JP2012164778A - Method for manufacturing reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a reactor having good heat dissipation characteristics while being small.SOLUTION: The method for manufacturing the reactor by producing an assembly of a coil and a magnetic core having an inner core part where the coil is arranged and an outer core part where the coil is not arranged, and housing the assembly in a case having a bottom plate and a sidewall part provided standing on the bottom plate and surrounding the assembly, comprises a preparing step for preparing the bottom plate independent of the sidewall part in which a heat radiation layer consisting of an insulation high heat conductivity adhesive is formed thereon; a holding step for holding the bottom plate on a pedestal for positioning at a predetermined position; a placing step for placing the assembly on the heat radiation layer; and a curing step for curing the insulation high heat conductivity adhesive configuring the heat radiation layer. In the placing step, a positioning jig such as a first jig, a second jig and the pedestal are used to perform positioning of the assembly relative to the heat radiation layer.

Description

  The present invention relates to a method of manufacturing a reactor used for a component part of a power conversion device such as a vehicle-mounted DC-DC converter such as a hybrid vehicle.

  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 Document 1 discloses a reactor used in a converter mounted on a vehicle such as a hybrid vehicle. The reactor includes a coil, an annular magnetic core in which the coil is disposed, a case that houses an assembly of the coil and the magnetic core, and a sealing resin that is filled in the case. This reactor is generally used by being fixed to a cooling base in order to cool a coil that generates heat when energized.

  The case is typically an aluminum die-cast product, and is used as a heat dissipation path for fixing heat to the coil and the like by being fixed to the cooling base.

JP 2010-050408 JP

  In recent years, further miniaturization and weight reduction are desired for in-vehicle components such as hybrid vehicles. However, it is difficult to further reduce the size of a reactor including a conventional aluminum case.

  Since aluminum is a conductive material, at least it must be electrically insulated from the coil. Therefore, normally, a relatively large gap is provided between the coil and the inner surface (bottom surface and side wall surface) of the case in order to ensure an electrical insulation distance. It is difficult to reduce the size because of this insulation distance.

  For example, the reactor can be miniaturized by omitting the case. However, since the coil and the magnetic core are exposed, it is not possible to secure mechanical characteristics such as protection and strength from the external environment such as dust and corrosion to the coil and the magnetic core.

  Moreover, it is desired that the sealing resin filled in the case is excellent in heat dissipation. For example, heat dissipation can be improved by using a resin containing a filler made of ceramics as a sealing resin. However, since the outer shape formed by the combination of the coil and the magnetic core is a complicated shape, the resin containing the filler is contained in the case so that no gaps or voids are generated between the combination and the inner surface of the case. If it tries to fill, it will take time and it will be inferior to the productivity of a reactor. Moreover, although heat dissipation can be improved by raising the content rate of the filler in sealing resin, since sealing resin becomes embrittled, it becomes easy to be damaged by a thermal shock. Therefore, development of a reactor excellent in heat dissipation is desired without using a sealing resin containing a filler.

  Then, one of the objectives of this invention is providing the manufacturing method of the reactor which is excellent in heat dissipation, although it is small.

  The inventors of the present invention have found that the above object can be achieved by providing the case with a split structure and providing a heat dissipation layer having excellent heat dissipation at a position in contact with the assembly in the bottom plate portion of the case. The present invention is based on the above findings.

The method for manufacturing a reactor according to the present invention includes a coil, a magnetic core having an inner core portion in which the coil is disposed and an outer core portion in which the coil is not disposed, and is erected on the bottom plate portion and the bottom plate portion. In order to manufacture the reactor by housing the combination in a case provided with a side wall portion surrounding the periphery of the combination, the following steps are provided.
Preparation step: A heat dissipation layer made of an insulating high thermal conductive adhesive is formed, and a bottom plate portion independent of the side wall portion is prepared.
Fixing step: The bottom plate portion is fixed to a predetermined position of a positioning base.
Placement step: the assembly is placed on the heat dissipation layer.
Curing step: The insulating high thermal conductive adhesive constituting the heat dissipation layer is cured.
The placing step includes a first jig for positioning in a direction perpendicular to the axial direction of the coil with respect to the bottom plate portion of the assembly, and a second jig for positioning in the axial direction of the coil with respect to the bottom plate portion of the combination. Are arranged on the pedestal. And the positioning with respect to the said thermal radiation layer of an assembly is performed by pinching this assembly from both ends with the said 1st jig | tool and a 2nd jig | tool.

  According to this manufacturing method, by using positioning jigs such as the first jig, the second jig, and the pedestal, positioning of the assembly with respect to the heat dissipation layer can be easily and accurately performed. By curing the insulating high thermal conductive adhesive that constitutes the heat dissipation layer in the state, the assembly can be prevented from moving on the heat dissipation layer. That is, the contact area between the assembly and the heat dissipation layer can be ensured accurately, and a reactor excellent in heat dissipation can be obtained. By performing the above positioning, it is easy to align the assembly and other components, for example, align the terminal fitting for connecting to an external device such as a power source and the end of the coil. According to the manufacturing method of the present invention, since the bottom plate portion and the side wall portion are independent separate members attached by the fixing material, the assembly can be positioned with the side wall portion removed, and the accuracy is easily achieved. Positioning can be performed well. Therefore, it is excellent also in the manufacturability of the reactor. According to the reactor obtained by the said manufacturing method, the protection from the environment of a coil and a magnetic core and mechanical protection can be aimed at by providing a case.

  The reactor obtained by the manufacturing method of the present invention is such that the surface on the installation side (hereinafter referred to as the coil installation surface) when the reactor is installed on the fixed object in the coil is in contact with the heat dissipation layer, so the heat of the coil Can be efficiently transmitted to the heat dissipation layer, and can be released to a fixed object such as a cooling base via the heat dissipation layer, which is excellent in heat dissipation. In particular, since the heat dissipation layer is made of an insulating high thermal conductive adhesive, even when the bottom plate portion is made of a conductive material, the coil is brought into contact with the heat dissipation layer to ensure the space between the coil and the bottom plate portion. Can be insulated. Therefore, the heat dissipation layer can be made thin, and from this point as well, the heat of the coil is easily released to the fixed object, and the reactor is excellent in heat dissipation. In particular, since the bottom plate portion and the side wall portion are separate members, both can be made of different materials. For example, the bottom plate portion is made of a material having a higher thermal conductivity than the side wall portion. Furthermore, it can be set as the reactor which is excellent in heat dissipation.

  In addition, by reducing the thickness of the heat dissipation layer as described above, the distance between the coil installation surface and the inner surface of the bottom plate portion that is the inside of the case can be reduced, and the reactor can be downsized. Furthermore, according to the said reactor, since a baseplate part and a side wall part are separate members, both constituent materials can be changed easily. For example, when the side wall portion is made of a material having excellent electrical insulation, the distance between the outer peripheral surface of the coil and the inner peripheral surface of the side wall portion can be reduced, so that a smaller reactor can be achieved.

