JP2012209324A - Reactor and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor which improves the heat radiation performance, and to provide a manufacturing method of the reactor.SOLUTION: A reactor 1 has: a cylindrical coil 2 formed by winding a conductor wire 21 and generating magnetic flux by energization; a core 3 composed of a magnetic power mixed resin formed by mixing an insulation resin with magnetic powder and burying the coil 2 therein; and a columnar core member 5 disposed in the axial direction X of the coil 2 on the inner peripheral side of the coil 2. Heat radiation members 6, contacting with the coil 2 and the core member 5 and having higher heat conductivity than the core 3, are disposed between the coil 2 and the core member 5.

Description

  The present invention relates to a reactor used in a power converter and the like and a method for manufacturing the reactor.

2. Description of the Related Art Conventionally, reactors used for power converters such as inverters for vehicles and DC-DC converters are known.
In recent years, as a means to reduce costs by reducing the number of parts, etc., it is composed of a cylindrical coil that generates magnetic flux when energized and a magnetic powder mixed resin in which magnetic powder is mixed with insulating resin, and the coil is embedded inside There is a reactor having a core.

Since this reactor has a structure in which the coil is embedded in the core, it is required to efficiently dissipate the heat generated from the coil.
Therefore, Patent Document 1 discloses a reactor in which a heat radiating core member is disposed on the inner peripheral side of a coil. According to this, the heat generated in the coil can be transmitted to the core member via the core and radiated.

JP 2009-130965 A

  However, even in the case of a reactor in which a core member for heat dissipation is arranged as in Patent Document 1, in order to transmit the heat generated in the coil to the core member, the core must be interposed. For this reason, the heat dissipation property could not be sufficiently improved. Further, although means for improving the thermal conductivity of the core is conceivable, in this case, there is a problem in that the magnetic characteristics of the reactor change if the core composition is greatly changed.

  The present invention has been made in view of such a problem, and an object of the present invention is to provide a reactor capable of improving heat dissipation and a method for manufacturing the same.

A first invention is a cylindrical coil that is formed by winding a conductor wire and generates a magnetic flux when energized, and a core that is made of a magnetic powder mixed resin obtained by mixing magnetic powder in an insulating resin and has the coil embedded therein. A reactor having a columnar core member disposed in the axial direction of the coil on the inner circumferential side of the coil,
The reactor is characterized in that a heat dissipating member having a higher thermal conductivity than that of the core is interposed between the coil and the core member (Claim 1).

According to a second aspect of the present invention, there is provided a cylindrical coil formed by winding a conductor wire and generating a magnetic flux when energized, and a core comprising a magnetic powder mixed resin obtained by mixing magnetic powder in an insulating resin and having the coil embedded therein. And a columnar core member disposed in the axial direction of the coil on the inner peripheral side of the coil, and between the coil and the core member, both are in contact with each other and from the core Is a method of manufacturing a reactor having a heat dissipation member having a high thermal conductivity,
A plurality of the heat dissipation members provided with contact portions having contact surfaces that contact the inner peripheral surface of the coil are attached to a columnar coil winding jig, and the contact portions of the heat dissipation member are attached to the coil winding jig. An attachment step of exposing the outer peripheral surface of the tool and positioning the contact surface of the contact portion of the heat radiating member outside the outer peripheral surface of the coil winding jig;
In the outer periphery of the coil winding jig, the conductor wire is wound on the contact surface of the contact portion of the plurality of heat dissipating members to form the coil,
A removal step of removing the coil and the heat dissipating member from the coil winding jig in a state where the coil and the heat dissipating member are assembled to each other,
An engaging step of engaging the heat dissipating member with an engaging portion provided on the core member in a state where the coil and the heat dissipating member are assembled to each other;
An accommodating step of accommodating the coil, the heat dissipation member, and the core member in a mold in a state of being assembled with each other;
The reactor includes a core molding step in which the magnetic powder mixed resin is filled and cured in the mold and the core is molded (Claim 8).

  In the reactor according to the first invention, the heat radiating member is interposed between the coil and the core member so as to be in contact with both. Moreover, the heat dissipation member has higher thermal conductivity than the core. Therefore, the heat generated in the coil can be transmitted to the core member via the heat dissipation member and radiated. Thereby, compared with the case where the heat radiating member is not provided, the heat radiating property from the coil to the core member, that is, the heat radiating property in the inner direction of the coil can be improved. As a result, the temperature rise of the reactor can be effectively suppressed.

