JP2012209328A - Reactor structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor structure which is easily manufactured compared to conventional reactor structures.SOLUTION: A case 4 includes a side wall part 41 enclosing around a reactor 10 and a first pressing protrusion 41a and a second pressing protrusion 41b which protrude from the side wall part 41 to the interior of the case 4. The first pressing protrusion 41a contacts with one outer core part 33 and presses the one outer core part 33 in a first vertical direction. The first pressing protrusion 41a is made of a resin material elastically deformed by slide contact with the one outer core part 33. The second pressing protrusion 41b contacts with the other core part 34 and presses the other core part 34 in a second vertical direction. These pressing protrusions 41a and 41b sandwich the magnetic core 3 from the vertical direction and thereby positioning the reactor 10 relative to the case 4.

Description

  The present invention relates to a reactor structure used for a component part of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor structure that is small and excellent in heat dissipation.

  A reactor structure is one of the components of a circuit that performs voltage step-up and step-down operations. For example, Patent Document 1 discloses a reactor structure used in a converter mounted on a vehicle such as a hybrid vehicle. This reactor structure has a configuration in which a reactor formed by combining a coil member having a pair of coils connected in parallel and an annular magnetic core fitted in the pair of coils is housed in a case and sealed with resin. Is provided. A reactor structure having such a configuration is usually used with a terminal fitting connected to the coil end.

  Furthermore, in the reactor structure of this patent document 1, it is comprised so that the position of the reactor with respect to a case can be determined by providing the recessed part with which a part of reactor is engaged in the bottom face of a case. By making the position of the reactor relative to the case appropriate, the connection work between the coil and the terminal fitting can be facilitated, the gap between the case and the reactor can be made uniform, and the thickness of the resin filling the gap Unevenness is less likely to occur.

JP 2010-21448 A

  By the way, the annular magnetic core provided in the reactor structure includes a pair of inner core portions disposed inside each coil, one outer core portion connecting one ends of both inner core portions, and both inner core portions. It is configured by connecting the other outer core portion connecting the other ends. These core parts are usually joined in an annular shape with an adhesive or an adhesive tape. However, there is a problem that the joining operation of the core portion using these adhesives and adhesive tapes is complicated.

  First, when an adhesive is used, it is necessary to keep the inner core portion and the outer core portion in a predetermined state until the adhesive is cured. This is because the magnetic properties of the magnetic core change depending on the distance between the inner core portion and the outer core portion via the adhesive, so that the inner core portion has the desired magnetic properties until the adhesive is cured. This is because it is necessary to hold the outer core portion. On the other hand, when an adhesive tape is used, considerable care is required to join the inner core portion and the outer core portion with high accuracy. In any case, since a considerable amount of labor is required for the joining operation of the core portion, it is desired to reduce the labor and improve the manufacturability of the reactor structure.

  This invention is made | formed in view of the said situation, and one of the objectives of this invention is to provide the reactor structure which can be manufactured more easily than before.

The reactor structure of the present invention includes a coil member having a pair of coils connected in parallel, an annular magnetic core, a case that houses a reactor that is a combination of the coil member and the magnetic core, and a reactor and a case. A sealing resin filled in the gap is provided. The magnetic core includes a pair of inner core portions arranged inside each coil, one outer core portion connecting one ends of both inner core portions, and the other outer core portion connecting the other ends of both inner core portions. And formed. The case of the reactor structure according to the present invention includes a side wall that surrounds the periphery of the reactor, and a first pressing protrusion and a second pressing protrusion that protrude from the side wall into the case. The first pressing protrusion is a member that abuts one outer core portion and presses the one outer core portion in the first vertical direction, and the second pressing protrusion protrudes into the case from the side wall portion, and the other A member that abuts the outer core portion and presses the other outer core portion in the second longitudinal direction. At least the first pressing projection of the two pressing projections is made of a resin material that has a lower elastic modulus than the one outer core portion and elastically deforms by sliding contact with the one outer core portion. .
Here, the vertical direction is a direction along the axial direction of the coil. Among the vertical directions, the direction from one outer core portion to the other outer core portion is defined as a first vertical direction and a first vertical direction. The direction opposite to is the second vertical direction.

  According to the configuration of the reactor structure of the present invention, the first pressing projection out of the two pressing projections is made of a resin material that is elastically deformed by sliding contact with one outer core portion. When arranging, the magnetic core can be tightened from the vertical direction (direction along the coil axis direction) by two pressing protrusions. As a result, since the plurality of core portions constituting the magnetic core can be connected without an adhesive, the reactor structure according to the present invention can be manufactured in a shorter time than in the prior art.