  In addition, according to the reactor, since the heat dissipation layer is provided, heat can be efficiently radiated from at least the coil installation surface via the heat dissipation layer as described above. For example, the case is filled with a sealing resin. In this case, even if a resin having inferior thermal conductivity is used, the heat dissipation property can be improved by the heat dissipation layer. Therefore, according to the reactor, the degree of freedom in selecting an available sealing resin can be increased. For example, a resin containing no filler can be used. Or even if it is a form which does not have sealing resin, sufficient heat dissipation can be secured by a heat dissipation layer.

  As one aspect of the present invention, the bottom plate portion has a fixing hole through which a fastening member for fixing to a fixing target is inserted, and the fixing hole is provided as at least one of the first jig and the second jig. The form used for arrangement | positioning is mentioned.

  As one form of this invention, the said baseplate part has a fitting part which positions both by fitting this baseplate part and the said side wall part, and this fitting part is said 1st jig | tool and 2nd. The form used for at least one arrangement | positioning of a jig | tool is mentioned.

  The positioning can be performed with higher accuracy by arranging the first jig and the second jig for positioning the combined body with respect to the heat dissipation layer using the constituent members of the reactor. A bottom plate part can be used as a constituent member of the reactor. The arrangement of the first jig and the second jig on the pedestal may be arranged directly on the pedestal, or indirectly on the pedestal via a reactor component (bottom plate) fixed to the pedestal. May be. In the former case, a heat dissipation layer is formed on the bottom plate, and the bottom plate is fixed at a predetermined position of the pedestal. By placing the first jig and the second jig on the pedestal, The positioning of the assembly with respect to the heat dissipation layer can be performed with high accuracy. In the latter case, the bottom plate portion is fixed at a predetermined position of the pedestal, and the positioning can be performed with higher accuracy by arranging the first jig and the second jig with respect to the bottom plate portion. In addition, by using the fixing hole and the fitting portion provided in the bottom plate portion, there is no need to separately provide an arrangement mechanism for arranging the first jig and the second jig at a predetermined position of the base, and the number of parts Can be reduced. The use of the fixing hole and the fitting portion may be performed on only one of the first jig and the second jig, or may be performed on both.

  As one form of this invention, the form hardened | cured in the state which mounted the weight above the said assembly in the said hardening process is mentioned.

  Since the heat dissipation layer is flexible before the insulating high thermal conductive adhesive is cured, there is a possibility that a portion where the combined body cannot be partially contacted on the heat dissipation layer is formed, and the heat dissipation property is deteriorated. For example, in the combination, the entire installation surface of the coil is in contact with the heat dissipation layer, but the installation surface of the outer core portion may be in a non-contact state. By placing a weight on the upper side of the combined body, the combined body can be pressed onto the heat radiating layer, and deterioration of heat dissipation can be prevented. With this weight, the whole assembly may be pushed, only the coil may be pushed, or only the outer core part may be pushed. The non-contact state between the assembly and the heat dissipation layer is particularly likely to occur in the outer core portion that is the end of the assembly. Therefore, by pushing the outer core portion with a weight, the end of the combined body is pressed, and the entire combined body can be brought into contact with the heat dissipation layer.

  As an aspect of the present invention, the magnetic core has an inner core portion and an outer core portion that are not joined by an adhesive. The core portion and the outer core portion are positioned in a predetermined contact state and positioned with respect to the heat dissipation layer, and in the curing step, the inner core portion and the outer core portion are fixed to the bottom plate portion in the contact state by the heat dissipation layer. A form is mentioned.

  When the inner core portion and the outer core portion are bonded with an adhesive, the bonding process takes a lot of time. In this case, it is necessary to first bond the inner core portion and the outer core portion with an adhesive, and bond the combined body in a state where both are bonded onto the heat dissipation layer. On the other hand, when the inner core portion and the outer core portion are not joined by the adhesive, the inner core portion and the outer core portion are predetermined by the first jig and the second jig according to the manufacturing method of the present invention. Because the combination in this state is placed on the heat dissipation layer and the adhesive is cured, the two are in contact without separately bonding the inner core portion and the outer core portion. It can be fixed to the bottom plate portion as it is. Therefore, the bonding process can be simplified and the amount of adhesive used can be reduced.

  The method for manufacturing a reactor according to the present invention has a case in which the case is divided, and a heat dissipation layer having excellent heat dissipation is provided at a position in contact with the assembly in the bottom plate portion of the case, thereby obtaining a small reactor having excellent heat dissipation. be able to. In particular, this manufacturing method can accurately position the assembly with respect to the heat dissipation layer, can accurately ensure the contact area between the assembly and the heat dissipation layer, and can obtain a reactor with excellent heat dissipation. .

FIG. 1 is a schematic perspective view showing a reactor according to the first embodiment. FIG. 2 is an exploded perspective view illustrating an outline of a combination of a coil and a magnetic core provided in the reactor of the first embodiment. FIG. 3 is an exploded perspective view schematically showing the reactor of the first embodiment. FIG. 4 is an explanatory diagram for explaining a process of fixing a combined body of a coil and a magnetic core included in the reactor of Embodiment 1 to a heat dissipation layer. FIG. 5 is an explanatory diagram for explaining another process of fixing the combined body of the coil and the magnetic core included in the reactor of Embodiment 2 to the heat dissipation layer.

  Embodiments of the present invention will be described below with reference to the drawings. In the drawings, the same reference numerals denote the same members. In the following description, when the reactor is installed, the installation side is described as the lower side, and the opposite side is described as the upper side.

{Embodiment 1}
A first embodiment of the present invention will be described with reference to FIGS.
≪Overview≫
The manufacturing method of the reactor 1 of the present invention produces a combined body 10 of a coil 2 and a magnetic core 3 having an inner core portion 31 in which the coil 2 is disposed and an outer core portion 32 in which the coil 2 is not disposed. The present invention relates to a method of manufacturing the reactor 1 by housing the assembly 10 in the case 4 including the portion 40 and the side wall 41 that stands on the bottom plate portion 40 and surrounds the periphery of the assembly 10. Hereinafter, first, each component of the reactor 1 will be described, and then a method for manufacturing the reactor 1 will be described in detail.

≪Reactor overall structure≫
The reactor 1 includes a combined body 10 and a case 4 that stores the combined body 10. The case 4 is a box that is open on one side, typically filled with sealing resin (not shown), and the assembly 10 is sealed except for the end of the winding 2w that forms the coil 2. Embedded in resin. A feature of the reactor 1 is that the case 4 has a structure that can be divided.

≪Union body≫
[coil]
The coil 2 will be described with reference to FIGS. 2 and 3 as appropriate. The coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a single continuous winding 2w having no joint part, and a coil connecting part 2r for connecting both the coil elements 2a and 2b. Each coil element 2a, 2b has the same number of turns and has a substantially rectangular shape (end face shape) viewed from the axial direction. These two coil elements 2a and 2b are arranged side by side so that their axial directions are parallel, and a part of the winding 2w is U-shaped on the other end side of the coil 2 (the back side in FIG. 3). A coil connecting portion 2r is formed by bending. With this configuration, the winding directions of both coil elements 2a and 2b are the same.

