JP2012146753A - Resin molding reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To combine down-sizing and suppression of deterioration in DC superposition characteristics without sacrificing easy manufacturing.SOLUTION: A resin molding reactor 1 comprises a resin gap member 5 composed of a material having a permeability lower than that of a core 4 and disposed in a case 3 so that a part of a closed magnetic path, formed by a magnetic flux generated around the winding 2 when it is electrified, passes through the inside of the resin gap member. The resin gap member 5 is formed so that the distance of the closed magnetic path passing through the inside of the resin gap member becomes shorter as the distance between the winding 2 and the resin gap member 5 increases. The winding 2 and the resin gap member 5, and a resin insulation member covering the winding 2 are formed integrally in advance.

Description

  The present invention relates to a resin-molded reactor manufactured by embedding a winding in a resin filled with magnetic powder.

  The resin molding reactor is manufactured by embedding a winding coated with a resin insulating member in a resin mixed with magnetic powder (see, for example, Patent Document 1). The resin in which the magnetic powder is mixed has a function as a magnetic core of the reactor, and the resin insulating member has a function of electrically insulating the winding from the resin serving as the magnetic core of the reactor.

  Incidentally, the resin-molded reactor described in Patent Document 1 has the following problems when considering its electrical characteristics. FIG. 13 is a cross-sectional view showing the structure of a conventional resin-molded reactor.

  As shown in FIG. 13, in the conventional resin-molded reactor 101, the inner circumferential side length La (hereinafter referred to as the inner circumferential side length La) of the magnetic path formed around the winding 102 is It becomes shorter than the peripheral length Lb on the outer peripheral side (hereinafter referred to as the outer peripheral peripheral length Lb). That is, the magnetic field non-uniformity occurs in which the magnetic field induced in the magnetic path becomes stronger on the inner peripheral side of the magnetic path and weaker on the outer peripheral side. For this reason, when the value of the current flowing through the winding 102 is gradually increased, the magnetic flux density is saturated earlier in the magnetic core on the inner peripheral side of the magnetic path than in the magnetic core on the outer peripheral side. Easy to do.

  Here, the magnetomotive force F applied to the winding 102 and the average value Ha of the magnetic field generated on the path of the inner circumference side circumference La (hereinafter referred to as the inner circumference side magnetic field average value Ha) or the outer circumference side circumference Lb. Based on Ampere's law, the relationship represented by the following formula (1) holds between the average value Hb of the magnetic field generated on the path (hereinafter referred to as the outer peripheral side magnetic field average value Hb). For this reason, the relationship represented by the following formula (2) is established between the inner peripheral magnetic field average value Ha and the outer peripheral magnetic field average value Hb.

  Therefore, as the ratio between the outer peripheral side circumferential length Lb and the inner peripheral side peripheral length La increases, the ratio between the inner peripheral side magnetic field average value Ha and the outer peripheral side magnetic field average value Hb increases, and the deterioration of the DC superimposition characteristic is remarkable. Become. In consideration of structural factors of the resin-molded reactor 101, the lateral dimension Wc1 or the longitudinal direction of the winding 102 increases as the lateral distance Wm between the magnetic path of the outer peripheral side circumference Lb and the winding 102 increases. As the dimension Wc2 becomes smaller, the circumference ratio (Lb / La) becomes larger, and the deterioration of the direct current superimposition characteristic appears more remarkably.

  For this reason, in a reactor structure such as the conventional resin-molded reactor 101, the aim is to reduce the size of the reactor without changing the material to be used, that is, by reducing the size of the winding 102, It is difficult to configure the reactor.

  On the other hand, in order to reduce the size of the reactor, it is conceivable to reduce the size of the magnetic core instead of the size of the winding 102. However, in order to maintain the direct current superposition characteristics, the size of the magnetic core cannot be reduced for the following reason.

  The energy stored in the reactor is kept in the form of magnetic energy in the magnetic core. That is, the energy E of the reactor 101 is expressed by the following expression (3) using the physique V of the magnetic core and the magnetic energy D per unit volume of the magnetic core.

  Here, it is known that the magnetic energy D per unit volume has an upper limit value Dm determined by the magnetic material, and when the magnetic energy D exceeds the upper limit value Dm, the magnetic properties of the magnetic core are lost. The energy of the reactor 101 at this time is the upper limit value Em of energy that can be stored in the reactor 101 (hereinafter referred to as the reactor energy upper limit value Em), and the winding current value Im (hereinafter referred to as the energy upper limit current value Im). And the inductance L of the reactor 101 are expressed by the following expression (4). For this reason, the energy upper limit current value Im is represented by the following formula (5).