  Moreover, the two pressing protrusions provided in the reactor structure of the present invention also have a function of determining the position of the reactor in the case. The magnetic core is tightened from the vertical direction by the two pressing protrusions, so that the position of the magnetic core in the vertical direction (direction along the coil axis direction) in the case is determined, and the horizontal direction of the magnetic core (parallel of the pair of coils) This is because the position of the (direction) is almost determined. Since the reactor is a member in which a pair of coils and a magnetic core are integrated, if the position of the magnetic core in the case is determined, the position of the reactor in the case is also determined. As described above, the two pressing protrusions can reduce the time and labor for positioning the reactor in the case. Also from this point, the reactor structure of the present invention can be manufactured more easily and in a shorter time than the conventional structure.

  As one form of this invention reactor structure, one outer core part is good also as a structure which has a 1st engagement recessed part with which a 1st press protrusion engages.

  Even in the configuration without the first engaging recess, it is possible to suppress the deviation of the reactor in the lateral direction (parallel direction of the pair of coils), but the prevention of the deviation of the reactor in the lateral direction is prevented. Depends on the friction between the outer core portion and the pressing protrusion. Therefore, by forming the first engaging recess that mechanically engages with the first pressing protrusion, the lateral position of the reactor in the case can be accurately determined, and the lateral displacement of the reactor (coil axial direction and It is also possible to effectively prevent the deviation in the intersecting direction.

  As one form of the reactor structure of the present invention, the second pressing protrusion is also made of a resin material having a lower elastic modulus than the other outer core part and elastically deforming by sliding contact with the other outer core part. preferable.

  According to the above configuration, when the reactor is arranged in the case, not only the first pressing protrusion but also the second pressing protrusion is elastically deformed, so that the possibility of damaging the other outer core portion by the second pressing protrusion can be reduced. .

  As one form of this invention reactor structure, the other outer core part is good also as a structure which has a 2nd engagement recessed part with which a 2nd press protrusion engages.

  Similarly to the first engaging recess corresponding to the first pressing protrusion, the second engaging recess corresponding to the second pressing protrusion is formed, whereby the lateral displacement of the reactor in the case can be more effectively prevented. .

  As a form of the reactor structure of the present invention, a case provided in the reactor structure projects from the side wall portion into the case, and sandwiches at least one of the pair of outer core portions from the lateral direction to determine the position of the reactor with respect to the case. It is preferable to provide a positioning protrusion. More preferably, two core positioning protrusions are provided in total, one pair for determining the position of one outer core part and one pair for determining the position of the other outer core part.

  By forming the core positioning protrusion, the lateral position of the reactor with respect to the case can be accurately determined, and the lateral displacement of the reactor can be effectively prevented. The core positioning protrusion may be made of a resin material that is elastically deformed by sliding contact with the outer core portion.

  As one form of this invention reactor structure, the reactor with which a reactor structure is equipped can be set as the structure provided with a pair of frame-shaped bobbin interposed between the end surface of a coil, and an outer core part. In this case, the case preferably includes a bobbin positioning protrusion that protrudes from the side wall portion into the case, sandwiches at least one of the pair of bobbins from the lateral direction, and determines the position of the reactor with respect to the case. More preferably, two bobbin positioning protrusions are provided in total, one pair for determining the position of one frame-shaped bobbin and one pair for determining the position of the other frame-shaped bobbin.

  By forming the bobbin positioning protrusion, the lateral position of the reactor with respect to the case can be accurately determined, and the lateral displacement of the reactor can be effectively prevented. The bobbin positioning protrusion may be made of a resin material that is elastically deformed by sliding contact with the outer core portion.

  As one form of the reactor structure of the present invention, a case provided in the reactor structure is formed on a bottom plate portion which is a member different from the side wall portion, and on an inner surface side of the bottom plate portion, and is interposed between the bottom plate portion and the coil. And a heat dissipation layer. In that case, it is preferable that the side wall portion is formed of the same resin material as the resin material constituting the first pressing member, and the heat dissipation layer has a higher thermal conductivity than the side wall portion.