  The winding 2w is preferably a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor made of a conductive material such as copper or aluminum. Here, a coated rectangular wire is used in which the conductor is made of a rectangular copper wire and the insulating coating is made of enamel (typically polyamideimide). The thickness of the insulating coating is preferably 20 μm or more and 100 μm or less. The thinner the thickness, the higher the space factor, and the thicker the thickness, the pinholes can be reduced and the electrical insulation can be improved. Both coil elements 2a, 2b are formed in a hollow rectangular tube shape by winding the above-mentioned covered rectangular wire edgewise. The winding 2w can be used in various shapes such as a circular shape, an elliptical shape, a polygonal shape, etc., in addition to the conductor made of a rectangular wire. A flat wire is easier to form a coil having a higher space factor than when a round wire having a circular cross section is used. In addition, it is also possible to form each coil element by separate windings and join the ends of the windings forming each coil element by welding or the like to form an integral coil.

  Both end portions of the winding 2w forming the coil 2 are appropriately extended from the turn forming portion on one end side (the front side in FIG. 3) of the coil 2 and pulled out of the case 4 (FIG. 1). At both ends of the drawn winding 2w, the terminal fitting 8 made of a conductive material is connected to the conductor portion exposed by peeling off the insulation coating. An external device (not shown) such as a power source for supplying power is connected to the coil 2 via the terminal fitting 8. Details of the terminal fitting 8 will be described later.

[Magnetic core]
The magnetic core 3 will be described with reference to FIG. The magnetic core 3 includes a pair of inner core portions 31 where the coil elements 2a and 2b are respectively disposed, and a pair of outer core portions 32 where the coil 2 is not disposed and is exposed from the coil 2. Here, each inner core part 31 is a rectangular parallelepiped shape, and each outer core part 32 is a prismatic body having a pair of trapezoidal surfaces. The magnetic core 3 has an outer core portion 32 disposed so as to sandwich the inner core portion 31 that is spaced apart, and the end surface 31e of each inner core portion 31 and the inner end surface 32e of the outer core portion 32 are in contact with each other to form an annular shape. Formed. The inner core portion 31 and the outer core portion 32 form a closed magnetic path when the coil 2 is excited.

  The inner core portion 31 is a laminated body configured by alternately laminating core pieces 31m made of a magnetic material and gap members 31g typically made of a nonmagnetic material, and the outer core portion 32 is made of a magnetic material. A core piece consisting of As each core piece, a molded body using magnetic powder or a laminated body in which a plurality of magnetic thin plates (for example, electromagnetic steel plates) having an insulating coating are laminated can be used.

  Examples of the molded body include iron group metals such as Fe, Co, and Ni, Fe-based alloys such as Fe-Si, Fe-Ni, Fe-Al, Fe-Co, Fe-Cr, and Fe-Si-Al, and rare earth metals. Compacts using powders made of soft magnetic materials such as magnetic materials and amorphous magnetic materials, sintered products obtained by sintering the above powders after press molding, and moldings such as injection molding and cast molding of the above powder and resin mixture A hardened body is mentioned. In addition, examples of the core piece include a ferrite core that is a sintered body of a metal oxide. The molded body can easily form various three-dimensional magnetic cores.

  As the green compact, one having an insulating coating on the surface of the powder made of the soft magnetic material can be suitably used. In this case, the powder is molded and then fired at a temperature lower than the heat resistance temperature of the insulating coating. Is obtained. Typically, the insulating coating includes a silicone resin or a phosphate.

  The material of the inner core portion 31 and the material of the outer core portion 32 can be made different. For example, when the inner core portion 31 is the above-mentioned green compact or the above laminated body, and the outer core portion 32 is the above-mentioned molded and hardened body, the saturation magnetic flux density of the inner core portion 31 can be easily increased as compared with the outer core portion 32. Here, each core piece is a compacted body of soft magnetic powder containing iron such as iron or steel.

  The gap material 31g is a plate-like material disposed in a gap provided between the core pieces 31m for adjusting the inductance, and is a material having a lower magnetic permeability than the core piece, such as alumina, glass epoxy resin, and unsaturated polyester. Typically, it is made of a nonmagnetic material (in some cases, an air gap).

  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.

  In addition, if the coating layer made of an insulating material is provided on the outer periphery of the inner core portion 31, the insulation between the coil 2 and the inner core portion 31 can be enhanced. The said coating layer is provided by arrange | positioning a heat shrinkable tube, a normal temperature shrinkable tube, an insulating tape, insulating paper, etc., for example. In addition to enhancing the insulating property by disposing the shrinkable tube on the outer periphery of the inner core portion 31 or attaching an insulating tape or the like, the core piece and the gap material can be integrated.

  In the magnetic core 3, the installation side surface of the inner core portion 31 and the installation side surface of the outer core portion 32 are not flush with each other. Specifically, when the reactor 1 is installed on a fixed object such as a cooling base, a surface on the outer core portion 32 on the installation side (hereinafter referred to as a core installation surface; the lower surface in FIG. 2) is installed on the inner core portion 31. It protrudes from the side surface. In addition, the core installation surface of the outer core portion 32 is flush with the surface on the installation side of the coil 2 (hereinafter referred to as the coil installation surface; the lower surface in FIG. 2). Adjust the length in the direction perpendicular to the surface of the fixed object (here, the direction perpendicular to the axial direction of the coil 2 and the vertical direction in FIG. 2) with the reactor 1 installed on the fixed object doing. Accordingly, the magnetic core 3 is H-shaped when seen from the side in a state where the reactor 1 is installed. Further, since the core installation surface and the coil installation surface are flush with each other, not only the coil installation surface of the coil 2 but also the core installation surface of the magnetic core 3 can be in contact with the heat radiation layer 42 (FIG. 3) described later. it can. Further, in a state where the magnetic core 3 is assembled in an annular shape, the side surface of the outer core portion 32 (the front side and the back surface in FIG. 2) protrudes outward from the side surface of the inner core portion 31. Therefore, the magnetic core 3 has an II shape when seen through from the upper surface or the lower surface in a state where the reactor is installed (in a state where the lower side is the installation side in FIG. 2). Such a three-dimensional magnetic core 3 can be easily formed by forming a compacted body, and a portion protruding from the inner core portion 31 in the outer core portion 32 can also be used as a magnetic flux passage. .

[Insulator]
The combined body 10 includes an insulator 5 between the coil 2 and the magnetic core 3 to enhance insulation between the coil 2 and the magnetic core 3. The insulator 5 includes a peripheral wall portion 51 disposed on the outer periphery of the inner core portion 31, and a pair of frame-like portions 52 that are in contact with the end surface of the coil 2 (surface on which the turn of the coil element appears to be annular). Is mentioned.

  Here, the peripheral wall portion 51 is configured by a pair of cross-sectional bodies, and the peripheral wall portions 51 are not in contact with each other and are disposed only on a part of the outer peripheral surface of the inner core portion 31. The peripheral wall portion 51 can be a cylindrical body disposed along the entire circumference of the outer peripheral surface of the inner core portion 31, but if the insulation distance between the coil 2 and the inner core portion 31 can be secured. As shown in FIG. 2, a part of the inner core portion 31 may not be covered by the peripheral wall portion 51. In addition, here, the peripheral wall portion 51 is provided with a window portion penetrating the front and back.

