioned with respect to the coils disposed on the outer periphery of the portions 13 and 14.

  In addition, since the bobbin 1 includes the flange portion 11f, the winding portion and the core can be reliably insulated. Moreover, the bobbin 1 can hold | maintain the space | interval of both coils by arrange | positioning the protruding item | lines 11p and 12p between both coils, and can also prevent that coils contact. Further, since the bobbin 1 has a tapered shape on the coil side surfaces of the frame-like portions 11 and 12, the coil and the frame-like portions 11 and 12 can be in surface contact with each other, and when the coil is compressed, the frame-like portion 11 , 12 can be distributed and received over a wide area, so that the thickness of the frame portion can be reduced.

<Embodiment 2>
FIG. 2 shows another reactor bobbin according to the present invention, (A) is a schematic perspective view showing a state before being combined, and (B) is a schematic explanatory view for explaining the arrangement state of the outer portion. The bobbin 2 is basically the same as the bobbin 1 shown in the first embodiment, and is disposed on the outer periphery of the pair of frame-like parts 21 and 22 having the rectangular holes 21h and 22h and the coil winding part 120c of the core 120. And the outer frame portions 23 and 24, and the frame-shaped portion and the outer shell portion are integrally molded. The main difference is in the form of the outer shell portions 23 and 24. Hereinafter, the description will be focused on this difference, and description of other points will be omitted. Note that the frame-like portion is omitted in FIG.

  The outer shell portion 23 shown in the second embodiment is composed of rod-shaped outer shell pieces (bar-shaped pieces) 23A, 23B, 23C, and 23D that are respectively arranged at four corners of a rectangular parallelepiped coil winding portion 120c. Each of the rod-like pieces 23A, 23B, 23C, 23D is L-shaped along the corner of the coil winding portion 120c, and from the corner of the periphery of the rectangular hole 21h provided in one frame-like portion 21, the coil side surface Are integrally formed with the frame-like portion 21 so as to protrude from the front. The rod-like pieces 23A, 23B, 23C, and 23D are provided only at the corners of the rectangular hole 21h, and a gap is provided between the rod-like pieces 23A, 23B, 23C, and 23D. A part of the coil winding portion 120c is exposed from this gap, and this gap forms an exposure formation location. Since the outer portion 24 is also integrally formed with the rod-like pieces 24A, 24B, 24C, and 24D in the same frame-like portion 21 as the outer portion 23, and the basic configuration is the same as that of the outer portion 23, the description thereof is omitted. The end portions of the outer shell portions 23 and 24 are brought into contact with the coil side surface of the other frame-like portion 22 when the reactor is assembled. That is, the width of the outer shell portions 23 and 24 (the length in the longitudinal direction of the coil winding portion) is substantially equal to the length in the longitudinal direction of the coil winding portion.

  In the reactor bobbin 2 having the above-described configuration, since the frame-shaped portion and the outer shell portion are integrally formed in the same manner as in the first embodiment described above, the reactor assembling workability is excellent and the number of parts is small. Moreover, the bobbin 2 is excellent in the heat dissipation of the reactor depending on the exposed formation location, and can reduce the material cost.

  In particular, the bobbin 2 can be formed with a rod-like piece at the outer portion so that the exposed portion can be increased, heat dissipation can be further improved, and the constituent material of the outer portion can be further reduced. Further, since the bobbin 2 has rod-shaped pieces arranged at the four corners of the rectangular coil winding part 120c, the coil arranged on the outer periphery of the outer shell part does not contact the core during the assembly of the reactor, and the coil is sufficiently Can be supported. Therefore, even after assembly, the core and the coil can be reliably insulated. Furthermore, since the bobbin 2 has the outer portions 23 and 24 arranged at the four corners of the coil winding portion 120c, the coil winding portion 120c can be appropriately positioned with respect to the outer portions 23 and 24. The core 120 can be appropriately positioned with respect to the coils 110a and 110b arranged on the outer periphery.

<Embodiments 3 to 5>
FIG. 3 is a schematic explanatory view for explaining the arrangement state of the outer shell in another reactor bobbin of the present invention, (A) is Embodiment 3, (B) is Embodiment 4, and (C) is Embodiment 5 is shown. The bobbins 3, 4, and 5 are all the same in basic configuration as the bobbin 2 shown in the second embodiment, and the main difference is in the form of the outer shell. Hereinafter, the description will be focused on this difference, and description of other points will be omitted.

  The outer portion 33 of the third embodiment shown in FIG. 3 (A) is a rectangular tube shape that follows the outer shape of the rectangular coil winding portion 120c, and a part of each outer surface of the coil winding portion 120c is exposed. As described above, a through hole 33h that penetrates from the outer peripheral surface of the outer shell 33 to the inner peripheral surface is provided. The outer portion 34 has the same configuration as the outer portion 33, and has a rectangular tube shape having a through hole 34h. The through holes 33h and 34h form an exposure formation location.

