JP2013004931A - Reactor and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that can suppress vibration when being used and noise accompanied by the vibration, and to provide a method for manufacturing the same.SOLUTION: A reactor 1 includes an assembly 10 that is formed by combining a coil member 2 and a magnetic core 3. The magnetic core 3 is formed by combining a plurality of core pieces (outer core sections 33 and 34, and split cores 31m) and gap plates 31g. An adhesive layer 7 comprised of a normal-temperature curable elastic adhesive is formed between the core pieces 31m, 33 and 34, and the gap plates 31g. In the reactor 1 that has the above structure, which can absorb vibration of the core pieces by the adhesive layer 7 having elasticity when the reactor 1 is used, as a result, noise can be suppressed.

Description

  The present invention relates to a reactor used for components of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a hybrid vehicle, and a manufacturing method thereof.

  A reactor is one of the circuit components that perform voltage step-up and voltage step-down operations. For example, Patent Document 1 discloses a reactor used for a converter mounted on a vehicle such as a hybrid vehicle. This reactor includes a combination formed by combining a coil member having a pair of coils connected in parallel and an annular magnetic core that is fitted into these coils so as to penetrate the inside of both coils. There is also a reactor having a configuration in which this combination is housed in a case and sealed with resin.

  The magnetic core constituting the reactor assembly is usually a combination of a plurality of core pieces and a gap plate interposed between the core pieces. In the combination, an epoxy resin adhesive or a urethane resin adhesive is used for bonding the core piece and the gap plate (see, for example, paragraph 0041 of Patent Document 1).

JP 2008-21688 A

  However, the reactor of Patent Document 1 has a problem that the core piece vibrates with use, and noise is generated due to the vibration of the core piece. The core pieces in the AC magnetic field vibrate by repeating expansion and contraction due to magnetostriction, the core pieces themselves generate noise, and the adjacent core pieces and the core pieces and the gap plate come into contact with each other due to the vibration of each core piece. But noise is generated.

  The present invention has been made in view of the above circumstances, and one of the objects of the present invention is to provide a reactor capable of suppressing the vibration of the core piece and reducing the noise caused by the vibration, and a method for manufacturing the same. It is in.

  The inventor paid attention to the method of bonding the core piece and the gap plate in the process of reviewing the configuration of the reactor. And the knowledge that the said objective was able to be achieved was acquired by using a room temperature-curable elastic adhesive for adhesion | attachment with a core piece and a gap board, and it came to complete this invention.

  This invention reactor is a reactor provided with the assembly of the coil member which has a pair of coil connected in the state parallel, and the cyclic | annular magnetic core which penetrates the inside of both coils. The magnetic core provided in the reactor of the present invention is formed by combining a plurality of core pieces and a gap plate interposed between the core pieces. An adhesive layer made of an elastic adhesive is provided.

  In the reactor of the present invention, since the adhesive layer formed by curing the room temperature curable elastic adhesive is arranged between the core piece and the gap plate, the vibration of the core piece itself during use is suppressed. In addition, contact between adjacent core pieces or between the core piece and the gap plate is also suppressed. As a result, the reactor according to the present invention is a reactor with less noise during use than before.

  Further, the reactor of the present invention is a reactor manufactured with higher productivity than before. This is because a normal temperature curable adhesive is used instead of a thermosetting adhesive in the production of the magnetic core provided in the reactor. As an epoxy resin-based or urethane resin-based adhesive used for joining the core piece and the gap plate in the conventional reactor as shown in Patent Document 1, a thermosetting material is used in consideration of heat resistance. It was done. Therefore, in the production process of the reactor, in order to cure the thermosetting adhesive, heating equipment such as a batch furnace is required, and heating time is also required. On the other hand, if the room temperature curable adhesive is used, it is not necessary to perform the curing treatment of the thermosetting adhesive which has been conventionally required, which contributes to the improvement of the productivity of the reactor of the present invention.

  The method for manufacturing a reactor according to the present invention is a method for manufacturing a reactor that includes a combination of a coil member having a pair of coils connected in parallel and an annular magnetic core that penetrates the inside of both coils. It is. In the method of manufacturing a reactor according to the present invention, a plurality of core pieces to be combined with each other and a gap plate interposed between the core pieces are prepared, and the core piece and the gap plate are fixed at room temperature. The magnetic core is manufactured by bonding with an elastic adhesive.