  By exposing a part of the inner core portion 31 from the peripheral wall portion 51, the material of the peripheral wall portion 51 can be reduced. Further, when the sealing resin is provided, the peripheral wall portion 51 having the window portion is used, or the inner core portion 31 is sealed with the peripheral wall portion 51 so that the entire periphery of the inner core portion 31 is not covered by the peripheral wall portion 51. The contact area with the stop resin can be increased, and bubbles can be easily removed when the sealing resin is poured, so that the productivity of the reactor 1 is excellent.

  The frame-like portion 52 is flat and has a pair of openings through which the respective inner core portions 31 are inserted, and protrudes toward the inner core portion 31 so that the inner core portion 31 can be easily introduced. A short cylindrical part is provided. The one frame-like portion 52 includes a flange portion 52f on which the coil connecting portion 2r is placed and insulates between the coil connecting portion 2r and the outer core portion 32.

  As the constituent material of the insulator, insulating materials such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, and liquid crystal polymer (LCP) can be used.

[Formation method of union]
As shown in FIG. 2, the assembly 10 is formed by stacking the core pieces 31m and the gap material 31g to form the inner core portion 31, and the peripheral wall portion 51 of the insulator 5 is disposed on the outer periphery. The coil elements 2a and 2b are inserted. The frame-shaped portion 52 and the outer core portion 32 are arranged on the coil 2 so that the end surfaces of both the coil elements 2a, 2b and the end surface 31e of the inner core portion 31 are sandwiched between the frame-shaped portion 52 and the outer core portion 32 of the insulator 5. , Forming the union 10. The end surface 31e of the inner core portion 31 is exposed from the opening of the frame-shaped portion 52 and contacts the inner end surface 32e of the outer core portion 32.

  The core piece 31m and the gap material 31g may be joined and integrated with an adhesive, a tape, or the like, but here, no adhesive is used. In addition, the pair of peripheral wall portions 51 are not configured to engage with each other, but are inserted into the coil elements 2a and 2b together with the inner core portion 31, and the outer core portion 32 is further disposed, whereby the coil elements 2a and 2b are arranged. The state arrange | positioned between the inner peripheral surface and the inner core part 31 is maintained, and it does not drop out.

≪Case≫
Case 4 will be described with reference to FIG. 3 as appropriate. The case 4 in which the assembly 10 of the coil 2 and the magnetic core 3 is accommodated includes a flat bottom plate portion 40 and a frame-like side wall portion 41 standing on the bottom plate portion 40. The side wall 41 is not integrally formed and is fixed by a fixing material. The bottom plate portion 40 is provided with a heat dissipation layer 42.

[Bottom plate and side wall]
(Bottom plate)
The bottom plate portion 40 is a substantially rectangular plate, and is fixed to the fixed object when the reactor 1 is installed on the fixed object. The example shown in FIG. 3 shows an installation state in which the bottom plate portion 40 is downward, but there may be an installation state in which the bottom plate portion 40 is upward or sideward. When the case 4 is assembled, the bottom plate portion 40 is formed with a heat radiation layer 42 on one surface arranged on the inner side. The outer shape of the bottom plate portion 40 can be selected as appropriate. Here, the bottom plate portion 40 has mounting portions 400 protruding from the four corners, and the outer shape thereof is a shape along the outer shape of the side wall portion 41 described later, and the bottom plate portion 40 and the side wall portion 41 are combined. When the case 4 is formed, the mounting portion 400 overlaps the mounting portion 411 of the side wall portion 41. In addition, the attachment part 411 may not be provided on the side wall part 41, and the outer shape may be such that the attachment part 400 of the bottom plate part 40 protrudes from the outer shape of the side wall part 41. Each mounting portion 400 is provided with a fixing hole 400h through which a fastening member (not shown) such as a bolt for fixing the case 4 to a fixing target such as a cooling base is inserted. The fixing hole 400h is provided so as to be continuous with a fixing hole 411h of the side wall portion 41 described later. As the fixing holes 400h and 411h, any of through holes not threaded and screw holes threaded can be used, and the number of the holes can be selected as appropriate.

(Sidewall)
The side wall 41 is a rectangular frame having both ends open, and when the case 4 is assembled by closing the lower opening side with the bottom plate part 40, the side wall 41 is disposed so as to surround the periphery of the combined body 10, and the upper opening side is It is opened without being blocked by the member. Here, the side wall portion 41 has a rectangular shape along the outer shape of the bottom plate portion 40 when the reactor 1 is installed on a fixed object, and the upper opening side region is the coil 2 and the magnetic core 3. And a curved surface shape along the outer peripheral surface of the combined body 10. In the assembled state of the case 4, the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 are close to each other, and the distance between the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 is 0 mm to 1.0 mm. The degree and very narrow. Further, here, the region on the upper opening side of the side wall portion 41 is provided with a bowl-shaped portion disposed so as to cover the trapezoidal surface of the outer core portion 32 of the combined body 10, and is housed in the case 4. 1, the coil 2 is exposed and the magnetic core 3 is substantially covered with the constituent material of the case 4. By providing the hook-shaped portion, it is possible to improve vibration resistance, improve the rigidity of the case 4 (side wall portion 41), and protect the assembly 10 from the external environment and mechanical protection. In addition, it is good also as a form which abbreviate | omits the said hook-shaped part, and the one trapezoid surface of both the outer core parts 32 is exposed with the coil 2.

[Terminal block]
In the region on the opening side of the side wall portion 41, a portion covering the upper side of the one outer core portion 32 functions as a terminal block 410 to which the terminal fitting 8 is fixed.

  The terminal fitting 8 includes a welding surface 81 connected to the end of the winding 2w constituting the coil 2, a connection surface 82 for connecting to an external device side such as a power source, and the welding surface 81 and the connection surface 82. It is a rectangular board | plate material provided with the connection part to connect. As shown in FIG. 3, this plate material is bent stepwise, and connects the lower end of the vertical welding surface 81 and one end of the horizontal connection surface 82 horizontally above the connection surface 82 by a connecting portion. The welding surface 81 and the connection surface 82 are each configured to be easily connected to a connection partner. In addition to welding such as TIG welding, crimping or the like can be used to connect the conductor portion of the winding 2w and the terminal fitting 8. The shape of the terminal fitting 8 is an example, and an appropriate shape can be used.

  The terminal block 410 is formed with a concave groove 410c in which the connecting portion of the terminal fitting 8 is disposed. The terminal metal fitting 8 fitted in the concave groove 410c is covered with a terminal fixing member 9 above, and is fixed to the terminal block 410 by tightening the terminal fixing member 9 with a bolt 91. As the constituent material of the terminal fixing member 9, an insulating material such as an insulating resin used for the constituent material of the case described later can be suitably used. In addition, a terminal block can be made into another member, for example, it can be set as the form which fixes a terminal block to a side wall part separately. Moreover, when forming a side wall part with an insulating material which is mentioned later, a side wall part, a terminal metal fitting, and a terminal stand part can also be made into the integrated form by insert-molding a terminal metal fitting.