  When the side wall portion is made of a resin material, the side wall portion and the first pressing protrusion (and the second pressing protrusion) can be integrally formed. Here, the case not only protects the reactor but also plays a role of radiating the heat generated by the reactor to the outside, and therefore, if it is made of a resin material, there is a possibility that the heat dissipation performance is lowered. On the other hand, if the side wall portion and the bottom plate portion are separate members and the heat dissipation of the bottom plate portion is increased, the heat dissipation of the entire case can be reduced even if the side wall portion is made of a low thermal conductive resin material. Can be secured.

  According to the configuration of the reactor structure of the present invention, a reactor structure that can be easily and quickly manufactured can be obtained.

FIG. 3 is an exploded perspective view illustrating an outline of the reactor structure according to the first embodiment. It is a disassembled perspective view which shows the outline of the reactor with which the reactor structure of Embodiment 1 is equipped. 3 is a top view of the reactor structure according to Embodiment 1. FIG. It is a top view of the reactor structure of Embodiment 2.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The same reference numerals in the figure indicate the same names.

<Embodiment 1>
≪Overall structure≫
As shown in FIGS. 1 and 3, the reactor structure 1 includes a reactor 10 that is an assembly of a coil member 2 and a magnetic core 3, and a case 4 that houses the reactor 10. The case 4 is a box that is open on one side, and the reactor 10 disposed in the case 4 is embedded in a sealing resin (not shown) except for the end of the winding 2 w that forms the coil member 2. The The most characteristic feature of the reactor structure 1 is that the reactor 10 in the case 4 is sandwiched between a first pressing protrusion 41 a and a second pressing protrusion 41 b provided on the side wall 41 of the case 10. . Here, in order to give the pressing protrusions 41 a and 41 b the role of sandwiching the reactor 10, it is important at which position of the case 4 the pressing protrusions 41 a and 41 b are provided. Therefore, in the following description of each constituent member, “direction definition” that serves as a reference for positions where the pressing protrusions 41 a and 41 b are provided when the description of the reactor 10 is completed.

≪Reactor≫
[Coil member]
The coil member 2 will be described with reference to FIGS. The coil member 2 includes a pair of coils 2a and 2b and a coil connecting portion 2r that connects both the coils 2a and 2b. The coils 2a and 2b are formed in a hollow rectangular tube shape with the same number of turns and the same winding direction, and are arranged side by side so that the axial directions are parallel to each other. The connecting portion 2r is a portion bent in a U shape that connects the coils 2a and 2b on the other end side of the coil member 2 (the back side in FIG. 1).

  The coil member 2 in this embodiment is composed of a single winding 2w provided with an insulating coating (typically polyimide amide) on the outer periphery of a flat conductor such as copper or aluminum, and the portions of the coils 2a and 2b are windings. It is formed in a rectangular tube shape by winding 2w spirally edgewise. Of course, the cross section of the winding 2w is not limited to a rectangular shape, and may be a circular shape, an elliptical shape, a polygonal shape, or the like, and the winding shape may be an elliptical cylindrical shape. In addition, the coil members may be manufactured by manufacturing the coils 2a and 2b with separate windings and joining the ends of the windings forming the coils 2a and 2b by welding or the like.

  Both end portions of the winding 2 w forming the coil member 2 are appropriately extended from the turn forming portion on one end side (the front side in FIG. 1) of the coil member 2 and pulled out of the case 4. The insulating coating is peeled off at both ends of the drawn winding 2w, and conductive terminal fittings are connected to the conductor portions exposed from the insulating coating. An external device (not shown) such as a power source for supplying power is connected to the coil member 2 through the terminal fitting.

[Magnetic core]
The magnetic core 3 will be described with reference to FIG. The magnetic core 3 has a pair of inner core portions 31 and 32 disposed inside the coils 2 a and 2 b and a pair of outer core portions 33 and 34 exposed from the coil member 2. Each inner core part 31 and 32 is a rectangular parallelepiped shape, and each outer core part 33 and 34 is a columnar body which has a dome-shaped surface. One end (the left side of the drawing) of the inner core portions 31 and 32 that are spaced apart is connected via one outer core portion 33, and the other end (the right side of the drawing) of the core portions 31 and 32 is the other outside. It is connected via the core part 34. As a result, the annular magnetic core 3 is formed by the inner core portions 31 and 32 and the outer core portions 33 and 34.

  The inner core portions 31 and 32 are laminated bodies configured by alternately laminating core pieces 31m made of a magnetic material and gap materials 31g made of a nonmagnetic material such as alumina, glass epoxy resin, and unsaturated polyester, The outer core portions 33 and 34 are core pieces made of a magnetic material. 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 sheets) having an insulating coating are laminated can be used. The core pieces constituting the inner core portions 31 and 32 and the outer core portions 33 and 34 may have different magnetic characteristics by using different magnetic materials.