  Further, as described above, since the thermal conductivity of the heat radiating member is higher than that of the core, the heat generated in the coil can be transmitted to the core member via the heat radiating member instead of the core to be radiated. Therefore, it is not necessary to consider the core material from the viewpoint of heat dissipation, and the core material can be selected from the viewpoint of magnetic characteristics. Thereby, a reactor with high inductance can be easily obtained while ensuring heat dissipation by the heat radiating member.

  In the reactor manufacturing method according to the second aspect of the invention, in the mounting step, the contact portion of the heat dissipation member is exposed to the outer peripheral surface of the coil winding jig, and the contact surface of the contact portion is exposed to the coil winding jig. A plurality of heat dissipating members are attached to the coil winding jig in a state of being positioned outward from the outer peripheral surface. And in the said coil formation process, a conductor wire is wound on the contact surface of the contact part of a several heat radiating member, and a coil is formed. That is, a coil is formed by winding a conductor wire around a heat radiating member. Therefore, adhesion between the coil and the heat dissipation member can be improved. Thereby, the heat transfer from a coil to a heat radiating member can be improved.

  Moreover, at the said removal process, it removes from a coil winding jig | tool in the state which assembled | attached the coil and the heat radiating member mutually. Here, the coil is not formed by winding a conductor wire around a coil winding jig, but is formed by winding it around a heat radiating member. Therefore, the coil can be removed from the coil winding jig without contacting the coil with the coil winding jig. Thereby, damage to the coil can be prevented.

  Further, in the engaging step, the heat dissipation member is engaged with the engaging portion of the core member, and in the housing step, the coil, the heat dissipation member, and the core member are housed in the mold in a state of being assembled with each other, In the core molding step, the magnetic powder mixed resin is filled in the mold and cured to mold the core. Therefore, it is possible to easily manufacture the reactor according to the first aspect in which the heat dissipation member is interposed between the coil and the core member.

  Thus, according to the said 1st and 2nd invention, the reactor which can improve heat dissipation, and its manufacturing method can be provided.

Explanatory drawing which shows the cross section of a reactor in an Example. Explanatory drawing which shows the longitudinal cross-section of a reactor in an Example. Explanatory drawing which shows the assembly | attachment state of a coil, a heat radiating member, and a core member in an Example. Explanatory drawing which shows the thermal radiation member in an Example. Explanatory drawing which shows the attachment process in an Example. Explanatory drawing which shows the attachment process in an Example. Explanatory drawing which shows the coil formation process in an Example. Explanatory drawing which shows the removal process in an Example. Explanatory drawing which shows the engagement process in an Example. Explanatory drawing which shows the engagement process in an Example. Explanatory drawing which shows the accommodation process in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the heat radiating member in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the heat radiating member in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the heat radiating member in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the connection part of a thermal radiation member in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the connection part of a thermal radiation member in an Example. Explanatory drawing which shows the example which changed the arrangement | positioning position of the connection part of a thermal radiation member in an Example.

In the first invention, the reactor can be used in, for example, a power converter such as an inverter for a vehicle or a DC-DC converter.
In addition, as the magnetic powder mixed resin constituting the core, for example, a resin obtained by mixing and dispersing magnetic powder such as iron powder in an insulating resin having thermosetting property, thermoplasticity or the like such as an epoxy resin is used. Can do.

Moreover, as said heat radiating member, it is preferable to use materials with high heat conductivity, such as metals, such as aluminum and its alloy, for example.
Further, as the core member, it is preferable to use a material having high thermal conductivity, such as a metal such as aluminum or an alloy thereof, similarly to the heat dissipation member.

Further, a plurality of plate-like heat radiating members are interposed between the coil and the core member, and both the main surfaces of the heat radiating member are substantially orthogonal to the circumferential direction of the coil. It is preferable that they are arranged as described above (claim 2).
In this case, the area where the magnetic flux generated around the coil crosses the heat radiating member can be made as small as possible. Thereby, the flow of magnetic flux is hardly inhibited by the heat radiating member, and the decrease in inductance can be prevented.
When both main surfaces of the heat radiating member are substantially orthogonal to the circumferential direction of the coil, both main surfaces of the heat radiating member are substantially parallel to the axial direction of the coil.