[Mounting location]
Similar to the bottom plate portion 40, the region on the installation side of the side wall portion 41 includes attachment portions 411 protruding from the four corners, and each attachment portion 411 is provided with a fixing hole 411h. The fixing hole 411h may be formed only from the constituent material of the side wall portion 41, or may be formed by arranging a cylindrical body made of another material. For example, when the side wall portion 41 is made of resin, the cylindrical body is excellent in strength when using a metal tube made of a metal such as brass, steel, stainless steel, etc., so that creep deformation of the resin is suppressed. Can do. Here, a metal tube is arranged to form the fixed 411h.

(Material)
If the constituent material of the case 4 is, for example, a metal material, the metal material generally has a high thermal conductivity, so that it can be a case with excellent heat dissipation. Specific metals include, for example, aluminum and its alloys, magnesium (thermal conductivity: 156 W / m ・ K) and its alloys, copper (390 W / m ・ K) and its alloys, silver (427 W / m ・ K) and Examples thereof include iron, austenitic stainless steel (for example, SUS304: 16.7 W / m · K). When the aluminum, magnesium, and alloys thereof are used, a lightweight case can be obtained, which can contribute to reducing the weight of the reactor. In particular, aluminum and its alloys are excellent in corrosion resistance and can be suitably used for in-vehicle components. When the case 4 is formed of a metal material, it can be formed by plastic working such as press working in addition to casting such as die casting.

  Alternatively, the constituent material of the case 4 is a non-metallic material such as polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, acrylonitrile-butadiene-styrene (ABS) resin, or the like. Since many materials are generally excellent in electrical insulation, the insulation between the coil 2 and the case 4 can be enhanced. Further, these non-metallic materials are lighter than the above-described metallic materials, and the reactor 1 can be made light. When the resin is mixed with a filler made of ceramic described later, the heat dissipation can be improved. When the case 4 is formed of resin, injection molding can be suitably used.

  The constituent material of the bottom plate part 40 and the side wall part 41 can be the same kind of material. In this case, both thermal conductivity becomes equal. Or since the baseplate part 40 and the side wall part 41 are separate members, both constituent materials can be varied. In this case, in particular, when both constituent materials are selected so that the thermal conductivity of the bottom plate portion 40 is larger than the thermal conductivity of the side wall portion 41, the heat of the coil 2 and the magnetic core 3 disposed on the bottom plate portion 40 is selected. Can be efficiently discharged to a fixed object such as a cooling base. Here, the bottom plate portion 40 is made of aluminum, and the side wall portion 41 is made of PBT resin.

(Consolidation method)
Various fixing materials can be used as a method of integrally connecting the bottom plate portion 40 and the side wall portion 41. Examples of the fixing material include bonding members such as adhesives and bolts. At this time, in order to perform mutual positioning of the bottom plate portion 40 and the side wall portion 41, a fitting portion that fits both may be formed in a part of each portion of the bottom plate portion 40 and the side wall portion 41. For example, a mode in which a pin is provided on one of the bottom plate portion 40 and the side wall portion 41 and a pin hole is provided on the other side is exemplified. Here, a bolt hole (not shown) is provided in the bottom plate portion 40 and the side wall portion 41, a bolt (not shown) is used as a fixing member, and the bolts are screwed together to integrate them.

[Heat dissipation layer]
In the bottom plate portion 40, a heat radiation layer 42 is provided at a location where the coil installation surface of the coil 2 and the core installation surface of the outer core portion 32 are in contact with each other. The heat radiation layer 42 preferably has a multilayer structure in which the surface side in contact with the coil installation surface and the core installation surface is made of an insulating material, and the side in contact with the bottom plate portion 40 is made of a material having excellent thermal conductivity. The heat radiation layer 42 is made of an insulating material having a thermal conductivity of more than 2 W / m · K. The heat dissipation layer 42 preferably has a higher thermal conductivity, and is composed of a material of 3 W / m · K or higher, particularly 10 W / m · K or higher, more preferably 20 W / m · K or higher, especially 30 W / m · K or higher. Is preferred.

Examples of the material having excellent thermal conductivity include non-metallic inorganic materials such as ceramics such as a kind of material selected from oxides, carbides, and nitrides of metal elements, B, and Si. More specific ceramics are silicon nitride (Si ₃ N ₄ ): about 20 W / m · K to 150 W / m · K, alumina (Al ₂ O ₃ ): about 20 W / m · K to about 30 W / m · K, Aluminum nitride (AlN): 200W / m ・ K ~ 250W / m ・ K, Boron nitride (BN): 50W / m ・ K ~ 65W / m ・ K, Silicon carbide (SiC): 50W / m ・ K About 130W / m · K. These ceramics are excellent in heat dissipation and also in electrical insulation. When forming with the said ceramics, vapor deposition methods, such as PVD method and CVD method, can be utilized, for example. Alternatively, a ceramic sintered plate or the like can be prepared and formed with an appropriate adhesive.

  Alternatively, as the material, an insulating resin containing a filler made of the ceramic can be given. Examples of the insulating resin include an epoxy resin and an acrylic resin. By including the filler having excellent heat dissipation and electrical insulation in the insulating resin, the heat dissipation layer 42 having excellent heat dissipation and electrical insulation can be formed. Further, even when a resin containing a filler is used, the heat dissipation layer 42 can be easily formed by applying the resin to the bottom plate portion 40 or the like. When the heat dissipation layer 42 is formed from the insulating resin, it can be easily formed by using, for example, screen printing.

  When the heat dissipation layer 42 is formed of an insulating high heat conductive adhesive, the adhesion between the coil 2 and the heat dissipation layer 42 can be improved. Here, the heat radiation layer 42 is formed of an epoxy adhesive containing a filler made of alumina (thermal conductivity: 3 W / m · K). The viscosity of the heat dissipation layer 42 before curing is (200 to 400 Pa · s). Here, the heat dissipation layer 42 is formed of a two-layer structure of the adhesive layer, and the thickness of one layer is 0.2 mm, for a total of 0.4 mm. The shape of the heat dissipation layer 42 is not particularly limited as long as the coil installation surface and the core installation surface have an area that can sufficiently contact the heat dissipation layer 42. Here, as shown in FIG. 3, the heat dissipation layer 42 has a shape along the shape formed by the coil installation surface of the coil 2 and the core installation surface of the outer core portion 32.

[Sealing resin]
The case 4 may be filled with a sealing resin (not shown) made of an insulating resin. In this case, the end of the winding 2w is pulled out from the upper opening side of the case 4 and exposed from the sealing resin. Examples of the sealing resin include an epoxy resin, a urethane resin, and a silicone resin. In addition, the sealing resin contains a filler having excellent insulation and thermal conductivity, for example, a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide. Then, the heat dissipation can be further enhanced.

  When the case 4 is filled with the sealing resin, the packing 6 may be disposed in order to prevent uncured resin from leaking through the gap between the bottom plate portion 40 and the side wall portion 41. Here, the packing 6 is an annular body having a size that can be fitted to the outer periphery of the combined body 10 of the coil 2 and the magnetic core 3, and is made of a synthetic rubber. Material can be used. On the installation surface side of the side wall portion 41 of the case 4, there is a packing groove (not shown) in which the packing 6 is disposed.