  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.

[Bobbin]
The reactor 10 according to the present embodiment includes a bobbin 5 for enhancing insulation between the coil member 2 and the magnetic core 3. As the bobbin constituent material, an insulating material such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, or liquid crystal polymer (LCP) can be used. The bobbin 5 is a pair of frame-shaped bobbins that are in contact with the inner bobbin 51 (52) disposed on the outer periphery of the inner core portion 31 (32) and the end surface of the coil member 2 (the surface where the coil turns appear to be annular). And 53, 54.

  The inner bobbin 51 includes a pair of bobbin pieces 51a and 51b made of an insulating material having a cross section] (the inner bobbin 52 has the same configuration). The bobbin piece 51a (51b) is configured to cover the entire upper surface (the entire lower surface) of the inner core portion 31, and part of the left and right surfaces. Therefore, both the bobbin pieces 51a and 51b attached to the inner core portion 31 are not in contact with each other. By setting it as such a structure, the material of the inner side bobbin 51 (52) can be reduced, and the contact area of the inner core part 31 (32) and sealing resin can be enlarged. The inner bobbin 51 may be a cylindrical body that is disposed along the entire circumference of the outer peripheral surface of the inner core portion 31 when attached to the inner core portion 31.

  The frame bobbins 53 and 54 are flat and have a pair of openings through which the respective inner core portions 31 and 32 are inserted, so that the inner core portions 31 and 32 can be easily introduced. A short cylindrical portion projecting on the side of 31 and 32 is provided. Further, the frame-shaped bobbin 54 is provided with a flange portion 54f on which the coil connecting portion 2r is placed and insulates between the coil connecting portion 2r and the outer core portion 32.

≪Definition of direction≫
Based on the configuration of the reactor 10 described above, in the state where the reactor 10 is disposed in the case 4, the direction along the axial direction of the coils 2a and 2b is defined as the vertical direction, and the parallel direction of the coils 2a and 2b is defined as the horizontal direction. Further, in the vertical direction, the direction from the one outer core portion 33 toward the other outer core portion 34 (the lower direction in FIG. 3 and FIG. 4 of Embodiment 2 described later) is the first vertical direction and vice versa. The direction (upward direction in FIG. 3 and FIG. 4 of Embodiment 2 described later) is the second vertical direction.

≪Case≫
Case 4 will be described with reference to FIGS. The case 4 in which the reactor 10 is housed includes a flat bottom plate portion 40 and a frame-like side wall portion 41 standing on the bottom plate portion 40, so that the bottom plate portion 40 and the side wall portion 41 can be removed. Yes.

[Bottom plate and side wall]
(Bottom plate)
The bottom plate portion 40 is a rectangular plate, and is fixed to the fixing target when the reactor structure 1 is installed on the fixing target. 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 bottom plate portion 40 has flange portions 400 protruding from the four corners, and bolt portions (not shown) for fixing the case 4 to the fixing object are inserted into the flange portions 400, respectively. 400h is provided. The bolt hole 400h is provided so as to be continuous with a bolt hole 411h of the side wall 41 described later. As the bolt holes 400h and 411h, any of through holes that are not threaded and screw holes that are threaded can be used, and the number and the like can be appropriately selected.

≪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 member 2 and the core installation surface of the outer core portions 33 and 34 come into contact with each other. The heat dissipation layer 42 is made of an insulating material having a thermal conductivity of more than 2 W / m · K. The higher the thermal conductivity of the heat dissipation layer 42, the better. Specific examples of the constituent material of the heat dissipation layer 42 include non-metallic inorganic materials such as ceramics such as a metal element or a kind of material selected from oxides, carbides, and nitrides of Si. For example, silicon nitride (Si ₃ N ₄ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), silicon carbide (SiC), and the like can be given.

(Sidewall)
The side wall portion 41 is a substantially rectangular frame-like body, and when the case 4 is assembled by closing one opening portion with the bottom plate portion 40, the side wall portion 41 is disposed so as to surround the reactor 10, and the other opening portion is opened. Is done. Here, as for the side wall part 41, the area | region used as the installation side when the reactor structure 1 is installed in fixation object is a rectangular shape along the external shape of the said baseplate part 40, and the area | region of the open opening side is the reactor 10. It is a curved surface shape along the outer peripheral surface. In a state where the case 4 is assembled, the outer peripheral surface of the reactor 10 and the inner peripheral surface of the side wall portion 41 are held at predetermined intervals by pressing projections 41a and 41b and positioning projections 41c to 41f described below.