  The outer portion 43 of the fourth embodiment shown in FIG. 3 (B) has a C-shaped cylindrical shape that covers three surfaces of the four surfaces forming the outer peripheral surface of the rectangular parallelepiped coil winding portion 120c, and a part of one surface is exposed. . That is, the outer portion 43 has a shape in which a rectangular tubular body is partially cut out from one opening to the other along the longitudinal direction of the coil winding portion (coil axial direction). There is a gap 43g. Further, a through hole 43h that penetrates from the outer peripheral surface of the outer shell portion 43 to the inner peripheral surface is provided so that a part of the remaining three surfaces of the coil winding portion 120c is exposed. The outer portion 44 has the same configuration as the outer portion 43, and has a C-shaped cylindrical shape having a gap 44g and a through hole 44h. The gaps 43g and 44g and the through holes 43h and 44h that can be formed in the cutout portions form exposure formation portions.

  The outer portion 53 of the fifth embodiment shown in FIG. 3 (C) covers the outer peripheral surface of the rectangular parallelepiped coil winding portion 120c by combining a pair of [shaped outer pieces 53A and 54B. However, when the outer shell pieces 53A and 53B are combined, a gap 53g is provided between both opposing ends. That is, the [outer shape pieces 13A and 13B described in the first embodiment are engaged with each other to form a complete cylindrical shape, whereas the outer shape portion 53 of the fifth embodiment is completely formed by the gap 53g. Does not form a cylinder. This gap 53g is maintained by integrally molding both outer shell pieces 53A and 54B into one frame-like portion. Further, a through hole 53h penetrating from the outer peripheral surface of the outer shell 53 to the inner peripheral surface is provided in a portion corresponding to the plate-like piece of each outer shell 53A, 53B so that a part of the coil winding portion 120c is exposed. Yeah. The outer portion 54 has the same configuration as the outer portion 53, and includes outer-shaped pieces 54A and 54B having a through-hole 54h, and a pair of gaps 54g is provided between the outer pieces 54A and 54B. The gaps 53g, 54g and the through holes 53h, 54h form an exposure formation location.

  Reactor bobbins 3, 4, and 5 of Embodiments 3, 4, and 5 are shaped to cover the four corners of coil winding portion 120c as in Embodiment 1 described above, so that the core and the coil are reliably insulated. it can. Further, the outer shell portions 33, 34, 43, and 44 of Embodiments 3 and 4 that are cylindrical, and the outer shell portions 53 and 54 of Embodiment 5 that are close to a cylindrical shape, are outer shell portions of Embodiment 2 that are configured by rod-shaped pieces. The mechanical strength is higher than those of 23 and 24, and the coils 110a and 110b are easily supported during the assembly of the reactor.

  In particular, the bobbin 3 shown in the third embodiment is excellent in insulation because a cylindrical outer portion exists over the entire outer periphery of the coil winding portion 120c. In particular, the bobbin 4 shown in the fourth embodiment has a gap in addition to the through hole, so that the number of exposed portions of the coil winding portion can be increased, and the heat dissipation can be improved. In particular, the bobbin 5 shown in the fifth embodiment is further excellent in heat dissipation due to more gaps.

(Modification 1)
In the second embodiment, the configuration in which all the rod-like pieces 23A to 23D and 24A to 24D constituting the outer shell portions 23 and 24 are integrally formed in one frame-shaped portion 21, but as shown in the first embodiment, At least one bar-like piece in each of the outer shell parts 23 and 24 can be integrally formed with the other frame-like part 22. At this time, if the pair of diagonal pieces located at the opposite corners are integrally formed in the same frame-shaped portion, the bobbin 2 can easily position the coil winding portion 120 with respect to the coils 110a and 110b. For example, a pair of rod-like pieces (23A, 23C), (24A, 24C) is integrally formed on one frame-like portion 21, and a pair of rod-like pieces (23B, 23D), (24B, 24D) on the other frame-like portion 22. ). The fifth embodiment can also be configured such that one outer piece 53A, 54A is integrally formed in one frame-like portion, and the other outer piece 53B, 54B is integrally formed in the other frame-like portion.

(Modification 2)
In Embodiments 2 to 5, the configuration in which all the outer pieces constituting the outer portion are integrally formed on one frame-like portion has been described, but the width of the outer piece (the length in the longitudinal direction of the coil winding portion) is set. For example, it can be divided into two parts, and one divided piece can be integrally formed with one frame-like portion, and the other divided piece can be integrally formed with the other frame-like portion. At this time, the total width of the divided pieces may be substantially the same as or shorter than the length in the longitudinal direction of the coil winding portion. In the former case, an engaging portion that engages with each other may be provided at the end of the split piece. In the latter case, a gap is provided between the divided pieces arranged in the coil winding portion, and this gap also forms an exposure forming portion.