≪Manufacturing method≫
The reactor 1 having the above-described configuration can be typically manufactured by the steps of preparation of the bottom plate portion → fixing of the assembly on the heat radiation layer formed on the bottom plate portion → assembly of the case.

[Preparation process]
A heat radiating layer 42 made of an insulating high thermal conductive adhesive is formed, and a bottom plate portion 40 independent of the side wall portion 41 is prepared. As shown in FIG. 3, the bottom plate portion 40 is formed by stamping an aluminum plate into a predetermined shape and screen-printing or applying a heat-radiating layer 42 having a predetermined shape on one surface. The heat dissipation layer 42 formed on the bottom plate portion 40 may be formed immediately before the fixing process of the assembly 10 described later, or the previously formed bottom plate portion 40 may be used. In the latter case, release paper may be arranged so that foreign matter or the like does not adhere to the heat dissipation layer 42 until the combination 10 is arranged.

<Fixing the assembly on the heat dissipation layer>
The combined body 10 is fixed at a predetermined position on the heat radiation layer 42 formed on the bottom plate portion 40 prepared in the preparation step. At this time, as shown in FIG. 4, using the positioning jig 100, the assembly 10 is positioned and fixed with respect to the heat radiation layer 42 by the steps of fixing the bottom plate portion → mounting the combination body → hardening the heat radiation layer. .

[Fixing process]
The bottom plate portion 40 is fixed to a predetermined position of the positioning base 101. When placing the combined body 10 on the heat dissipation layer 42, the bottom plate portion 40 on which the heat dissipation layer 42 is formed is fixed to facilitate positioning of the combined body 10 with respect to the heat dissipation layer 42.

  The bottom plate portion 40 and the base 101 are formed with a fixing portion (not shown) for fixing the both 40 and 101, and positioning is performed by this fixing portion. Examples of the fixing portion include a joining member such as a pin. A plurality of pins are formed on the pedestal 101, and pin holes that match the pins are formed in the bottom plate portion 40, thereby fixing both 40 and 101. As the fixing portion, a fixing hole 400h (FIG. 3) through which a fastening member for fixing the bottom plate portion 40 to the fixing target is inserted, or a fitting portion (fitting) for positioning the bottom plate portion 40 and the side wall portion 41. A pin that fits these holes may be formed on the base 101 using a joint hole (not shown).

(pedestal)
The pedestal 101 is a substantially rectangular plate, and a fixing portion for fixing the bottom plate portion 40 is formed on a surface on which the bottom plate portion 40 is installed. The fixing part only needs to be able to fix the bottom plate part 40 to the pedestal 101, and examples thereof include a form in which a pin is formed and a form in which a screw hole into which a screw is fitted is formed. In both forms, the bottom plate portion 40 has holes that fit into pins and screws.

  Further, the base 101 is formed with an arrangement portion for arranging a first jig 110 and a second jig 120 described later. Examples of the arrangement portion include a joining member such as a pin and a bolt, and a concave portion that fits with the lower ends of the jigs 110 and 120. Here, a pin (not shown) is formed on the pedestal 101 in order to place the first jig 110, and a guide groove 102 is formed in order to place the second jig 120. By fitting this pin into a pin hole formed in the first jig 110, the first jig 110 can be arranged with respect to the base 101. By forming the guide groove 102, the second jig 120 can be slid according to the length along the axial direction of the coil 2 of the combined body 10, and accurately according to the length of the combined body 10. Positioning can be performed. The second jig 120 is fixed to the pedestal 101 using bolts 125. The shape and material of the pedestal 101 are not particularly limited as long as the pedestal 101 has an area where the bottom plate portion 40 and the first jig 110 and the second jig 120 can be sufficiently fixed. Further, as long as the combination 10 can be positioned with respect to the heat dissipation layer 42, the form of the arrangement portion is not particularly limited.

[Placement process]
The combined body 10 is placed on the heat dissipation layer 42. First, the first jig 110 for positioning in the direction orthogonal to the axial direction of the coil 2 with respect to the bottom plate portion 40 of the combined body 10 is arranged on the base 101. Next, the assembly 10 is placed on the heat dissipation layer 42 with respect to the first jig 110. A second jig 120 for positioning the coil 2 in the axial direction with respect to the bottom plate portion 40 of the combined body 10 is disposed on the base 101 on the opposite side of the first jig 110 with the combined body 10 interposed therebetween. The combination 10 is sandwiched between the first jig 110 and the second jig 120 from both ends, whereby the combination 10 is positioned with respect to the heat radiation layer 42 before the curing step described later. That is, the positioning is performed before the insulating high thermal conductive adhesive constituting the heat radiation layer 42 is cured. Here, the first jig 110 and the second jig 120 are positioned by the outer core portion 32. Specifically, one of the outer core portions 32 of the assembly 10 is abutted against the first jig 110 arranged on the base 101. The position where the second jig 120 is slid along the guide groove 102 of the pedestal 101 in a state where the combination 10 is positioned with respect to the first jig 110 and is held against the other of the outer core portions 32 of the combination 10 Then, the second jig 120 is arranged on the base 101 with the bolt 125. The combination 10 is positioned at a predetermined position on the heat radiation layer 42 by sandwiching the outer core portion 32 from both ends by the first jig 110 and the second jig 120. The arrangement order of the first jig 110 and the second jig 120 is not limited. For example, the three members (10, 110, 120) may be simultaneously placed on the pedestal 101 while the first jig 110 and the second jig 120 are held against the combined body 10.

  The first jig 110 and the second jig 120 may be arranged in a direction orthogonal to the axial direction of the coil 2 or may be arranged in the axial direction of the coil 2. When arranged in the axial direction of the coil 2, the jigs 110 and 120 may be arranged in contact with the coil 2, or may be arranged in a shape in contact with the outer core portion 32 without being in contact with the coil 2. Good. By placing the jigs 110 and 120 in a non-contact state with the coil 2, it is possible to prevent the insulation coating provided on the outer periphery of the winding forming the coil 2 from being damaged.

  A heat dissipation layer 42 is formed on the bottom plate portion 40, and the bottom plate portion 40 is fixed at a predetermined position of the base 101. Therefore, the first jig 110 and the second jig 120 are arranged on the base 101. By doing so, the assembly 10 can be positioned with respect to the heat radiation layer 42 with high accuracy. The arrangement of the first jig 110 and the second jig 120 on the pedestal 101 includes a fixing hole 400h (FIG. 3) through which a fastening member for fixing the bottom plate part 40 to a fixing target is inserted, and the bottom plate part 40. It is also possible to use a fitting portion (not shown) for positioning with the side wall portion 41. In this case, an arrangement portion suitable for the fixing hole and the fitting portion may be formed in each jig 110, 120. By positioning both jigs 110 and 120 indirectly on the base 101 via the bottom plate portion 40, the positioning can be performed with higher accuracy.