  A pair of pressing protrusions 41a and 41b, two pairs of core positioning protrusions 41c and 41d, and two pairs of bobbin positioning protrusions 41e and 41f are provided on the inner peripheral surface of the side wall 41. (Indicated by hatching in FIG. 3 and FIG. 4 of the second embodiment described later). These protrusions 41 a to 41 f are integrally formed on the side wall 41 with the same material as the side wall 41. Note that the protrusions 41 a to 41 f formed of a material different from that of the side wall portion 41 may be attached to the side wall portion 41.

(Pressing protrusion)
As shown in FIG. 3, the pressing protrusion (first pressing protrusion) 41a and the pressing protrusion (second pressing protrusion) 41b sandwich the reactor 10 from the vertical direction (the direction along the axial direction of the coils 2a and 2b). Is arranged. The space between the pressing protrusion 41 a and the pressing protrusion 41 b is shorter than the length of the reactor 10 in the vertical direction before the reactor 10 is housed in the case 4. Here, the pressing protrusions 41a and 41b have a lower elastic modulus than the outer core portions 33 and 34, and are elastically deformed by sliding contact with the outer core portion 33 (34) when the reactor 10 is disposed in the case 4. To do. As a result, the pressing protrusion 41a presses the outer core portion 33 in the first vertical direction, and the pressing protrusion 41b presses the outer core portion 34 in the second vertical direction, whereby the reactor 10 is tightened in the vertical direction, and the case 4 The position of the reactor 10 in the vertical direction is determined.

  The shape of the pressing protrusions 41a and 41b in the present embodiment is such that two protrusions are formed on a flat plate. The protrusions extend in the depth direction of the case 4 and are easily elastically deformed by sliding contact with the outer core portions 33 and 34. Moreover, the protrusion illustrated in the present embodiment has a configuration that is gradually inclined so that the amount of protrusion from the side wall portion 41 becomes smaller from the upper side of the case 4 toward the lower side. This is because, as will be described later, in assembling the reactor structure 1 of the present embodiment, the side wall 41 of the case 4 is covered from the upper side of the reactor 10, so that the side wall 41 is easily covered on the reactor 10. Here, if it is the structure which fits the reactor 10 with respect to the case 4 from upper direction, the structure where the protrusion inclined gradually so that the protrusion amount from the side wall part 41 may become small as it goes upwards from the downward direction of the case 4 And good.

  The pressing protrusions 41a and 41b only need to be made of a material that is elastically deformed at least one, and the shape of the pressing protrusions 41a and 41b is not particularly limited. For example, as shown in Embodiment 2 to be described later, the pressing protrusions 41a and 41b may be formed in a trapezoidal shape. Further, the shapes of the pressing protrusions 41a and 41b are not necessarily the same. For example, the pressing protrusion 41a may have the shape shown in FIG. 3, and the remaining pressing protrusion 41b may have a flat plate shape.

(Core positioning protrusion)
The core positioning protrusions 41c and 41d sandwich the outer core portion 33 (34) from the lateral direction, and determine the lateral position of the outer core portion 33 (34) in the case 4, that is, the lateral position of the reactor 10. It is. The core positioning protrusions 41 c and 41 d of the present embodiment are configured to protrude in the lateral direction from the inner peripheral surface of the side wall portion 41. However, the core positioning protrusions 41c and 41d only need to be able to prevent the lateral displacement of the outer core portion 33 (34). For example, the core positioning protrusions 41c and 41d protrude in an oblique direction intersecting both the horizontal direction and the vertical direction. Then, the outer core portion 33 (34) may be abutted. In that case, the core positioning protrusions 41c and 41d abut on the curved surface portion of the outer core portion 33 (34).

  The core positioning protrusions 41c and 41d of the present embodiment are made of the same elastically deformable resin material as the side wall 41 including the pressing protrusions 41a and 41b, but are not limited thereto. For example, it may be a metal material or a resin material that is difficult to elastically deform.

(Bobbin positioning protrusion)
The bobbin positioning protrusions 41e and 41f are members that sandwich the frame bobbin 53 (54) from the lateral direction and determine the lateral position of the frame bobbin 53 (54) in the case 4, that is, the lateral position of the reactor 10. is there. The bobbin positioning protrusions 41e and 41f protrude laterally from the inner peripheral surface of the side wall portion 41, and abut against the left and right end surfaces of the frame-shaped bobbin 53 (54), respectively.