  According to the manufacturing method of the reactor of the present invention, it is possible to manufacture the reactor of the present invention in which the core piece and the gap plate are joined by the adhesive layer having elasticity. In addition, according to the method of manufacturing a reactor of the present invention, since a room temperature curable elastic adhesive is used for bonding the core piece and the gap plate, a curing treatment as when using a thermosetting adhesive is performed. There is no need to do it. Accordingly, the reactor manufacturing process can be simplified and the productivity of the reactor can be improved.

  Hereinafter, the preferable form of this invention reactor is demonstrated in detail.

  As one form of this invention reactor, it is preferable that the Shore hardness of an contact bonding layer is D10-D60.

  The present inventor has found that the vibration of the core piece can be effectively suppressed if the adhesive layer has a Shore hardness in the above range. From the viewpoint of vibration suppression, particularly preferred Shore hardness of the adhesive layer is D10 to D50.

  As one form of this invention reactor, it is preferable that the glass transition point of an contact bonding layer is -40 degreeC-70 degreeC.

  If the glass transition point of the adhesive layer is within the above range, the adhesive layer will not be cured at the use temperature of the reactor. Therefore, the elasticity of the adhesive layer can be maintained while the reactor is used. As a result, the vibration of the core piece accompanying the use of the reactor can be effectively suppressed.

  As one form of this invention reactor, this invention reactor can be set as the structure provided with the case which accommodates an assembly inside. In this case, the case is formed on the side wall portion surrounding the assembly, the bottom plate portion which is a separate member from the side wall portion, and the case inner surface side of the bottom plate portion, and the heat dissipation interposed between the bottom plate portion and the coil. And a layer.

  Although this invention reactor does not make a case essential, it can protect a combination from the physical impact from the outside by setting it as a structure provided with a case, and can also improve the heat dissipation of a combination. . Particularly, by arranging the side wall portion and the bottom plate portion separately, it is easy to arrange the assembly (including alignment) in the case. Moreover, the heat dissipation of a reactor can be improved by interposing a thermal radiation layer between a baseplate part and a coil.

  According to the structure of this invention reactor, it can be set as the reactor which a noise is hard to generate | occur | produce with use. Moreover, according to the structure of this invention reactor, it can be set as the reactor which can be produced simply and in a short time.

1 is an exploded perspective view showing an outline of a reactor described in Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the combination body of the reactor shown in FIG.

  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≫
A reactor 1 shown in FIG. 1 includes a combined body 10 formed by combining a coil member 2 and a magnetic core 3, and a case 4 that houses the combined body 10. The case 4 is a box that is open on one side, and the combined body 10 arranged 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. Is done. The most characteristic feature of the reactor 1 is that a magnetic core 3 is formed by combining a plurality of core pieces (outer core portions 33 and 34, divided cores 31m) and a gap plate 31g as shown in FIG. In addition to the configuration, a room temperature curable elastic adhesive is used for joining the core pieces 33, 34, 31m and the gap plate 31g. Hereinafter, each structure of the reactor 1 is demonstrated in detail, and the manufacturing method of the said reactor 1 is demonstrated then.

≪Union body≫
[Coil member]
The coil member 2 constituting the combined body 10 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 U-shaped bent portion that connects the coils 2a and 2b on the other end side of the coil member 2 (the right side in FIGS. 1 and 2).

  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 of the coil member 2 (on the left side in FIG. 1 and FIG. 2) and pulled out of the case 4. The insulating coating is peeled off at both ends of the drawn winding 2w, and a conductive terminal fitting (not shown) is connected to the conductor portion 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, for example. 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 portion 31 (32) is a laminate formed by alternately laminating divided cores (core pieces) 31m made of a substantially rectangular parallelepiped magnetic material and gap plates 31g having a lower magnetic permeability than the divided core 31m. The outer core portions 33 and 34 are columnar core pieces having a dome-shaped bottom surface and top surface. 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 split core 31m 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.

  The molded body constituting the core piece is, for example, an iron group metal such as Fe, Co, or Ni, or an Fe group such as Fe—Si, Fe—Ni, Fe—Al, Fe—Co, Fe—Cr, or Fe—Si—Al. Powder compacts using powders made of soft magnetic materials such as alloys, rare earth metals and amorphous magnetic materials, sintered products obtained by sintering the above powders after press molding, and mixtures of the above powders and resins by injection molding or casting Examples thereof include molded hardened bodies that have been molded. In addition, as the core piece, use of a ferrite core which is a sintered body of a metal oxide can be mentioned. The molded body is particularly preferable because various three-dimensional magnetic cores can be easily formed.