(Modification 3)
In addition, the outer shell portion may be formed by combining the rod-shaped outer shell piece shown in the second embodiment and the] -like outer shell piece shown in the first and fifth embodiments.

  The above-described embodiment can be appropriately changed without departing from the gist of the present invention, and the present invention is not limited to the above-described configuration. For example, the number and shape of through holes provided in the outer shell, the size of the gap, the width of the plate-like piece, the width of the strip-like piece, and the like can be appropriately changed. Moreover, the shape of a coil winding part can be changed into various shapes, such as a column shape.

  The reactor of this invention can be utilized suitably for the components of power converters, such as the converter mounted in vehicles, such as a hybrid vehicle and an electric vehicle. The reactor bobbin of the present invention can be suitably used as a component part of the reactor.

1,2,3,4,5 bobbin
11,12,21,22 Frame 11h, 12h, 21h, 22h Rectangular hole 11p, 12p
11f Flange part 13,14,23,24,33,34,43,44,53,54 Outer part
13A, 13B, 14A, 14B, 53A, 53B, 54A, 54B shell 13a _A , 13a _B , 14a _A , 14a _B
13b _A , 13b _B , 14b _A , 14b _B strip 13h, 14h, 33h, 34h, 43h, 44h, 53h, 54h Through hole
23A, 23B, 23C, 23D, 24A, 24B, 24C, 24D Bar-shaped piece 43g, 44g, 53g, 54g Clearance
100 Reactor 110a, 110b Coil 110r Rewinding part 110e End of winding
120 Magnetic core 120c Coil winding part 120e End core 130 Bobbin
130t Tube part 130f Frame part

Claims (11)

A reactor comprising an annular core having a pair of coil winding parts, a pair of coils arranged in each coil winding part, and a bobbin arranged between the core and the coil,
Each of the coils is formed by spirally winding an edge-wise winding with a rectangular wire,
The bobbin includes a pair of frame-shaped portions that are in contact with both ends of the coil, and an outer portion disposed on an outer periphery of the coil winding portion,
The outer portion and at least one frame-shaped portion are integrally formed molded bodies,
In each of the frame-shaped portions, the coil side surface with which the end face of the coil abuts is a tapered shape in which the thickness is partially varied so as to be a shape along the end face shape of the coil,
The outer shell portion has an exposed portion that is exposed without covering a part of the coil winding portion.   2. The outer shell part according to claim 1, comprising a first outer shell piece integrally formed on one frame-like portion and a second outer shell piece integrally formed on the other frame-like portion. Reactor. The outer portion is composed of a plurality of rod-shaped outer pieces,
Each outer piece is arranged with a gap between them,
3. The reactor according to claim 1, wherein the exposure forming portion is formed by the gap. The outer portion is constituted by an outer piece having a through hole penetrating from the outer peripheral surface of the outer portion to the inner peripheral surface,
The reactor according to any one of claims 1 to 3, wherein the exposed portion is formed by the through hole. The coil winding part has a rectangular parallelepiped shape,
4. The reactor according to claim 3, wherein each of the rod-shaped outer pieces is disposed at each of four corners of the coil winding portion. And a resin portion covering the core, the coil, and the bobbin.
6. The reactor according to any one of claims 1 to 5, wherein a portion of the coil winding portion exposed from the exposed formation portion is in contact with the resin portion. The pair of coils is formed by one continuous winding, and is connected by a winding portion formed by a part of the winding,
The reactor according to any one of claims 1 to 6, wherein one of the pair of frame-shaped portions has a flange portion on which the winding portion is disposed.   8. The reactor according to any one of claims 1 to 7, wherein each of the frame-like portions includes a protrusion that protrudes from a side surface of the coil and is disposed between the coils. The core has a pair of end cores that are disposed so as to sandwich the pair of coil winding portions that are spaced apart to form an annular core,
The surface sandwiching the pair of coil winding portions in each end core is composed of one plane,
2. The frame-like portion is interposed between an end face of the coil and the end core, and a core side surface with which the end core abuts on the frame-like portion is a flat surface. The reactor according to any one of? 8. Reactor bobbins arranged between an annular core having a pair of coil winding sections and a pair of coils that are wound in a spiral shape and disposed in each coil winding section,
A pair of frame-shaped portions that are in contact with both ends of the coil; and an outer shell portion disposed on the outer periphery of the coil winding portion,
The outer portion and at least one frame-shaped portion are integrally formed molded bodies,
In each of the frame-shaped portions, the coil side surface with which the end face of the coil abuts is a tapered shape in which the thickness is partially varied so as to be a shape along the end face shape of the coil,
The reactor bobbin characterized in that the outer shell portion has an exposed portion that is exposed without covering a part of the coil winding portion.
However, the coil is formed by winding a winding having a rectangular wire in a spiral edgewise manner.   A converter comprising the reactor according to any one of claims 1 to 9.

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