(First jig)
The first jig 110 is a member that performs positioning in a direction orthogonal to the axial direction of the coil 2 with respect to the bottom plate portion 40 of the assembly 10. The first jig 110 includes a first base 111 and first leg pieces 112 at both ends of the first base 111. The first base 111 has an outer shape formed by forming a rectangular cutout, and has a first positioning surface 113 for positioning the assembly 10 on the outer edge surface of the recessed portion. The pair of first leg pieces 112 are formed at right angles to the first base portion 111 at intervals between which the bottom plate portion 40 is sandwiched. A mating portion (here, a pin hole) with respect to the placement portion of the pedestal 110 is formed in the first leg piece 112. When the first leg piece 112 is erected on the pedestal 110, the height of the first leg piece 112 is such that the position where the first leg piece 112 abuts on the outer core part 32 of the first base 111 is substantially the center in the height direction of the outer core part 32. It is preferable that the height be The first positioning surface 113 is shaped so as to surround the outer periphery of the outer core portion 32, and of the first positioning surface 113, the outer core portion 32 is formed by a pair of inner end surfaces facing the longitudinal direction of the first base portion 111. The length between the inner end faces substantially corresponds to the length in the direction perpendicular to the axial direction of the coil 2 of the outer core portion 32. Further, the long surface of the positioning surface 113 along the longitudinal direction of the first base portion 111 supports the end surface in the axial direction of the coil 2 of the outer core portion 32. By positioning at least both ends of the outer core portion 32 in the direction orthogonal to the axial direction of the coil 2 with the first positioning surfaces 113, positioning in the direction orthogonal to the axial direction of the coil 2 with respect to the bottom plate portion 40 of the assembly 10 is performed. be able to. The first base 111 and the first leg piece 112 may be formed integrally or may be configured by separate members.

(Second jig)
The second jig 120 is a member that positions the coil 2 in the axial direction with respect to the bottom plate portion 40 of the combined body 10. The second jig 120 has substantially the same configuration as the first jig 110, and includes a second base 121 and second leg pieces 122 at both ends of the second base 121. The second base 121 has a rectangular outer shape formed by forming a rectangular cutout, and has a second positioning surface 123 for positioning the combination 10 on the outer edge surface of the recessed portion. The pair of second leg pieces 122 are formed at right angles to the second base 121 at an interval between which the bottom plate portion 40 is sandwiched. When the second leg piece 122 is erected on the pedestal 110, the height of the second leg piece 122 is such that the position where the second leg piece 122 abuts on the outer core part 32 of the second base 121 is substantially the center in the height direction of the outer core part 32. It is preferable that the height be The second leg piece 122 has an opening on a side surface facing the first jig 110, and has a sliding recess such as a U-shaped groove 124 formed over the entire length of the second leg piece 122 in the longitudinal direction. Adjustment of the axial positioning of the coil 2 with respect to the bottom plate portion 40 of the assembly 10 by inserting the bolt 125 into the U-shaped groove 124 and sliding the second jig 120 along the depth direction of the U-shaped groove 124. It can be performed. The second jig 120 is slid using the U-shaped groove 124 and the guide groove 102 formed in the pedestal 110, and the length along the longitudinal direction of the second base 121 of the second positioning surface 123 is increased. The second jig 120 can be fixed to the pedestal 101 by fixing the bolt 125 in a state where the scale surface is in contact with the axial end of the coil 2 of the outer core portion 32. The coil 2 can be positioned in the axial direction. The slide of the second jig 120 may be performed using only the guide groove 102 formed in the pedestal 101. In this case, in order to fix the second jig 120 at a predetermined position of the base 101, in addition to the bolt 125, both joining members such as bolts are required. The second base 121 and the second leg piece 122 may be formed integrally or may be configured by separate members. Since the second jig 120 is a member for positioning the coil 2 in the axial direction with respect to the bottom plate portion 40 of the combined body 10, the side surface of the rectangular second base 121 without a notch is arranged in the axial direction of the coil 2 of the outer core portion 32. The coil 2 may be positioned in the axial direction with respect to the bottom plate portion 40 of the combined body 10 by contacting the end portion. The length of the side surface side of the second base 121 may correspond to the length in the direction orthogonal to the axial direction of the coil 2 of the outer core portion 32. Since alignment in the axial direction is sufficient, the length in the orthogonal direction may be longer or shorter.

  The combination 10 is positioned at a predetermined position on the heat radiation layer 42 by sandwiching the outer core portion 32 from both ends by the first jig 110 and the second jig 120. Specifically, the first positioning surface 113 formed on the first jig 110 performs positioning in the direction orthogonal to the axial direction of the coil 2, and the side surface of the second base 121 that forms the second jig 120 The positioning of the coil 2 in the axial direction is performed by

[Curing process]
In the above placement step, when the combined body 10 can be positioned at a predetermined position on the heat dissipation layer 42, the insulating high thermal conductive adhesive constituting the heat dissipation layer 42 is cured in that state.

  In the magnetic core 3, even when the inner core portion 31 and the outer core portion 32 are not joined by an adhesive, both the first jig 110 and the second jig 120 are used to connect the both 31 and 32 in the above placement step. Since it can be positioned with respect to the heat dissipation layer 42 in a predetermined contact state, both of them 31 and 32 can be fixed to the bottom plate portion 40 in this contact state by the heat dissipation layer 42 in this curing step.

[Assembly of the case]
When the combination 10 is fixed at a predetermined position on the heat radiation layer 42, the positioning jig 100 is removed. Then, the side wall portion 41 configured in a predetermined shape by injection molding or the like is covered from above the combined body 10 so as to surround the combined body 10, and a fixing material (here, a bolt (not shown) separately prepared) ), The bottom plate portion 40 and the side wall portion 41 are integrated. At this time, the combined body 10 is configured such that one of the trapezoidal surfaces of each outer core portion 32 is covered by the terminal block 410 and the above-described hook-shaped portion, and the side wall portion 41 is attached to the combined body 10. It is possible to prevent the combined body 10 from dropping from the side wall portion 41 when positioning or installing the reactor 1 so that the bottom plate portion 40 is upward or sideward. A position fixing portion for preventing the outer core portion 32 from falling off may be separately provided inside the terminal block 410 or the bowl-shaped portion. Through this step, the box-shaped case 4 is assembled as shown in FIG. 1, and the combined body 10 can be stored in the case 4.

  The welding surface 81 of the terminal fitting 8 is welded to the end of the winding 2w protruding from the case 4, and the terminal fitting 8 is fitted into the concave groove 410c (FIG. 3) of the terminal block 410 (FIG. 3) of the side wall 41. . The terminal fixture 8 is fixed to the terminal block 410 by covering the connecting portion of the terminal fitting 8 with the terminal fixing member 9 and fixing the terminal fixing member 9 to the side wall portion 41 with the bolts 91. By this step, the reactor 1 without the sealing resin is formed. According to the manufacturing method of the present invention, since the assembly 10 can be accurately positioned on the heat dissipation layer 42, the winding 2w and the terminal fitting 8 can be easily aligned.

  On the other hand, the reactor 1 having the sealing resin is formed by filling the case 4 with a sealing resin (not shown) and curing the resin. Alternatively, the terminal fitting 8 may be fixed to the terminal block 410 with the bolt 91, and after filling the sealing resin, the end of the winding 2w and the welding surface 81 of the terminal fitting 8 may be welded.

≪Usage≫
Reactor 1 having the above-described configuration is, for example, an electric vehicle in which energization conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz. It can be suitably used as a component part of a vehicle-mounted power conversion device such as a hybrid vehicle.