Further, it is preferable that the plurality of heat dissipating members are connected to each other by an annular connecting portion provided along the inner peripheral surface of the coil.
In this case, since a plurality of heat radiating members are connected and integrated by the connecting portion, handling of the heat radiating members becomes easy.

Moreover, it is preferable that the heat radiating member is provided with a contact portion having a contact surface that contacts the inner peripheral surface of the coil.
In this case, the heat radiating member can be sufficiently and reliably brought into contact with the coil by the contact portion. Moreover, the contact area of a coil and a heat radiating member can be ensured by the contact surface of a contact part, and the heat transfer from a coil to a heat radiating member can be improved.

The heat dissipation member preferably includes a coil support portion that protrudes outward from the contact surface of the contact portion and supports at least one end surface of the coil in the axial direction ( Claim 5).
In this case, the coil support part can easily position the coil with respect to the heat dissipation member.

Further, the heat dissipation member may be provided with a locking portion that protrudes outward from the contact surface of the contact portion and that is locked between the conductor wires constituting the coil. Preferred (claim 6).
In this case, the heat radiating member can be sufficiently and reliably fixed to the coil by the locking portion.

Moreover, it is preferable that the said core member is provided with the engaging part which engages with the said heat radiating member (Claim 7).
In this case, the heat radiating member can be sufficiently and reliably brought into contact with the core member by the engaging portion. Further, heat transfer from the heat radiating member to the core member can be increased.

In the second invention, it is preferable that the plurality of heat dissipating members are connected to each other by an annular connecting portion provided along the inner peripheral surface of the coil.
In this case, since a plurality of heat radiating members are connected and integrated by the connecting portion, handling of the heat radiating members becomes easy. Thereby, in the said attachment process and the said removal process, a some heat radiating member can be easily attached with respect to the coil winding jig | tool, and can be easily removed from the coil winding jig | tool.

The heat dissipation member preferably includes a coil support portion that protrudes outward from the contact surface of the contact portion and supports at least one end surface of the coil in the axial direction ( Claim 10).
In this case, the coil support part can easily position the coil with respect to the heat dissipation member. Thereby, in the said coil formation process, a conductor wire can be wound to a desired position with sufficient precision around a heat radiating member.

Further, the heat dissipation member may be provided with a locking portion that protrudes outward from the contact surface of the contact portion and that is locked between the conductor wires constituting the coil. Preferred (claim 11).
In this case, the heat radiating member can be sufficiently and reliably fixed to the coil by the locking portion. Thereby, in the said coil formation process, a coil and a heat radiating member can be easily fixed by winding a conductor wire around a heat radiating member.

The reactor concerning the Example of this invention and its manufacturing method are demonstrated using figures.
As shown in FIGS. 1 to 4, the reactor 1 of this example is formed by winding a conductor wire 21 and generating a magnetic flux by energization, and a magnetic powder mixed resin in which magnetic powder is mixed with insulating resin. And a core 3 in which the coil 2 is embedded, and a columnar core member 5 disposed in the axial direction X of the coil 2 on the inner peripheral side of the coil 2.
Between the coil 2 and the core member 5, a heat dissipating member 6 that is in contact with both and has a higher thermal conductivity than the core 3 is interposed.
This will be described in detail below.

As shown in FIGS. 1 and 2, the reactor 1 is used in, for example, a power converter such as an inverter for a vehicle and a DC-DC converter.
As described above, the reactor 1 includes the coil 2, the core 3, the core member 5, and the heat dissipation member 6, and further includes the case 4.

As shown in the figure, the coil 2 is formed in a cylindrical shape by winding a conductor wire 21 made of a copper wire in a spiral shape. The coil 2 is embedded in the core 3.
The core 3 is made of a magnetic powder mixed resin obtained by mixing and dispersing iron powder as magnetic powder in an epoxy resin as insulating resin. The core 3 is disposed so as to cover the coil 2 and fill the case 4.

  As shown in the figure, the case 4 has a disc-shaped bottom surface portion 41 and a cylindrical side surface portion 42 erected from the outer peripheral edge of the bottom surface portion 41, one of which is an open box shape. It has become. Inside the case 4, a coil 2, a core 3, and the like are accommodated. The case 4 is made of aluminum or an alloy thereof.