  The core positioning protrusions 41c and 41d of the present embodiment are made of the same elastically deformable resin material as the side wall 41 including the pressing protrusions 41a and 41b, but are not limited thereto. For example, it may be a metal material or a resin material that is difficult to elastically deform.

(Installation point)
As in the case of the bottom plate portion 40, the installation side region of the side wall portion 41 is formed with attachment locations including flange portions 411 protruding from the four corners, and each flange portion 411 is provided with a bolt hole 411h. The bolt hole 411h may be formed only from the constituent material of the side wall 41. In addition, a metal cylinder may be insert-molded at the position of the flange portion 411, and the metal cylinder may be used as the bolt hole 411h. In that case, creep deformation of the flange portion 411 can be suppressed.

  As a method for connecting the bottom plate portion 40 and the side wall portion 41 other than the bolt, an appropriate adhesive may be used. When an adhesive is used, a convex portion is formed on one of the bottom plate portion 40 and the side wall portion 41, and a concave portion that fits the convex portion is formed on the other side, and the position of the side wall portion 41 with respect to the bottom plate portion 40 is determined. Keep it unambiguous. Otherwise, the position of the reactor 10 relative to the case 4 will not be constant even though the position of the reactor 10 relative to the side wall 41 is determined by the pressing protrusions 41a and 41b.

(Material)
The resin material of the side wall portion 41 integrally including the protrusions 41a to 41f is formed of a resin material that is elastically deformed when being in sliding contact with the outer core portions 33 and 34. The standard of the elastically deformable material is a material having a Young's modulus lower than that of the outer core portions 33 and 34. For example, a resin material having a Young's modulus at 25 ° C. of 10 GPa or less is suitable. Examples of such a material include polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like. Since many of these resin materials are excellent in electrical insulation, the insulation between the reactor 10 and the case 4 can be enhanced. Moreover, when it is set as the form which mixed the filler (refer the filler of the sealing resin mentioned later) which consists of ceramics in this resin material, heat dissipation can be improved. When forming case 4 with resin, injection molding can be used suitably.

  Here, when the material of the side wall part 41 is comprised with a material different from each protrusion 41a-41f, it is preferable to comprise the side wall part 41 with a metal material. Since metal materials generally have high thermal conductivity, a case with excellent heat dissipation can be obtained. Specific examples include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron, and austenitic stainless steel. In particular, aluminum and its alloys are suitable because they are lightweight and excellent in corrosion resistance. 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.

[Sealing resin]
The case 4 is filled with a sealing resin made of an insulating resin. At that time, the end of the winding 2 w is pulled out 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. This sealing resin contains a filler excellent in 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. It is preferable to improve the heat dissipation of the sealing resin.

  When the case 4 is filled with the sealing resin, the packing 6 is preferably disposed in order to prevent the 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 engaged with the outer periphery of the reactor 10 of the coil member 2 and the magnetic core 3 and is made of synthetic rubber. Material can be used.

  The reactor structure 1 demonstrated above can be used for power converters, such as an electric vehicle and a hybrid vehicle. The energization conditions of the reactor structure for such use are 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.

≪Manufacture of reactor structure≫
The reactor structure 1 provided with the said structure can be manufactured as follows.

  First, the reactor 10 is formed by combining the coil member 2 and the magnetic core 3. Specifically, as shown in FIG. 2, the core piece 31m and the gap material 31g are laminated without an adhesive to form the inner core portion 31 (32), and the inner bobbin 51 (52) is disposed on the outer periphery. In the state, the inner core portion 31 (32) is inserted into each coil 2a (2b). And while arrange | positioning the outer core part 33 so that the ends of the inner core parts 31 and 32 may be connected via the frame-shaped bobbin 53, the other ends of the inner core parts 31 and 32 are connected via the frame-shaped bobbin 54 The outer core part 34 is arrange | positioned so that may be connected, and the reactor 10 is formed. The end surface of the inner core portion 31 (32) is exposed from the opening of the frame-shaped bobbin 53 (54) and contacts the inner end surface of the outer core portion 33 (34).