  On the other hand, the gap plate 31g may be made of a nonmagnetic material such as alumina, glass epoxy resin, or unsaturated polyester, or a soft magnetic material dispersed in these nonmagnetic materials. In any case, the gap plate 31g has a lower magnetic permeability than the core piece.

  For bonding the core pieces 31m, 33, 34 and the gap plate 31g, a room temperature curable elastic adhesive is used. The cured room temperature curable elastic adhesive remains as an adhesive layer 7 between the core pieces 31m, 33, 34 and the gap plate 31g. In FIG. 2, in the exploded view of the inner core portion 31, one of the plurality of adhesive layers 7 is illustrated by cross-hatching, but actually, between the core pieces 31m, 33, 34 and the gap plate 31g. An adhesive layer 7 is formed on all of them.

  The room temperature curable adhesive used preferably uses an adhesive having a shore hardness of D10 to D60 when the adhesive layer 7 is cured to become the adhesive layer 7. The more preferable Shore hardness of the adhesive layer 7 is D10 to D50. It is also preferable to use a room temperature curable elastic adhesive in which the glass transition point of the adhesive layer 7 is in the range of −40 ° C. to 70 ° C. The glass transition point of the adhesive layer 7 is more preferably −40 ° C. to 50 ° C. A typical example of a room temperature curable adhesive satisfying such characteristics is acrylic rubber. As the acrylic rubber, for example, a free sample 13X-200 manufactured by Three Bond Co., Ltd. can be used.

[Bobbin]
The combined body 10 of 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.

≪Case≫
The case 4 will be described with reference to FIG. The case 4 in which the assembly 10 is accommodated includes a flat bottom plate portion 40 and a frame-like side wall portion 41 standing on the bottom plate portion 40, and the bottom plate portion 40 and the side wall portion 41 are configured as separate members. Has been.

[Bottom plate and side wall]
(Bottom plate)
The bottom plate portion 40 is a rectangular plate member that is fixed to the fixed object when the reactor 1 is installed on the fixed object such as a cooling base. 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≫
The bottom plate portion 40 includes a heat dissipation layer 42 at a location where the coil installation surface of the coil member 2 contacts. As shown in FIG. 1, the heat dissipation layer 42 may be formed over a portion corresponding to the core installation surface of the outer core portions 33 and 34. The heat radiation layer 42 is preferably made of an insulating material having a thermal conductivity of more than 2 W / m · K. The heat conductivity of the heat radiation layer 42 is preferably as high as possible, and is made of an insulating material of 3 W / m · K or more, especially 10 W / m · K, more preferably 20 W / m · K, especially 30 W / m · K or more. Is preferred. Examples of the constituent material of the heat dissipation layer 42 satisfying such thermal characteristics include non-metallic inorganic materials such as ceramics such as a metal element or a kind of material selected from Si oxides, carbides, and nitrides. . Examples of the ceramic include silicon nitride (Si ₃ N ₄ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), and silicon carbide (SiC).

  When the heat dissipation layer 42 is formed from the ceramics, for example, a vapor deposition method such as a PVD method or a CVD method can be used. Alternatively, the heat dissipation layer 42 may be formed by bonding the ceramic sintered plate to the bottom plate portion 40 with an appropriate adhesive. In addition, the heat radiation layer 42 may be made of an insulating resin (for example, an epoxy resin or an acrylic resin) containing a filler made of the ceramics. If the insulating resin containing filler is used, the heat dissipation layer 42 having excellent heat dissipation and electrical insulation can be formed. Such a heat dissipation layer 42 can be formed by applying an insulating resin containing a filler to the bottom plate portion 40 or screen printing. In particular, if the heat dissipation layer 42 is an adhesive, the adhesion between the coil 2 and the heat dissipation layer 42 can be improved.

  Here, in the part (the cross-hatching part of the heat dissipation layer 42 shown in FIG. 1) of the heat dissipation layer 42 provided in the bottom plate 40 that is in contact with the outer core parts 33 and 34, the heat dissipation layer 42 and the outer side are separated by a room temperature curable elastic adhesive. It is preferable that the core portions 33 and 34 are bonded together. By doing so, the adhesive layer 8 made of a room temperature curable elastic adhesive is also formed between the heat radiation layer 42 and the outer core portions 33 and 34, and the vibration of the combined body 10 (magnetic core 3) in the case 4. Can be suppressed. The room temperature curable elastic adhesive used here may be a room temperature curable elastic adhesive used for bonding the core pieces 31m, 33, 34 and the gap material 31g.