  As shown in FIGS. 1 to 3, the core member 5 has a columnar shape and extends in the axial direction X of the coil 2 (hereinafter simply referred to as the axial direction X) so as to penetrate the inner peripheral side of the coil 2. It is arranged. Further, the core member 5 is fixed to the bottom surface portion 41 of the case 4 with bolts or the like. The core member 5 may be formed integrally with the case 4. The core member 5 is made of aluminum or an alloy thereof.

  Further, the core member 5 is provided with four engaging portions 51 for engaging a plate-like heat radiating member 6 described later. The engaging portion 51 is formed in a concave groove shape on the outer peripheral surface 502 of the core member 5. Further, the engaging portion 51 is formed from the upper end surface 503 of the core member 5 to the middle of the core member 5 in the axial direction.

  As shown in FIGS. 1 to 3, four plate-like heat radiating members 6 are provided between the coil 2 and the core member 5 so as to be in contact with both. The heat dissipating member 6 is disposed such that both main surfaces 601 are substantially orthogonal to the circumferential direction of the coil 2. That is, both main surfaces 601 of the heat radiating member 6 are substantially parallel to the axial direction X. Further, the four heat radiating members 6 are arranged substantially radially around the axis 200 of the coil 2.

As shown in FIG. 4, the heat radiating member 6 is provided with a contact portion 61 having a contact surface 611 that contacts the inner peripheral surface 201 of the coil 2. The contact portion 61 is formed by being bent along the inner peripheral surface 201 of the coil 2 from the outer end of the heat radiating member 6. As shown in FIGS. 1 and 3, the contact surface 611 of the contact portion 61 is in close contact with the inner peripheral surface 201 of the coil 2.
On the other hand, as shown in FIGS. 1 and 3, the heat radiating member 6 is engaged with engaging portions 51 provided on the core member 5. Thereby, the heat radiating member 6 is in contact with the core member 5 in an engaged state.

  As shown in FIG. 4, the heat radiating member 6 protrudes outward from the contact surface 611 of the contact portion 61 and also has a coil support portion 62 that supports one end surface (lower end surface 204) in the axial direction X of the coil 2. Is provided. The coil support portion 62 is formed to protrude outward from the lower end of the contact surface 611 of the contact portion 61. As shown in FIG. 2, the coil support portion 62 is in contact with the lower end surface 204 of the coil 2 and supports the lower end surface 204.

  As shown in FIG. 4, the four heat radiating members 6 are connected to each other by an annular connecting portion 63 provided along the inner peripheral surface 201 of the coil 2. The four heat radiating members 6 are integrally formed by connecting the contact portions 61 to each other by the connecting portion 63. The connecting portion 63 is provided at an intermediate position in the axial direction X (FIG. 2) in the heat radiating member 6. In addition, the connection portion 63 is provided with a contact support surface 631 that contacts the inner peripheral surface 201 of the coil 2. As shown in FIG. 3, the contact support surface 631 of the connecting portion 63 is in contact with the inner peripheral surface 201 of the coil 2.

Next, the manufacturing method of the reactor 1 of this example is demonstrated.
In the manufacturing method of the reactor 1 of this example, an attachment process, a coil formation process, a removal process, an engagement process, an accommodation process, and a core molding process are performed.

  In the attaching step, as shown in FIGS. 5 and 6, a plurality of heat radiating members 6 provided with a contact portion 61 having a contact surface 611 that contacts the inner peripheral surface 201 of the coil 2 are replaced with a columnar coil winding jig 7. The contact portion 61 of the heat radiating member 6 is exposed to the outer peripheral surface 702 of the coil winding jig 7, and the contact surface 611 of the contact portion 61 of the heat radiating member 6 is exposed to the outer peripheral surface 702 of the coil winding jig 7. More outward.

In the coil forming step, as shown in FIG. 7, the conductor wire 21 is wound on the contact surface 611 of the contact portion 61 of the plurality of heat radiating members 6 to form the coil 2 on the outer periphery of the coil winding jig 7. .
Moreover, in a removal process, as shown in FIG. 8, it removes from the coil winding jig | tool 7 in the state which assembled | attached the coil 2 and the heat radiating member 6 mutually.

Further, in the engaging step, as shown in FIGS. 9 and 10, the heat radiating member 6 is engaged with the engaging portion 51 provided on the core member 5 in a state where the coil 2 and the heat radiating member 6 are assembled to each other.
In the housing step, as shown in FIG. 11, the coil 2, the heat radiating member 6, and the core member 5 are housed in the case (molding die) 4 in a state where they are assembled together.
In the core molding step, the core 3 is molded by filling the case (molding die) 4 with the magnetic powder mixed resin and curing the resin.
This will be described in detail below.