  Therefore, even if a current exceeding the energy upper limit current value Im flows through the winding 102, the reactor 101 cannot store energy exceeding the reactor energy upper limit value Em, and the electrical characteristics of the reactor can be maintained. Disappear. That is, the energy upper limit current value Im is a limit current value at which the reactor can be energized, and is a parameter that characterizes the DC superposition characteristics. When the specifications of the material of the reactor 101 and the inductance are not changed, the relationship represented by the following expression (6) is established based on the above expression (5).

  The above equation (6) represents that the DC superimposition characteristic is characterized only by the magnetic core body V. Therefore, in order to maintain the DC superposition characteristics, the magnetic core size V cannot be reduced.

  In order to solve this problem, by providing the magnetic core with a slit-like gap formed so that the width is larger on the inner peripheral side than on the outer peripheral side of the magnetic path, the magnetic flux density passing through the magnetic core is not uniform. A technique for mitigating and suppressing deterioration of the DC superimposition characteristics due to miniaturization is known (see, for example, Patent Document 2).

JP 2007-19402 A JP-A-8-115825

  However, in order to provide the gap in a resin molding reactor manufactured by embedding a winding in a resin mixed with magnetic powder, the gap is formed in the resin after the winding is embedded in the resin. A process will be added and there existed a problem that the ease of manufacture which is the advantage of a resin molding reactor was impaired.

  The present invention has been made in view of these problems, and an object of the present invention is to provide a resin-molded reactor capable of realizing both miniaturization and suppression of deterioration of direct current superposition characteristics without impairing ease of manufacture. To do.

  The resin-molded reactor according to claim 1, which has been made to achieve the above object, is formed by winding a conductive wire, and the exposed surface is covered with a resin insulating member made of a resin having electrical insulation properties. It has a winding, a case for storing the winding, and a core that is a mixture of magnetic powder and resin and is filled in the case so as to cover the winding stored in the case.

  That is, after housing the winding in the case, a core that is a mixture of magnetic powder and resin is injected into the case, and the injected core is cured, whereby a resin-molded reactor is manufactured.

  It is made of a material having a lower magnetic permeability than the core, and a part or all of the closed magnetic circuit formed by the magnetic flux generated around the winding by energizing the winding passes inside the case. The resin gap member is provided, and the resin gap member is formed so that the distance through which the closed magnetic path passes through the inside of the resin gap member becomes shorter as the distance between the winding and the resin gap member becomes larger. . As a result, in the closed magnetic circuit, the ratio of the inner peripheral side passing through the low magnetic permeability region is larger than that of the outer peripheral side. Therefore, in the closed magnetic circuit generated around the winding, between the inner peripheral side and the outer peripheral side. The nonuniformity of the magnetic flux density passing through the magnetic core can be reduced.

  The resin gap member and the resin insulation member are formed so as to be structurally integrated in advance and fixed onto the winding. For this reason, after the integrated winding and the resin gap member are accommodated in the case, the core, which is a mixture of magnetic powder and resin, is injected into the case, and the injected core is cured, whereby the resin A molded reactor can be manufactured. That is, the manufacturing process of forming the gap after curing the core injected into the case can be omitted. Thereby, it is possible to realize both the miniaturization and the suppression of the deterioration of the direct current superposition characteristics without impairing the ease of manufacture, which is an advantage of the resin-molded reactor.

  Further, in the resin-molded reactor according to claim 1, when the winding cross section orthogonal to the winding direction of the winding is formed in a polygonal shape, the angle of the closed magnetic circuit that forms a polygonal shape around the winding Since the magnetic flux is concentrated at the portion, and the magnetic flux density is increased and is easily saturated, particularly at the inner peripheral side of the corner portion, the resin gap member is made of resin insulation at the corner portion of the polygonal shape as described in claim 2. It is good to be connected with a member. Thereby, the nonuniformity of the magnetic flux density in the corner portion of the closed magnetic circuit where the magnetic flux density is likely to be saturated can be alleviated, and the deterioration of the direct current superimposition characteristic due to downsizing can be suppressed.