(Sidewall)
The side wall 41 is a cylindrical frame, and when the case 4 is assembled by closing one opening with the bottom plate 40, the side wall 41 is disposed so as to surround the assembly 10 and the other opening is open. Is done. Here, as for the side wall part 41, the area | region used as the installation side when the reactor 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 assembly 10's. It is a curved surface shape along the outer peripheral surface.

  In addition, you may provide the terminal stand (not shown) which can fix a terminal metal fitting in the side wall part 41. FIG. For example, it is preferable to provide a hook-shaped portion so as to cover the substantially trapezoidal surface of the outer core portion 33 at the upper opening of the case 4 shown in FIG. 1, and use the upper surface of the hook-shaped portion as a terminal block.

(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. It is preferable to be determined uniquely. In this case, it is preferable to fix the reactor 1 to the fixing target by bolting the bottom plate part 40 to the fixing target without forming the bolt hole 411h in the side wall 41. By doing so, when the bottom plate portion 40 is made of a metal material and the side wall portion 41 is made of a resin material as will be described later, creep deformation of the resin material due to bolting can be suppressed, and the fixed state of the reactor 1 with respect to the fixing object is loosened. This can be suppressed.

(Material)
The constituent material of the case 4 can be a metal material, for example. Since the metal material generally has excellent thermal conductivity, the case 4 having excellent heat dissipation can be produced. Specific metal materials that can be used include, for example, aluminum, magnesium, copper, silver, alloys thereof, and stainless steel. In particular, if aluminum or an alloy thereof is used, the case 4 that is lightweight and excellent in corrosion resistance can be produced. 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.

  Further, as the constituent material of the case 4, a non-metallic material such as polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, acrylonitrile-butadiene-styrene (ABS) resin can be used. Since many of these resin materials are excellent in electrical insulation, the insulation between the assembly 10 and the case 4 can be enhanced. When the resin material is mixed with a filler made of ceramics (see a sealing resin filler described later), the heat dissipation can be improved. When forming case 4 with resin, injection molding can be used suitably.

  Here, the constituent material of the bottom plate part 40 and the constituent material of the side wall part 41 constituting the case 4 can be appropriately selected. The bottom plate portion 40 and the side wall portion 41 may be made of the same kind of constituent material or different kinds of constituent materials. In particular, the bottom plate portion 40 is preferably made of a metal material such as aluminum and the side wall portion 41 is made of a resin material such as PBT resin. By doing so, the heat of the combined body 10 can be quickly radiated to the cooling base (fixed object to which the reactor 1 is attached) via the bottom plate portion 40, and the combined body 10 is effectively insulated from the outside by the side wall portion 41. can do.

[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. The packing 6 in the present embodiment is an annular body having a size that can be engaged with the outer periphery of the combined body 10 of the coil member 2 and the magnetic core 3, and is made of synthetic rubber. Any suitable material can be used.

  The reactor 1 demonstrated above can be used for power converters, such as an electric vehicle and a hybrid vehicle. The energization conditions of the reactor 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 reactors≫
The reactor 1 provided with the said structure can be manufactured as follows.

  First, the combined body 10 is formed by combining the coil member 2 and the magnetic core 3. Specifically, as shown in FIG. 2, the inner core portion 31 (32) is formed by adhering the split core 31m and the gap plate 31g with a room temperature curable elastic adhesive.

  Next, the inner core part 31 (32) is inserted in each coil 2a (2b) in the state which has arrange | positioned the inner bobbin 51 (52) on the outer periphery of the produced inner core part 31 (32). 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 assembly 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). For bonding the inner core portion 31 (32) and the outer core portion 33 (34), a room temperature curable elastic adhesive may be used.

  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 radiation layer 42 that also serves as an adhesive of a predetermined shape is formed on one surface by screen printing. Then, the combined body 10 assembled as described above is placed on the heat radiation layer 42, thereby fixing the combined body 10 to the bottom plate portion 40. Here, a room temperature curable elastic adhesive is used not only for bonding the core mounting surfaces of the outer core portions 33 and 34 and the heat dissipation layer 42 but also for bonding the coil mounting surfaces of the coils 2 a and 2 b and the heat dissipation layer 42. It doesn't matter.