  On the other hand, as shown in FIG. 1, an aluminum plate is punched into a predetermined shape to form a bottom plate portion 40, and a heat dissipation layer 42 having a predetermined shape is formed on one surface by screen printing. On the heat radiation layer 42, the reactor 10 assembled as described above is placed. When the heat radiation layer 42 is formed of an adhesive, the reactor 10 can be temporarily fixed to the bottom plate portion 40. A packing 6 is disposed on the outer periphery of the reactor 10.

  On the other hand, a side wall 41 configured in a predetermined shape by injection molding or the like is placed from above the reactor 10 so as to surround the outer periphery of the reactor 10. At this time, the outer core portion 33 (34) of the reactor 10 and the pressing projection 41a (41b) provided on the side wall portion 41 of the case 4 are in sliding contact, and the pressing projections 41a and 41b are elastically deformed. As a result, as shown in FIG. 3, the magnetic core 3 is fastened in the vertical direction by the pressing protrusions 41a and 41b, and the magnetic core 3 is held so as not to be divided into the core pieces. Here, since the core positioning projections 41c and 41d and the bobbin positioning projections 41e and 41f are provided on the side wall 41 of the case 4, the lateral position of the reactor 10 with respect to the case 4 is also held at a predetermined position.

  Next, the bottom plate part 40 and the side wall part 41 are integrated with a bolt (not shown) prepared separately. By this step, the box-shaped case 4 is assembled, and the reactor 10 can be stored in the case 4. At that time, the position of the reactor 10 with respect to the case 4 is fixed at a predetermined position.

  Finally, the case 4 is filled with a sealing resin and cured. At this time, the reactor 10 is disposed at an appropriate position in the case 4 by the pressing protrusions 41a and 41b, the core positioning protrusions 41c and 41d, and the bobbin positioning protrusions 41e and 41f, and the inner peripheral surface of the case 4 and the outer peripheral surface of the reactor 10 Since a uniform gap is formed between them, the sealing resin can be filled between the case 4 and the reactor 10 without a gap.

≪Effect≫
The reactor structure 1 having the above-described configuration can be manufactured easily and in a short time. That is, by arranging the reactor 10 in the case 4, the shape of the magnetic core 3 in the reactor 10 can be held by the pressing protrusions 41 a and 41 b of the case 4, and the reactor 10 is placed at a predetermined position in the case 4. It is because it can arrange. Further, when the reactor 10 is fixed at a predetermined position in the state sandwiched between the pressing protrusions 41a and 41b in the case 4, uneven filling of the sealing resin into the case 4 can be suppressed, and sealing can be performed. The positional deviation of the reactor 10 in the case 4 due to the resin filling pressure can also be prevented. If there is no position shift of the reactor 10 in the case 4 after filling with the sealing resin, it becomes easy to connect the completed reactor structure 1 to another electric device. This is because the terminal fittings attached to the ends of the coils 2a and 2b are in the positions as designed.

  An adhesive or an adhesive tape may be used when combining the core pieces. In that case, the adhesive and the adhesive tape are used only for temporary assembly of the magnetic core 3. This is because the shape of the magnetic core 3 in the reactor structure 1 and the adjustment of the appropriate gap length between the core pieces constituting the magnetic core 3 are performed by the vertical tightening of the magnetic core 3 by the pressing protrusions 41a and 41b. is there. That is, even if an adhesive or an adhesive tape is used, it is not necessary to adjust the gap length between the core pieces strictly by them, and the adjustment work can be omitted. In particular, when an adhesive is used, the reactor structure 1 can be completed without waiting for complete curing of the adhesive.

<Embodiment 2>
Embodiment 2 demonstrates the reactor structure which formed the engagement recessed part fitted to a press protrusion in the outer core part of a magnetic core based on FIG.

  As shown in FIG. 4, in the reactor structure 9 of the present embodiment, the pressing protrusions 41 g and 41 h are protrusions having a substantially trapezoidal cross-sectional shape and extending in the depth direction of the case 4. The outer core portion 33 (34) is formed with an engaging recess 33g (34h) formed of a substantially trapezoidal groove corresponding to the pressing protrusion 41g (41h). The trapezoid of the pressing protrusion 41g (41h) is formed to be slightly wider than the trapezoid of the engaging recess 33g (34h). Therefore, when both of them are in sliding contact, the pressing protrusion 41g (41h) is elastically deformed, and the pressing protrusion 41g (41h) and the engaging recess 33g (34h) are engaged. As a result, the magnetic core 3 is tightened in the vertical direction, and the vertical position of the reactor 10 with respect to the case 4 is determined.

