JP2014027024A - Reactor, converter and electrical power conversion apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that is superior in assembling workability.SOLUTION: A reactor 1 has: a coil 2 formed by winding a winding wire 2w; a magnetic core 3; a case 4 housing an assembly 10 of the coil 2 and the magnetic core 3; and a terminal fitting 8 connected to an end of the winding wire 2w. The case 4 has a bottom plate part 40, and a side wall part 41 surrounding a periphery of the assembly 10. At least of part of the side wall part 41 is formed of an insulating resin. A fastening base part 415 for holding the terminal fitting 8 by a fastening member (bolt 419), a swinging motion restraint part 416 for restraining the swing motion of the terminal fitting 8 when the bolt 419 is fastened, and a positioning part 417 for positioning the terminal fitting 8 are integrally molded to the side wall part 41 by the insulating resin. The terminal fitting 8 has a locking part 86 which is locked to the swinging motion restraint part 416. The terminal fitting 8 is hard to swing by the swinging motion restraint part 416 and the locking part 86, has a good stability to easily fasten the bolt 419 and has a good workability.

Description

  The present invention relates to a reactor, a converter including a reactor, and a power converter including the converter, which are used in a vehicle-mounted DC-DC converter or a component of a power converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor excellent in assembly workability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. Patent Document 1 describes, as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, a coil formed by winding a winding, an annular magnetic core on which the coil is disposed, and a coil and a magnetic core. The thing which comprises the case which accommodates a combined body, and sealing resin with which it fills in the case is disclosed.

  Patent Document 1 discloses, in particular, a case in which the side wall portion surrounding the assembly in the case is made of an insulating resin. Moreover, a part of side wall part which consists of insulating resin is utilized for the terminal block. The terminal fitting fixed to the terminal block is formed by forming a strip-shaped material such as a copper plate into an appropriate shape, and one end portion of the strip-shaped material itself is used as a joint with the winding. The terminal block is formed as follows. An intermediate portion of the strip material is disposed on a base portion integrally formed with the side wall portion. Next, a plate-like terminal fixing member made of an insulating resin is prepared, the terminal fixing member is arranged so as to cover the middle part of the band-shaped material, and the terminal fitting is sandwiched between the base portion of the side wall and the terminal fixing member. . And a bolt is fastened to a terminal fixing member, and a terminal metal fitting is fixed to the base part of a side wall part. If the positioning groove for the terminal fitting is provided in the base portion, the terminal fitting can be easily arranged at a predetermined position, and the workability is excellent.

JP 2011-243943

  In forming the terminal block, improvement in workability is desired.

  Since the above-described terminal fittings are relatively long, when the terminal fittings are arranged on the base portion of the side wall, there are many areas protruding from the base portion of the terminal fittings. For this reason, there is a possibility that both ends of the terminal fitting rotate or swing around the region of the terminal fitting supported by the base portion of the side wall. With the above-described positioning groove, this swing cannot be restricted. Therefore, in order to tighten the bolt stably, it is necessary to support the terminal fitting with a finger or the like to prevent the swinging, resulting in a decrease in workability. As a result, the assembly workability of the reactor is reduced.

  Further, in order to firmly fix the terminal fitting to the side wall portion, it is desirable to provide a bolt hole in the terminal fitting itself and directly fix the terminal fitting and the side wall portion with the bolt. However, also in this case, when the bolt is tightened, the terminal fitting can swing around the bolt hole. Further, as the bolt rotates, the terminal fitting may also rotate on the horizontal plane. Therefore, also in this case, when fastening the bolt, it is necessary to support the terminal fitting, and improvement in workability is desired.

  The inventor has studied a configuration in which a plurality of protrusions are provided in the terminal metal placement region in the base portion of the side wall, and a through-hole through which these protrusions are inserted is provided in the belt-like material. With this configuration, the terminal fitting can be positioned and the rotation of the terminal fitting accompanying the rotation at the time of bolt tightening can be effectively prevented. Further, it is expected that the swinging of the terminal fitting can be suppressed to some extent if the projection is long enough to be caught in the through hole without coming out of the through hole when the terminal fitting swings. However, when the protrusion is lengthened, there arises a problem that the height of the reactor increases (the reactor becomes larger) and the protrusion easily breaks. Further, due to the lengthening of the protrusion, it is difficult to arrange the terminal fitting (insert the through hole into the protrusion). From this point, workability is reduced.

  When many protrusions are provided, the terminal fitting is likely to be stable, and it is expected that swinging can be suppressed. However, in this case, the number of through holes in the terminal fitting also increases. Then, in order to ensure a predetermined conductor cross-sectional area, it is necessary to enlarge at least a part of the terminal metal fitting, resulting in an increase in size of the component. Further, in order to easily arrange the terminal fittings when many protrusions and through holes are provided, it is desirable that the through holes be sufficiently larger than the outer shape of the protrusions. This also leads to an increase in the size of the terminal fitting.

  It is expected that swinging can be suppressed by increasing the area for supporting the terminal fitting in the side wall. However, in this case, the side wall is increased in size.

  Accordingly, one of the objects of the present invention is to provide a reactor having excellent assembly workability. Another object of the present invention is to provide a converter including the reactor and a power conversion device including the converter.

  The present invention achieves the above-described object by providing the positioning part of the terminal fitting and the portion for suppressing the swinging integrally with the case, and also providing the terminal fitting with the portion for suppressing the swinging. .