  First, as shown in FIG. 5, a coil winding jig 7 is prepared. The cylindrical coil winding jig 7 is provided with four attachment portions 71 for attaching the plate-like heat radiating member 6. The attachment portion 71 is formed in a concave groove shape on the outer peripheral surface 702 of the coil winding jig 7. The mounting portion 71 is formed from the upper end surface 703 of the coil winding jig 7 to the middle of the coil winding jig 7 in the axial direction.

Next, as shown in the figure, the four heat dissipating members 6 are attached to the coil winding jig 7. Specifically, each heat radiating member 6 is inserted into the attachment portion 71 of the coil winding jig 7 from above.
As shown in FIG. 6, the contact portion 61 of the heat radiating member 6 is exposed to the outer peripheral surface 702 of the coil winding jig 7, and the contact surface 611 of the contact portion 61 of the heat radiating member 6 is exposed to the coil winding jig. 7 is located outward from the outer peripheral surface 702.

Next, as shown in FIG. 7, the conductor wire 21 is spirally wound on the contact surfaces 611 of the contact portions 61 of the four heat radiating members 6 on the outer periphery of the coil winding jig 7. Thereby, the cylindrical coil 2 is formed.
Next, as shown in FIG. 8, both are removed from the coil winding jig 7 in a state where the coil 2 is assembled to the heat radiating member 6.

Next, as shown in FIGS. 9 and 10, the four heat radiating members 6 are engaged with the four engaging portions 51 provided on the core member 5 in a state where the coil 2 is assembled to the heat radiating member 6. .
Next, as shown in FIG. 11, the coil 2, the heat radiating member 6 and the core member 5 are housed in the case 4 in a state where they are assembled together. Then, the core member 5 is fixed to the bottom surface portion 41 of the case 4 with a bolt or the like. Thereafter, the case 4 is filled with a magnetic powder mixed resin and cured to mold the core 3.
Thereby, the reactor 1 (FIG. 1, FIG. 2) of this example is obtained.

Next, the effect in the reactor 1 of this example and its manufacturing method is demonstrated.
In the reactor 1 of this example, a heat radiating member 6 is interposed between the coil 2 and the core member 5 so as to be in contact with both. Further, the heat radiating member 6 has a higher thermal conductivity than the core 3. Therefore, heat generated in the coil 2 can be transmitted to the core member 5 via the heat radiating member 6 to be radiated. Thereby, compared with the case where the heat radiating member 6 is not provided, the heat radiating property from the coil 2 to the core member 5, that is, the heat radiating property in the inner direction of the coil 2 can be enhanced. As a result, the temperature rise of the reactor 1 can be effectively suppressed.

  Further, as described above, since the heat conductivity of the heat radiating member 6 is higher than that of the core 3, the heat generated in the coil 2 is transmitted to the core member 5 via the heat radiating member 6 instead of the core 3 to dissipate heat. can do. Therefore, it is not necessary to consider the material of the core 3 from the viewpoint of heat dissipation, and the material of the core 3 can be selected from the viewpoint of magnetic characteristics. Thereby, the reactor 1 with high inductance can be obtained easily, ensuring heat dissipation by the heat radiating member 6.

  In the manufacturing method of the reactor 1, in the attaching step, the contact portion 61 of the heat radiating member 6 is exposed to the outer peripheral surface 702 of the coil winding jig 7 and the contact surface 611 of the contact portion 61 is exposed to the coil winding treatment. A plurality of heat dissipating members 6 are attached to the coil winding jig 7 in a state of being positioned outward from the outer peripheral surface 702 of the tool 7. In the coil forming step, the conductor wire 21 is wound on the contact surface 611 of the contact portion 61 of the plurality of heat radiating members 6 on the outer periphery of the coil winding jig 7 to form the coil 2. That is, the coil 2 is formed by winding the conductor wire 21 around the heat radiating member 6. Therefore, the adhesion between the coil 2 and the heat dissipation member 6 can be enhanced. Thereby, the heat transfer from the coil 2 to the heat radiating member 6 can be enhanced.