  On the other hand, a side wall 41 configured in a predetermined shape by injection molding or the like is placed from above the combination 10 so as to surround the outer periphery of the combination 10. At that time, the packing 6 is disposed along the outer edge portion of the bottom plate portion 40. And the baseplate part 40 and the side wall part 41 are integrated by the bolt (not shown) prepared separately. By this step, the box-shaped case 4 can be assembled and the combined body 10 can be stored in the case 4.

  Finally, the reactor 4 is completed by filling the case 4 with a sealing resin and curing the sealing resin.

≪Effect≫
The reactor 1 provided with the structure demonstrated above can be produced easily and in a short time. This is because, when the magnetic core 3 is assembled, a room temperature curable elastic adhesive is used for joining the core pieces 31m, 33, 34 and the gap plate 31g. If a room temperature curable elastic adhesive is used, the curing process required when the core pieces 31m, 33, 34 and the gap plate 31g are joined using the thermosetting adhesive can be omitted. The manufacturing process of the reactor 1 can be shortened by the amount of processing.

  Moreover, in the reactor 1 of this embodiment, the noise accompanying use can be suppressed. That is, the adhesive layer 7 having elasticity is used for joining the core pieces 31m, 33, 34 and the gap plate 31g, and the vibration of the core pieces 31m, 33, 34 itself is suppressed by the adhesive layer 7 and adjacent to each other. This is because the contact between the core pieces 31m, 33, 34 and the contact between the core pieces 31m, 33, 34 and the gap plate 31g is also suppressed. Furthermore, in the reactor 1 of the present embodiment, the adhesive layer 8 having elasticity is also used for joining the core installation surfaces of the core pieces (outer core portions) 33 and 34 and the heat radiation layer 42 of the bottom plate portion 40. The expansion and contraction of the outer core portions 33 and 34 in the coil axis direction due to magnetostriction can be suppressed. As a result, vibration of the outer core portions 33 and 34 can be suppressed, and contact between the outer core portions 33 and 34 and the bottom plate portion 40 can also be suppressed.

  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. For example, in the embodiment described above, the reactor 1 including the case 4 has been described, but the case 4 may not be used.

  The reactor of the present invention can be suitably used for components of power conversion devices such as in-vehicle converters such as hybrid vehicles, electric vehicles, and fuel cell vehicles.

DESCRIPTION OF SYMBOLS 1 Reactor 2 Coil member 2a, 2b Coil 2r Coil connection part 2w Winding 3 Magnetic core 31, 32 Inner core part 31m Division | segmentation core (core piece) 31g Gap board 33, 34 Outer core part (core piece)
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 5 Bobbin 51, 52 Inner bobbin 51a, 51b Bobbin piece 53, 54 Frame-like bobbin 54f Flange part 6 Packing 7, 8 Bonding Tier 10 Union

Claims (6)

A reactor comprising a combination of a coil member having a pair of coils connected in parallel and an annular magnetic core penetrating the inside of both coils,
The magnetic core is formed by combining a plurality of core pieces and a gap plate interposed between the core pieces,
A reactor comprising an adhesive layer made of a room temperature curable elastic adhesive between the core piece and the gap plate.   The reactor according to claim 1, wherein the adhesive layer has a Shore hardness of D10 to D60.   The reactor according to claim 1 or 2, wherein a glass transition point of the adhesive layer is -40 ° C to 70 ° C.   The reactor according to any one of claims 1 to 3, wherein the room temperature curable elastic adhesive is acrylic rubber. A case for storing the combined body therein;
The case is
A side wall surrounding the periphery of the combination;
A bottom plate that is a separate member from the side wall;
Formed on the case inner surface side of the bottom plate portion, and a heat dissipation layer interposed between the bottom plate portion and the coil,
The reactor of any one of Claims 1-4 characterized by the above-mentioned. A reactor manufacturing method for producing a reactor including a combination of a coil member having a pair of coils connected in parallel and an annular magnetic core penetrating the inside of both coils,
Prepare a plurality of core pieces to be the magnetic core by combining, and a gap plate interposed between the core pieces,
A method of manufacturing a reactor, wherein the magnetic core is manufactured by bonding the core piece and a gap plate with an elastic adhesive curable at room temperature.

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