≪Effect≫
According to the manufacturing method, by using positioning jigs such as the first jig, the second jig, and the pedestal, positioning of the assembly with respect to the heat dissipation layer can be easily and accurately performed. By curing the insulating high thermal conductive adhesive that constitutes the heat dissipation layer in the state, the assembly can be prevented from moving on the heat dissipation layer. That is, the contact area between the assembly and the heat dissipation layer can be ensured accurately, and a reactor excellent in heat dissipation can be obtained. By performing the above positioning, it is easy to align the assembly and other components, for example, align the terminal fitting for connecting to an external device such as a power source and the end of the coil. Moreover, since the positioning with respect to the heat dissipation layer of the assembly can be accurately performed by using the positioning jig, the degree of freedom in selecting the usable insulating high thermal conductive adhesive can be increased. According to the manufacturing method of the present invention, since the bottom plate portion and the side wall portion are independent separate members attached by the fixing material, the assembly can be positioned with the side wall portion removed, and the accuracy is easily achieved. Positioning can be performed well. Therefore, it is excellent also in the manufacturability of the reactor.

{Embodiment 2}
Next, a method for manufacturing the reactor of the second embodiment will be described with reference to FIG. The method for manufacturing the reactor of the second embodiment is different from that of the first embodiment in the method of fixing the combined body 10 on the heat radiation layer 42. Hereinafter, description will be made centering on this difference, and other configurations are the same as those of the first embodiment, and thus description thereof will be omitted.

  In the method of fixing the combined body 10 on the heat radiation layer 42, when the insulating high thermal conductive adhesive constituting the heat radiation layer 42 is cured with the combination 10 positioned at a predetermined position on the heat radiation layer 42, the combination body A weight 200 is placed above 10. Since the insulating high thermal conductive adhesive before curing is flexible, there is a possibility that the combination 10 is partially in a non-contact state on the heat dissipation layer 42. Therefore, by placing the weight 200 above the combined body 10, the combined body 10 can be pressed onto the heat radiation layer.

(Weight)
The weight 200 is a member that presses the combined body 10 from above to press-contact the combined body 10 on the heat radiation layer 42. The weight 200 includes a main body portion 201 of a rectangular plate and a long block-shaped press contact piece 202 provided at both ends of the main body portion 201. The main body 201 and the pressure contact piece 202 may be formed integrally or may be formed of separate members. The shape of the weight 200 is not particularly limited as long as the combined body 10 can be pressed onto the heat radiation layer 42. The combined body 10 may be pushed by the weight 200 itself, or another member serving as a weight may be placed on the weight 200 and pushed. In the former case, the weight 200 is preferably made of a relatively heavy material such as iron.

  It is preferable that the weight 200 pushes the outer core portion 32 with priority. Here, the outer core portion 32 is pushed by the pressure contact piece 202, and the main body portion 201 is not in contact with the coil 2. The non-contact state between the combined body 10 and the heat dissipation layer 42 is particularly likely to occur in the outer core portion 32 that is the end portion of the combined body 10. Therefore, by pressing the outer core portion 32 with the weight 200, the entire combined body 10 is dissipated. It can be in contact with layer 42. By appropriately selecting the shape of the weight, the entire assembly 10 may be pushed, or only the coil 2 may be pushed. By placing the weight 200 in a non-contact state with the coil 2, it is possible to prevent the insulating coating provided on the outer periphery of the winding forming the coil 2 from being damaged.

  In the case where the weight 200 is placed above the combined body 10, in the mounting step of mounting the combined body 10 on the heat radiation layer 42, the first jig 110, the second jig 120, and the combined body 10 For this, it is preferable to provide a gap so that the combination 10 does not move on the heat radiation layer 42. By doing so, when the weight 200 is placed, the combined body 10 can be pressed against the heat radiation layer 42 while maintaining a horizontal state. Further, after the press contact, positioning may be further performed by adjusting the first jig 110 and the second jig 120 to fill the gap.

  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 method for manufacturing a reactor according to the present invention can be suitably used for a method for manufacturing a reactor that is used as a component part of a power conversion device such as a vehicle-mounted converter mounted on a vehicle such as a hybrid vehicle, an electric vehicle, or a fuel cell vehicle. .

1 Reactor 10 Union
2 Coil 2a, 2b Coil element 2r Coil connection part 2w Winding
3 Magnetic core 31 Inner core 31e End face 31m Core piece 31g Gap material
32 Outer core part 32e Inner end face
4 Case 40 Bottom plate part 41 Side wall part 42 Heat radiation layer
400,411 Mounting part 400h, 411h Fixed hole 410 Terminal block 410c Concave groove
5,5α Insulator 51,51α Peripheral wall 52,52α Frame 52f Flange
6 Packing
8 Terminal fitting 81 Weld surface 82 Connection surface
9 Terminal fixing member 91 bolt
100 Positioning jig 101 Base 102 Guide groove
110 First jig 111 First base 112 First leg 113 First positioning surface
120 Second jig 121 Second base 122 Second leg piece 123 Second positioning surface
124 U-shaped groove 125 bolt
200 Weight 201 Body 202 Pressing piece

Claims (5)

An assembly of a coil and a magnetic core having an inner core portion in which the coil is disposed and an outer core portion in which the coil is not disposed is manufactured, and is erected on the bottom plate portion and the bottom plate portion to surround the periphery of the combination A reactor manufacturing method for manufacturing a reactor by storing the combination in a case including a side wall,
A heat dissipation layer made of an insulating high thermal conductive adhesive is formed, and a preparation step for preparing a bottom plate part independent of the side wall part,
A fixing step of fixing the bottom plate portion to a predetermined position of a positioning base;
A placing step of placing the combination on the heat dissipation layer;
A curing step of curing the insulating high thermal conductive adhesive constituting the heat dissipation layer,
The previous placement process is
A first jig for positioning in the direction orthogonal to the axial direction of the coil with respect to the bottom plate portion of the assembly and a second jig for positioning in the axial direction of the coil with respect to the bottom plate portion of the combination are arranged on the base. And
A reactor manufacturing method, wherein the assembly is positioned with respect to the heat radiation layer by sandwiching the combination from both ends by the first jig and the second jig. The bottom plate portion has a fixing hole through which a fastening member for fixing to a fixing target is inserted,
2. The method of manufacturing a reactor according to claim 1, wherein the fixing hole is used for arranging at least one of the first jig and the second jig. In the bottom plate portion, there is a fitting portion that positions both by fitting the bottom plate portion and the side wall portion,
2. The method of manufacturing a reactor according to claim 1, wherein the fitting portion is used for arranging at least one of the first jig and the second jig.   The method for manufacturing a reactor according to any one of claims 1 to 3, wherein, in the curing step, curing is performed in a state where a weight is placed above the combined body. The magnetic core, the inner core portion and the outer core portion are not joined by an adhesive,
In the above placing step, the first and second jigs are positioned with respect to the heat dissipation layer with the inner core portion and the outer core portion in a predetermined contact state,
The reactor according to any one of claims 1 to 4, wherein in the curing step, the heat dissipation layer fixes the inner core portion and the outer core portion to the bottom plate portion in the contact state. Production method.

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