  Here, the engagement between the pressing protrusion 41g (41h) and the engaging recess 33g (34h) also has an effect of suppressing the lateral displacement of the reactor with respect to the case 4 due to its form. Therefore, in the reactor structure 9 of the second embodiment, the core positioning protrusions 41c and 41d provided in the reactor 1 of the first embodiment can be omitted.

  Even with the configuration of the second embodiment described above, the reactor structure 9 can be manufactured by arranging the reactor 10 in the case 4 in which the magnetic core 3 composed of a plurality of core pieces is left in an adhesive-less state. it can. Moreover, the reactor structure 9 which automatically arrange | positioned the reactor 10 with respect to case 4 in the predetermined position only by arrange | positioning the reactor 10 in case 4 is producible.

  The above-described embodiment can be appropriately changed without departing from the gist of the present invention, and is not limited to the above-described configuration.

  The reactor structure of the present invention can be suitably used for a component part of a power conversion device such as a vehicle-mounted converter such as a hybrid vehicle, an electric vehicle, and a fuel cell vehicle.

DESCRIPTION OF SYMBOLS 1,9 Reactor structure 2 Coil member 2a, 2b Coil 2r Coil connection part 2w Winding 3 Magnetic core 31, 32 Inner core part 31m Core piece 31g Gap material 33, 34 Outer core part 33g Engagement recessed part (1st engagement) Recess) 34h Engagement recess (second engagement recess)
4 Case 40 Bottom plate part 400 Flange part 400h Bolt hole 42 Heat radiation layer 41 Side wall part 411 Flange part 411h Bolt hole 41a, 41g Press protrusion (1st press protrusion)
41b, 41h Pressing protrusion (second pressing protrusion)
41c, 41d Core positioning protrusion 41e, 41f Bobbin positioning protrusion 5 Bobbin 51, 52 Inner bobbin 51a, 51b Bobbin piece 53, 54 Frame-shaped bobbin 54f Flange part 6 Packing 10 Reactor

Claims (7)

A coil member having a pair of coils connected in parallel;
Formed by a pair of inner core portions arranged inside each coil, one outer core portion connecting one ends of both inner core portions, and the other outer core portion connecting the other ends of both inner core portions. An annular magnetic core,
A reactor structure comprising: a case that houses a reactor that is a combination of the coil member and the magnetic core; and a sealing resin that fills a gap between the reactor and the case,
Among the longitudinal directions along the axial direction of the coil, when the direction from one outer core portion to the other outer core portion is the first longitudinal direction, and the opposite direction is the second longitudinal direction,
The case is
A side wall surrounding the reactor;
A first pressing protrusion that protrudes from the side wall portion into the case, contacts the one outer core portion, and presses the one outer core portion in the first vertical direction;
A second pressing protrusion that protrudes from the side wall portion into the case, contacts the other outer core portion, and presses the other outer core portion in the second vertical direction;
With
The first pressing protrusion has a lower elastic modulus than the one outer core portion and is made of a resin material that is elastically deformed by sliding contact with the one outer core portion. .   2. The reactor structure according to claim 1, wherein the one outer core portion includes a first engagement recess with which the first pressing protrusion is engaged.   The second pressing protrusion is made of a resin material having a lower elastic modulus than the other outer core portion and elastically deforming by sliding contact with the other outer core portion. 2. The reactor structure according to 2.   4. The reactor structure according to claim 3, wherein the other outer core portion has a second engagement recess with which the second pressing protrusion is engaged. 5. When the parallel direction of the pair of coils is the lateral direction,
The case is
A core positioning protrusion that protrudes from the side wall portion into the case, sandwiches at least one of the pair of outer core portions from the lateral direction, and determines a position of the reactor with respect to the case. The reactor structure as described in any one of 4. When the parallel direction of the pair of coils is the lateral direction,
The reactor is
A pair of frame-shaped bobbins interposed between the end face of the coil and the outer core portion;
The case is
A bobbin positioning protrusion that projects from the side wall into the case, sandwiches at least one of the pair of frame-shaped bobbins from the lateral direction, and determines the position of the reactor with respect to the case. The reactor structure according to any one of 5. The case is
A bottom plate that is a separate member from the side wall;
A heat dissipation layer formed on the inner surface side of the bottom plate portion and interposed between the bottom plate portion and the coil;
With
The side wall portion is formed of the resin material, and
The reactor structure according to any one of claims 1 to 6, wherein the heat dissipation layer has a higher thermal conductivity than the side wall portion.

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