  Further, in the resin molding reactor according to claim 1 or 2, as described in claim 3, the resin gap member has an integral structure on the winding in advance using a resin mixed with magnetic powder as a material. You may make it form so that it may fix.

  In the resin-molded reactor configured as described above, since the resin gap member has some magnetism, the magnetic flux leaking from the resin gap member to the winding is reduced, and the eddy current is induced by the eddy current being induced in the winding. Since the loss is reduced, the electrical characteristics of the resin-molded reactor of the present invention can be improved.

  Further, in the resin-molded reactor according to any one of claims 1 to 3, as described in claim 4, the resin gap member and the resin insulating member, and part or all of the case are wound beforehand. It may be formed so as to be fixed as an integral structure on the line.

  According to the resin-molded reactor configured as described above, in the manufacturing process, the winding to which the resin gap member is fixed and a part or all of the case can be carried as one unit rather than separately, and the resin-molded reactor can be carried. The manufacturing process can be simplified.

Further, in the resin-molded reactor according to any one of claims 1 to 4, as described in claim 5, a plurality of windings may be accommodated in one case. .
According to the resin-molded reactor configured as described above, after accommodating a plurality of windings in one case, a core that is a mixture of magnetic powder and resin is injected into the case, and the injected core is cured. Thus, a plurality of resin-molded reactors corresponding to the number of windings are manufactured. That is, it is possible to manufacture a plurality of resin-molded reactors in one core injection step without performing a step of injecting the core into the case separately (hereinafter referred to as a core injection step) for each of the plurality of windings. it can. For this reason, the manufacturing process in the case of manufacturing a plurality of resin molding reactors can be simplified.

  Moreover, in the resin-molded reactor according to any one of claims 1 to 5, as described in claim 6, the case includes a part of the winding housed in the case, A through hole for projecting outward may be formed.

  According to the resin-molded reactor configured as described above, a part of the winding housed in the case can be protruded to the outside of the case. For this reason, this projecting portion is brought into contact with the heat sink, so that heat generated by the copper loss of the winding can be released from the projecting portion to cool the winding, and the heat dissipation efficiency of the resin-molded reactor can be improved. it can.

  Further, in the resin-molded reactor according to any one of claims 1 to 6, as described in claim 7, at least a part of the winding housed in the case covers the surface thereof. You may make it contact the inner surface of a case through the resin insulation member which is.

  According to the resin-molded reactor configured as described above, the heat generation due to the copper loss of the winding can be released from the contact portion between the winding and the inner surface of the case to cool the winding. That is, the heat dissipation efficiency of the resin-molded reactor can be improved by using the case as a heat sink for cooling the winding.

  Moreover, in the resin-molded reactor according to any one of claims 1 to 7, the hollow hole formed on the inner peripheral side of the winding housed in the case as described in claim 8 May be provided with a partition member that partly contacts the inner surface of the case.

  In the resin-molded reactor configured as described above, the core filled in the hollow hole of the winding and the partition member are in contact with each other, and the partition member is in contact with the inner surface of the case. The core can be cooled by releasing the heat of the core filled therein from the case. That is, the heat dissipation efficiency of the resin-molded reactor can be improved by using the case as a heat sink for cooling the core filled in the hollow hole of the winding.

It is the perspective view and sectional drawing of the resin molding reactor 1. FIG. 3 is a perspective view of a winding 2 and a resin gap member 5. FIG. It is a perspective view explaining the accommodation method of the coil | winding 2 and the resin gap member 5. FIG. It is the top view and sectional drawing of the resin shaping | molding reactor 1. FIG. FIG. 5 is a perspective view of a resin-molded reactor 11 and a perspective view for explaining a method of storing a winding 2 and a resin gap member 5. 3 is a cross-sectional view of a resin molded reactor 21. FIG. 3 is a perspective view of a winding 2, a resin gap member 5, and a case lid portion 26. FIG. 2 is a cross-sectional view of a resin-molded reactor 31, and a perspective view of a winding 2, a case 33, and a resin gap member 5. FIG. It is sectional drawing of the resin molding reactor 41, and the perspective view explaining the accommodation method of the coil | winding 42 and the resin gap member 45. FIG. It is sectional drawing and the top view of the resin molding reactor 51. It is a perspective view of the resin molding reactor of another embodiment. It is sectional drawing of the resin molding reactor of another embodiment. It is sectional drawing which shows the structure of the conventional resin molding reactor 101. FIG.