  Moreover, in a removal process, it removes from the coil winding jig | tool 7 in the state which assembled | attached the coil 2 and the heat radiating member 6 mutually. Here, the coil 2 is not formed by winding the conductor wire 21 around the coil winding jig 7 but is formed by winding it around the heat radiating member 6. Therefore, the coil 2 can be removed from the coil winding jig 7 without contacting the coil winding jig 7. Thereby, damage to the coil 2 can be prevented.

  In the engaging step, the heat radiating member 6 is engaged with the engaging portion 51 of the core member 5, and in the housing step, the coil 2, the heat radiating member 6, and the core member 5 are assembled in the case 4. In the core molding step, the case 4 is filled with a magnetic powder mixed resin and cured to mold the core 3. Therefore, the reactor 1 of this example in which the heat radiating member 6 is interposed between the coil 2 and the core member 5 can be easily manufactured.

  In this example, the core member 5 is fixed to the bottom surface portion 41 of the case 4 with a bolt or the like. Therefore, the heat generated in the coil 2 can be transmitted to the core member 5 via the heat radiating member 6 and further transmitted to the case 4 to be radiated. Thereby, heat dissipation can further be improved. Further, heat generated in the coil 2 can be transmitted to the bottom surface portion 41 and the side surface portion 42 of the case 4 via the core 3 to be radiated. Therefore, it is possible to sufficiently ensure heat dissipation not only in the inner direction of the coil 2 but also in the outer direction. The core member 5 may be formed integrally with the case 4, and in this case, heat can be smoothly transferred from the core member 5 to the case 4.

  A plurality of plate-like heat radiating members 6 are interposed between the coil 2 and the core member 5, and both the main surfaces 601 of the heat radiating member 6 are substantially orthogonal to the circumferential direction of the coil 2. Are arranged to be. Therefore, the area where the magnetic flux generated around the coil 2 crosses the heat radiating member 6 can be made as small as possible. Thereby, the flow of magnetic flux is hardly hindered by the heat radiating member 6, and a decrease in inductance can be prevented.

  The plurality of heat radiating members 6 are connected to each other by an annular connecting portion 63 provided along the inner peripheral surface 201 of the coil 2. Therefore, since the plurality of heat radiating members 6 are connected and integrated by the connecting portion 63, the heat radiating member 6 can be easily handled. In the attachment step and the removal step, the plurality of heat radiating members 6 can be easily attached to the coil winding jig 7 and can be easily removed from the coil winding jig 7.

  Further, the heat radiating member 6 is provided with a contact portion 61 having a contact surface 611 that contacts the inner peripheral surface 201 of the coil 2. Therefore, the heat radiating member 6 can be sufficiently and reliably brought into contact with the coil 2 by the contact portion 61. Moreover, the contact area of the coil 2 and the heat radiating member 6 can be ensured by the contact surface 611 of the contact part 61, and the heat transfer from the coil 2 to the heat radiating member 6 can be improved.

  The heat radiating member 6 is provided with a coil support portion 62 that protrudes outward from the contact surface 611 of the contact portion 61 and supports one end surface (lower end surface 204) of the coil 2 in the axial direction X. Yes. Therefore, the coil support part 62 can easily position the coil 2 with respect to the heat dissipation member 6. In the coil forming step, the conductor wire 21 can be wound around the heat radiating member 6 with high accuracy.

  Further, the core member 5 is provided with an engaging portion 51 for engaging the heat radiating member 6. Therefore, the heat radiating member 6 can be brought into sufficient and reliable contact with the core member 5 by the engaging portion 51. Further, heat transfer from the heat radiating member 6 to the core member 5 can be enhanced.

  Thus, according to this example, the reactor 1 which can improve heat dissipation and its manufacturing method can be provided.

  In this example, as shown in FIG. 2, the heat dissipating member 6 is in contact with the entire axial direction X on the inner peripheral surface 201 of the coil 2, but for example, as shown in FIG. Only the upper part of the axial direction X in the surface 201 may be in contact, or as shown in FIG. 13, only the lower part of the axial direction X in the inner peripheral surface 201 of the coil 2 may be in contact.

  Moreover, as shown in FIG. 14, you may contact only the intermediate part of the axial direction X (FIG. 2) in the internal peripheral surface 201 of the coil 2. As shown in FIG. At this time, the heat radiation member 6 is provided with a locking portion 64 that protrudes outward from the contact surface 611 of the contact portion 61 and that is locked between the conductor wires 21 constituting the coil 2. Thereby, the heat radiating member 6 can be sufficiently and reliably fixed to the coil 2 by the locking portion 64.