(First embodiment)
A first embodiment of the present invention will be described below with reference to the drawings.
Fig.1 (a) is a perspective view of the resin molding reactor 1 of this embodiment. FIG.1 (b) is a figure which shows the AA cross-section part of Fig.1 (a). FIG. 2A is a perspective view of the winding 2. FIG. 2B is a perspective view of the winding 2 and the resin gap member 5.

As shown in FIG. 1A, the resin-molded reactor 1 includes a winding 2, a case 3, a core 4, and a resin gap member 5.
Of these, the winding 2 is formed by winding a rectangular wire so as to circulate in a substantially rectangular shape, as shown in FIG. Both end portions 2a and 2b of the winding 2 are arranged so as to protrude in a direction perpendicular to one side from one side among the four sides constituting the rectangle. Furthermore, the surface of the flat wire which comprises the coil | winding 2 is coat | covered with the resin insulation member. Thereby, the coil | winding 2 is electrically insulated from the circumference | surroundings.

  Further, as shown in FIG. 1A, the case 3 is formed in a rectangular parallelepiped box shape using, for example, aluminum, and is configured so that the winding 2 can be accommodated therein. The case 3 has an opening 3a for inserting the winding 2 formed on one of the six surfaces constituting the rectangular parallelepiped, and the winding 2 is connected to the inside of the case 3 through the opening 3a. It is stored in.

  The core 4 is a mixture of magnetic powder (for example, carbonyl iron powder) and resin (for example, epoxy resin), and fills the inside of the case 3 to function as a magnetic core of the resin-molded reactor 1.

  Further, as shown in FIG. 2B, the resin gap member 5 is made of a resin having a lower permeability than the core 4 (in this embodiment, a resin mixed with magnetic powder) as a material. It is formed so as to cover the long side portion of the shape. And the resin gap member 5 is arrange | positioned at the corner | angular part of substantially rectangular magnetic path MP1, MP2 formed around the coil | winding 2, as shown in FIG.1 (b). The resin gap member 5 is formed such that the distance through which the magnetic paths MP1 and MP2 pass through the resin gap member 5 decreases as the distance Ls from the winding 2 increases. Further, the resin gap member 5 is formed so as to be fixed on the winding 2 as an integral structure in advance by using a molding method such as an injection molding method. The gap member 5 is formed by fitting (or adhering) a resin molded part in advance so as to sandwich the winding 2, or molding a resin insulating member on the winding 2 by an injection molding method. May be formed on the resin insulating member by fusion bonding to form an integral structure including the windings.

  Next, the manufacturing procedure of the resin molding reactor 1 will be described. FIG. 3 is a perspective view for explaining a method of housing the winding 2 and the resin gap member 5 in the case 3. FIG. 4A is a plan view of the resin-molded reactor 1. FIG.4 (b) is a figure which shows the BB cross section part of Fig.1 (a).

  As shown in FIG. 3, among the four sides constituting the rectangle of the winding 2, the side 2 d facing the side 2 c on the side where both ends 2 a and 2 b are arranged faces the opening 3 a of the case 3. The winding 2 and the resin gap member 5 are accommodated in the case 3 by inserting the winding 2 in which the resin gap member 5 is integrally formed into the opening 3a. Thereby, both ends 2a and 2b of the winding 2 are arranged so as to protrude from the opening 3a as shown in FIG.

  In addition, as shown in FIG. 4B, the case 3 includes only the end edge in the vicinity of the side 2d of the winding 2 on the surface 3b facing the opening 3a among the six surfaces constituting the rectangular parallelepiped. A through hole 3c is formed for drawing out from the through hole. For this reason, when the case 3 is arranged so that the through-hole 3c is down and the opening 3a is up while the winding 2 is housed in the case 3, the edge in the vicinity of the side 2d of the winding 2 The portion protrudes from the through hole 3c, and the end of the resin gap member 5 on the side 2d side of the winding 2 contacts the inside of the surface 3b of the case 3 (for example, the contact portion TC in FIG. 4B). The winding 2 is in an upright state in the case 3.

  In this state, resin (core material) mixed with magnetic powder is injected from the opening 3a of the case 3, and the injected resin is cured. Thereby, the resin molding reactor 1 shown to Fig.1 (a) is manufactured.

  The resin-molded reactor 1 configured in this way is made of a material having a lower magnetic permeability than the core 4, and is one of the closed magnetic paths formed by the magnetic flux generated around the winding 2 when the winding 2 is energized. The resin gap member 5 is disposed in the case 3 so that a part or the whole passes through the inside. The resin gap member 5 has a closed magnetic circuit as the distance between the winding 2 and the resin gap member 5 increases. The distance passing through the inside of the resin gap member 5 is shortened. As a result, in the closed magnetic circuit, the ratio of the inner peripheral side passing through the low magnetic permeability region is larger than that of the outer peripheral side. Therefore, in the closed magnetic circuit generated around the winding 2, between the inner peripheral side and the outer peripheral side. The non-uniformity of the magnetic flux density passing through the magnetic core can be alleviated.

  The resin gap member 5 and the resin insulating member are formed so as to be structurally integrated in advance and fixed onto the winding. For this reason, after housing the integrated winding 2 and the resin gap member 5 in the case 3, the core 4, which is a mixture of magnetic powder and resin, is injected into the case 3. The resin-molded reactor 1 can be manufactured by curing. That is, the manufacturing process of forming the gap after curing the core 4 injected into the case 3 can be omitted. Thereby, coexistence with size reduction and suppression of the deterioration of a direct current | flow superimposition characteristic is realizable, without impairing the ease of manufacture which is the advantage of the resin molding reactor 1. FIG.

  In addition, since the winding cross section orthogonal to the winding direction of the winding 2 is formed in a polygonal shape, the magnetic flux concentrates at the corners of the closed magnetic circuit that forms a polygonal shape around the windings 2. The magnetic flux density is increased on the inner peripheral side of the magnetic flux, and is likely to be saturated. On the other hand, in the resin-molded reactor 1, the resin gap member 5 is connected to the resin insulating member at the polygonal corners. Thereby, the nonuniformity of the magnetic flux density in the corner portion of the closed magnetic circuit where the magnetic flux density is likely to be saturated can be alleviated, and the deterioration of the direct current superimposition characteristic due to downsizing can be suppressed.

  In addition, the case 3 is formed with a through hole 3 c for projecting a part of the winding 2 housed in the case 3 to the outside of the case 3. Thereby, a part of the winding 2 housed in the case 3 can be protruded to the outside of the case 3. For this reason, by making this protrusion part contact a heat sink, the heat_generation | fever by the copper loss of the coil | winding 2 can be discharge | released from the said protrusion part, the coil | winding 2 can be cooled, and the heat dissipation efficiency of the resin-molded reactor 1 is improved. Can be made.

  The resin gap member 5 is made of a resin mixed with magnetic powder. Thereby, since the resin gap member 5 has some magnetism, the magnetic flux leaking from the resin gap member 5 to the winding 2 is reduced, and eddy current loss due to induction of eddy current in the winding 2 is reduced. Therefore, the electrical characteristics of the resin-molded reactor 1 can be improved.

(Second Embodiment)
A second embodiment of the present invention will be described below with reference to the drawings.
FIG. 5A is a perspective view of the resin-molded reactor 11 of the present embodiment. FIG. 5B is a perspective view illustrating a method for housing the winding 2 and the resin gap member 5 in the case 13.

As shown in FIG. 5A, the resin-molded reactor 11 includes a winding 2, a case 13, a core 4, and a resin gap member 5.
Among these, the case 13 is provided with a partition member 13 a that partitions between two sides housed in the case 13 among the four sides constituting the rectangle of the winding 2.

Moreover, the case 13 is provided with the partition member 13a, the lower case 13b, and the upper case 13c, as shown in FIG.5 (b).
The lower case 13b is formed in a box shape whose upper surface and front surface are open, and a partition member 13a is installed therein. Further, the lower case 13b is formed with a concave portion 13d for projecting only the edge portion in the vicinity of the side 2d of the winding 2 from the inside of the case 3 at the upper side portion of the back surface. The upper case 13c is a plate-like member that can close the opening on the upper surface side of the lower case 13b.

Next, the manufacturing procedure of the resin molding reactor 11 will be described.
First, the winding 2 in which the resin gap member 5 is integrally formed is housed in the lower case 13b so as to be placed on the lower surface of the lower case 13b from the opening on the upper surface side of the lower case 13b ( (See arrow Y11 in FIG. 5B). At this time, the winding 2 is installed in the lower case 13b so that the edge of the winding 2 near the side 2d protrudes from the recess 13d. Then, by placing the upper case 13c on the opening on the upper surface side of the lower case 13b (see the arrow Y12 in FIG. 5B), the opening on the upper surface side is closed.