  Moreover, in this example, as shown in FIG. 4, the connection part 63 is provided in the intermediate position of the axial direction X (FIG. 2) in the heat radiating member 6, For example, as shown in FIG. It may be provided at the upper end portion in the axial direction X, or may be provided at the lower end portion in the axial direction X of the heat radiating member 6 as shown in FIG. Moreover, as shown in FIG. 17, you may provide in both the upper end part of the axial direction X in the heat radiating member 6, and a lower end part.

1 Reactor 2 Coil 21 Conductor Wire 3 Core 5 Center Core Member 6 Heat Dissipation Member X Axial Direction

Claims (11)

A cylindrical coil formed by winding a conductor wire and generating a magnetic flux when energized, a core made of a magnetic powder mixed resin obtained by mixing magnetic powder in an insulating resin and having the coil embedded therein, and an inner circumference of the coil A reactor having a columnar core member arranged on the side in the axial direction of the coil,
A reactor in which a heat dissipating member having a higher thermal conductivity than that of the core is interposed between the coil and the core member.   2. The reactor according to claim 1, wherein a plurality of the plate-like heat radiating members are interposed between the coil and the core member, and both main surfaces of the heat radiating member are arranged around the coil. A reactor characterized by being arranged so as to be substantially orthogonal to a direction.   The reactor according to claim 2, wherein the plurality of heat dissipating members are connected to each other by an annular connecting portion provided along an inner peripheral surface of the coil.   The reactor of any one of Claims 1-3 WHEREIN: The said thermal radiation member is provided with the contact part which has a contact surface which contacts the internal peripheral surface of the said coil, The reactor characterized by the above-mentioned.   5. The reactor according to claim 4, wherein the heat dissipation member is provided with a coil support portion that protrudes outward from the contact surface of the contact portion and supports at least one end surface of the coil in the axial direction. Reactor characterized by being.   6. The reactor according to claim 4, wherein the heat radiating member protrudes outward from the contact surface of the contact portion and is latched between the conductor wires constituting the coil. A reactor characterized in that a stop is provided.   The reactor of any one of Claims 1-6 WHEREIN: The engaging part which engages with the said heat radiating member is provided in the said core member, The reactor characterized by the above-mentioned. A cylindrical coil formed by winding a conductor wire and generating a magnetic flux when energized, a core made of a magnetic powder mixed resin obtained by mixing magnetic powder in an insulating resin and having the coil embedded therein, and an inner circumference of the coil And a columnar core member disposed in the axial direction of the coil on the side, and the coil and the core member are in contact with each other and have higher thermal conductivity than the core. A method of manufacturing a reactor having a heat dissipating member,
A plurality of the heat dissipation members provided with contact portions having contact surfaces that contact the inner peripheral surface of the coil are attached to a columnar coil winding jig, and the contact portions of the heat dissipation member are attached to the coil winding jig. An attachment step of exposing the outer peripheral surface of the tool and positioning the contact surface of the contact portion of the heat radiating member outside the outer peripheral surface of the coil winding jig;
In the outer periphery of the coil winding jig, the conductor wire is wound on the contact surface of the contact portion of the plurality of heat dissipating members to form the coil,
A removal step of removing the coil and the heat dissipating member from the coil winding jig in a state where the coil and the heat dissipating member are assembled to each other,
An engaging step of engaging the heat dissipating member with an engaging portion provided on the core member in a state where the coil and the heat dissipating member are assembled to each other;
An accommodating step of accommodating the coil, the heat dissipation member, and the core member in a mold in a state of being assembled with each other;
A core manufacturing step of filling the magnetic powder mixed resin into the molding die and curing it, and molding the core.   9. The method for manufacturing a reactor according to claim 8, wherein the plurality of heat dissipating members are connected to each other by an annular connecting portion provided along an inner peripheral surface of the coil. .   10. The method of manufacturing a reactor according to claim 8, wherein the heat radiating member protrudes outward from the contact surface of the contact portion and supports at least one end surface of the coil in the axial direction. A method for manufacturing a reactor, wherein a coil support is provided.   In the manufacturing method of the reactor of any one of Claims 8-10, while the said thermal radiation member protrudes outward from the said contact surface of the said contact part, the said conductor wires which comprise the said coil The manufacturing method of the reactor characterized by providing the latching | locking part latched between.

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