  After that, in a state where the winding 2 is housed in the case 13, the case 13 is arranged so that the back surface of the lower case 13b is down and the front surface is up. Material) is injected from the opening on the front side of the lower case 13b, and the injected resin is cured. Thereby, the resin molding reactor 11 shown to Fig.5 (a) is manufactured.

  The resin-molded reactor 11 configured as described above is wound through a hollow hole formed on the inner peripheral side of the winding 2 housed in the case 13 from the opening on one end side to the opening on the other end side. A partition member 13 a that partitions the line 2 and partially contacts the inner surface of the case 3 is provided. Thereby, the core 4 filled in the hollow hole of the winding 2 is in contact with the partition member 13a, and the partition member 13a is in contact with the inner surface of the case 13, so The heat of the core 4 filled can be released from the case 13 to cool the core 4. That is, the heat dissipation efficiency of the resin-molded reactor 11 can be improved by using the case 13 as a heat sink for cooling the core 4 filled in the hollow hole of the winding 2.

(Third embodiment)
A third embodiment of the present invention will be described below with reference to the drawings.
FIG. 6 is a cross-sectional view of the resin-molded reactor 21 of the present embodiment. FIG. 7A is a perspective view of the winding 2, the resin gap member 5, and the case lid 26 as viewed from both ends 2 a and 2 b of the winding 2. FIG. 7B is a perspective view of the winding 2, the resin gap member 5, and the case lid 26 as viewed from the end edge side near the side 2 d of the winding 2.

As shown in FIG. 6, the resin-molded reactor 21 includes a winding 2, a case 23, a core 4, a resin gap member 5, and a case lid portion 26.
Among these, the case 23 has an opening 23a for inserting the winding 2 formed in one of the six surfaces constituting the rectangular parallelepiped, and the winding 2 is connected to the case 23 through the opening 23a. It is stored inside. Further, an opening 23b is formed on the surface facing the opening 3a.

  As shown in FIGS. 6 and 7, the case lid 26 is formed by a molding method such as an injection molding method so that the opening 23 b can be closed while the winding 2 is housed in the case 23. Is a plate-like member that is formed in the shape previously combined with the resin gap member 5 using the same material as the resin gap member 5. The case lid portion 26 is formed with an opening portion 26 a for projecting only the edge portion near the side 2 d of the winding 2 from the inside of the case 23.

  According to the resin-molded reactor 21 configured as described above, in the manufacturing process, the winding 2 to which the resin gap member 5 is fixed and the case lid portion 26 can be carried as one unit rather than separately. The manufacturing process of the reactor 21 can be simplified.

(Fourth embodiment)
A fourth embodiment of the present invention will be described below with reference to the drawings.
Fig.8 (a) is sectional drawing of the resin molding reactor 31 of this embodiment. FIG. 8B is a perspective view of the winding 2, the case 33, and the resin gap member 5.

The resin-molded reactor 31 includes a winding 2, a case 33, a core 4, and a resin gap member 5 as shown in FIG.
Among these, the case 33 is formed with an opening 33 a for projecting the both ends 2 a and 2 b of the winding 2 from the inside of the case 33 on one of the six surfaces constituting the rectangular parallelepiped. Further, an opening 33 b for projecting only the end edge near the side 2 d of the winding 2 from the inside of the case 33 is formed on the surface facing the opening 33 a.

  The case 33 is combined with the resin gap member 5 in advance using the same material as the resin gap member 5 as shown in FIGS. 8A and 8B using a molding method such as an injection molding method. It is formed into a shape.

  According to the resin-molded reactor 31 configured as described above, in the manufacturing process, the winding 2 to which the resin gap member 5 is fixed and the case 33 can be carried as one unit rather than separately, and the resin-molded reactor 31 can be carried. The manufacturing process can be simplified. The case 33 made of resin is used in a reactor that generates little heat.

(Fifth embodiment)
A fifth embodiment of the present invention will be described below with reference to the drawings.
Fig.9 (a) is sectional drawing of the resin molding reactor 41 of this embodiment. FIG. 9B is a perspective view for explaining a method of housing the winding 42 and the resin gap member 45 in the case 43.

As shown in FIG. 9A, the resin molding reactor 41 includes a winding 42, a case 43, a core 4, and a resin gap member 45.
Among these, the winding 42 is formed in a cylindrical shape by winding a rectangular wire so as to circulate in a substantially circular shape.

  The resin gap member 45 is formed so as to cover the entire cylindrical portion of the winding 42. The resin gap member 45 is disposed at the corners of the substantially rectangular magnetic paths MP41 and MP42 formed around the winding 42. Further, the resin gap member 45 is formed such that the distance through which the magnetic paths MP41 and MP42 pass through the resin gap member 45 becomes shorter as the distance Ls from the winding 42 becomes larger. Further, the resin gap member 45 is formed so as to be fixed on the winding 42 in advance as an integral structure by using a molding method such as an injection molding method.

  Then, both end portions 42 a and 42 b of the winding 42 pass through the resin gap member 45 and are drawn out of the resin gap member 45 as shown in FIG. 9B. Further, in the resin gap member 45 formed so as to cover the winding 42, a through hole 45 a penetrating along the cylindrical axis of the winding 42 is formed.

  Further, the case 43 is formed in a bottomed cylindrical shape, and is configured so that the winding 42 can be accommodated therein through the opening 43a. A cylindrical member 43b that protrudes from the bottom surface along the cylindrical axis of the case 43 is provided inside the case 43, and the cylindrical member 43b is formed in a size that can be inserted into the through hole 45a. ing.

Next, the manufacturing procedure of the resin molding reactor 41 will be described.
First, by inserting the cylindrical member 43b into the through hole 45a, the winding 42 in which the resin gap member 45 is integrally formed is placed on the bottom surface of the case 43 from the opening 43a of the case 43. In the case 43 (see arrow Y41 in FIG. 9B).

  Thereafter, in a state where the winding 42 is housed in the case 43, a resin (core material) mixed with magnetic powder is injected from an injection hole (not shown) provided on the circumferential surface or bottom surface of the case 43. The injected resin is cured. Thereby, the resin molding reactor 41 shown to Fig.9 (a) is manufactured.

  According to the resin-molded reactor 41 configured as described above, the winding 42 is formed in a cylindrical shape by being wound around in a substantially circular shape, so that it is compared with a winding wound in a rectangular shape. The length of the conductor required to make the same number of turns with an equivalent physique can be shortened. For this reason, compared with the case where the winding is wound in a rectangular shape, heat generation due to copper loss of the winding 2 can be reduced, and the electrical characteristics of the resin-molded reactor 41 can be improved.

(Sixth embodiment)
The sixth embodiment of the present invention will be described below with reference to the drawings.
FIG. 10A is a cross-sectional view of the resin-molded reactor 51 of this embodiment. FIG. 10B is a plan view of the resin-molded reactor 51.

As shown in FIG. 10A, the resin-molded reactor 51 includes a winding 2, a case 53, a core 4, and a resin gap member 55.
Of these, the resin gap member 55 is made of a resin having a lower magnetic permeability than the core 4, and has a substantially rectangular long side portion in the winding 2, and a side 2 c on the side where both end portions 2 a and 2 b are disposed. It is formed so as to cover the opposite side 2d. And the resin gap member 55 is arrange | positioned at the corner | angular part of substantially rectangular magnetic path MP1 and MP2 formed around the coil | winding 2 similarly to 1st Embodiment. The resin gap member 5 is formed such that the distance through which the magnetic paths MP1 and MP2 pass through the resin gap member 5 becomes shorter as the distance Ls from the winding 2 becomes larger (see FIG. 1B). reference).

  Further, the case 53 is formed in a rectangular parallelepiped box shape, and is configured so that the winding 2 can be accommodated therein. The case 53 has an opening 53a for inserting the winding 2 formed on one of the six surfaces constituting the rectangular parallelepiped, and the winding 2 is connected to the inside of the case 53 through the opening 53a. It is stored in.

  Further, the case 53 is in contact with the edge portion in the vicinity of the side 2d of the winding 2 in which the resin gap member 55 is integrally formed on the inner side of the surface 53b facing the opening 53a among the six surfaces constituting the rectangular parallelepiped. And a recess 53c that can be accommodated. Therefore, unlike the first embodiment, the edge portion in the vicinity of the side 2d of the winding 2 does not protrude from the surface 53b toward the outside of the case 53, as shown in FIGS. 10 (a) and 10 (b). And stored in the case 53.

  According to the resin-molded reactor 51 configured as described above, the heat generation due to the copper loss of the winding 2 can be released from the contact portion between the winding and the inner surface of the case 53 to cool the winding 2. That is, the heat dissipation efficiency of the resin-molded reactor 51 can be improved by using the case 53 as a heat sink for cooling the winding 2.

As mentioned above, although one Embodiment of this invention was described, this invention is not limited to the said embodiment, As long as it belongs to the technical scope of this invention, a various form can be taken.
For example, in the above embodiment, a resin-molded reactor in which one winding is housed in one case is shown. However, as shown in FIG. 11, a plurality of (two in FIG. 11) windings 2 may be accommodated in one case 63. Thus, after the two windings 2 are accommodated in one case 63, the core 4 which is a mixture of magnetic powder and resin is injected into the case, and the injected core 4 is cured, whereby the winding 2 A plurality of resin-molded reactors corresponding to the number of are manufactured. That is, a plurality of resin-molded reactors are manufactured in one core injection step without performing a step of injecting a core into the case separately (hereinafter referred to as a core injection step) for each of the plurality of windings 2. Can do. For this reason, the manufacturing process in the case of manufacturing a plurality of resin molding reactors can be simplified.

  Moreover, in the said 1st Embodiment, as shown in FIG.1 (b), the coil cross section orthogonal to the winding direction of the coil | winding 2 is formed in polygonal shape, and the resin gap member 5 is this polygonal corner | angular part. 1 to 3 are formed over the inner surface of the case 3. However, a gap may be formed between the resin gap member 5 and the inner surface of the case 3 as shown in FIG. Thus, when the core material is injected from one location of the opening 3 a of the case 3 with the winding 2 being housed in the case 3, the core is formed in the entire gap between the winding 2 and the resin gap member 5. Since a material spreads, the manufacturing process of the resin molding reactor 1 can be simplified.

  Further, the resin gap member 5 and the resin insulating member may be formed in a shape in which a resin mixed with magnetic powder is previously combined as a material.

  1,21,31,41,51 ... resin-molded reactor, 2,42 ... winding, 3,13,23,43,53,63 ... case, 3c ... through hole, 4 ... core, 5,45, 55 ... Resin gap member, 13a ... Partition member, 26 ... Case lid

Claims (8)

A winding formed by winding a conductive wire and having an exposed surface covered with a resin insulating member made of a resin having electrical insulation;
A case for storing the winding;
A resin-molded reactor having a core filled in the case so as to cover the windings housed in the case, and a mixture of magnetic powder and resin,
The case is made of a material having a lower magnetic permeability than the core, and a part or all of a closed magnetic circuit formed by a magnetic flux generated around the winding by energizing the winding passes through the inside. A resin gap member disposed in the interior;
The resin gap member is
As the distance between the winding and the resin gap member increases, the closed magnetic path is formed such that the distance passing through the inside of the resin gap member is shortened.
The resin gap member and the resin insulation member are formed so as to be structurally integrated and fixed onto the winding in advance before filling the core. The winding has a polygonal cross section perpendicular to the winding direction of the winding,
The resin molding reactor according to claim 1, wherein the resin gap member is connected to the resin insulating member at the polygonal corner. 3. The resin gap member according to claim 1, wherein the resin gap member is formed so as to be structurally integrated in advance using a resin mixed with magnetic powder as a material and fixed on the winding. Resin molding reactor. The resin gap member, the resin insulating member, and a part or all of the case are structurally integrated in advance and fixed on the winding. Item 4. The resin-molded reactor according to any one of Items 3. The resin-molded reactor according to any one of claims 1 to 4, wherein a plurality of the windings are housed in one case. The case is
The through-hole for making a part of said coil | winding accommodated in the said case protrude outside the said case is formed in any one of Claims 1-5 characterized by the above-mentioned. The resin-molded reactor as described. The at least one part of the said coil | winding accommodated in the said case is contacting the inner surface of the said case through the said resin insulation member which has coat | covered the surface. Item 7. The resin-molded reactor according to any one of Items 6. A hollow hole formed on the inner peripheral side of the winding housed in the case is penetrated from the opening on the one end side to the opening on the other end side to partition the winding, and a part of the hollow of the case The resin-molded reactor according to any one of claims 1 to 7, further comprising a partition member that contacts the inner surface.