  The reactor according to the present invention includes a coil formed by winding a coil, a magnetic core in which the coil is disposed, a case that houses a combination of the coil and the magnetic core, and an end of the coil connected to each other. With terminal fittings. The case includes a bottom plate portion on which the combination is placed and a side wall portion surrounding the periphery of the combination. At least a part of the side wall portion is made of an insulating resin. The side wall portion includes a fastening base portion that fixes a part of the terminal fitting by a fastening member, a swing suppression portion that restricts swinging of the terminal fitting when the fastening member is tightened, and the terminal fitting. And a positioning portion for positioning with respect to the pedestal portion. The fastening base part, the swing suppression part, and the positioning part are integrally formed on the side wall part with the insulating resin. The said terminal metal fitting is formed from the strip | belt-shaped material. The said terminal metal fitting is formed from a part of said strip | belt-shaped material, and is provided with the latching | locking part latched by the said rocking | fluctuation suppression part.

  In the reactor according to the present invention, when the terminal fitting is fixed to the fastening base portion by the fastening member, the terminal fitting is latched by the swing suppression portion of the side wall portion and the terminal fitting is self-supporting. Is difficult to swing. Further, the horizontal rotation of the terminal fitting can be suppressed by the swing suppression portion. Therefore, the reactor of the present invention is substantially free from the need to separately support the terminal fitting when the terminal fitting is fixed to the fastening base portion to form the terminal block, and is excellent in tightening workability. Moreover, since the side wall part has a positioning part, the reactor of this invention can position a terminal metal fitting easily to a predetermined position, and is excellent also in the arrangement | positioning workability | operativity of a terminal metal fitting. From these points, the reactor of the present invention is excellent in assembling workability. In addition, it is not necessary to provide long protrusions, excessive protrusions, and through holes in the side wall part, or excessively increase the terminal metal support area in the side wall part, and the reactor of the present invention is small.

  As one form of this invention, the said latching part is a bending piece formed by bending a part of said strip | belt-shaped material, and the said rocking | fluctuation suppression part is a form which is a hole into which the said bending piece is inserted.

  In the above-described configuration, the latching portion and the swing suppression portion can be easily formed, which is excellent in manufacturability, and the terminal metal fitting can be easily assembled to the swing suppression portion and the positioning portion of the side wall portion. Also excellent.

  As a form in which the latching part is formed from a bent piece, the positioning part is at least one protrusion, and the terminal fitting has a positioning notch into which the at least one protrusion is fitted, There is a form in which at least one piece forming the positioning notch is bent to form the bent piece.

  The said form can position a terminal metal fitting to a side wall part easily by inserting a positioning notch in the processus | protrusion which comprises a positioning part, and is excellent in workability | operativity. And the said form is excellent also in the productivity of a terminal metal fitting, since a bending piece (holding part) can be formed by bend | folding at least one of the two sections which make a positioning notch.

  As one form of this invention, the said side wall part is provided with the collar part which covers the location arrange | positioned in the opening side of the said case in the said assembly, the said fastening stand part is provided protruding from the said collar part, The said fastening The form whose width | variety of the end surface of a base part is smaller than the width | variety of the contact region vicinity with the said fastening base part in the strip | belt-shaped material which comprises the said terminal metal fitting is mentioned.

  If the end surface of the fastening base portion that supports the terminal fitting is small, and the terminal fitting is wide and long, it will easily swing. However, the said form can suppress effectively the rocking | fluctuation of a terminal metal fitting by a rocking | fluctuation suppression part and a latching | locking part. Moreover, the said form can achieve size reduction because a fastening stand part is small.

  As one form of this invention, the end part of the said coil | winding is pulled out along the winding direction of the said coil | winding, and the coil | winding proximity | contact which is arrange | positioned in the vicinity of the end part of the said coil | winding in the inner surface of the said side wall part The location is made of the insulating resin, and the shortest distance between the winding proximity location and the end of the winding is 2.0 mm or less.

  In the above configuration, since the winding proximity portion of the side wall portion is made of an insulating resin, it is possible to ensure insulation between the winding and the side wall portion even when the end portions of the winding are close to or in contact with each other. Moreover, the said form is small because the side wall part and the edge part of a coil | winding adjoin or contact | connect. Furthermore, since the said form only pulls out the edge part of a coil | winding along a winding direction, the extraction process is easy and it is excellent also in manufacturability of a coil.

  The reactor of this invention can be utilized suitably for the component of a converter. The converter of the present invention includes the reactor of the present invention.

  The converter of this invention is excellent in productivity by providing the reactor of this invention which is excellent in assembly workability | operativity.

  The converter of this invention can be utilized suitably for the component of a power converter device. The power converter of the present invention includes the converter of the present invention.

  The power conversion device of the present invention is excellent in productivity by including the reactor of the present invention which is excellent in assembling workability.

  The reactor of the present invention is excellent in assembling workability.

FIG. 2 is a schematic perspective view showing the reactor of Embodiment 1, showing a state where a lid is opened. 1 is a schematic plan view of a reactor according to a first embodiment. 1 is an exploded perspective view showing an outline of a reactor of Embodiment 1. FIG. FIG. 4 is a partial cross-sectional view showing a (IV)-(IV) cross section in the reactor shown in FIG. (A) is the elements on larger scale of one collar part with which the reactor of Embodiment 1 is provided, (B) is the elements on larger scale of this terminal block. FIG. 2 is an exploded perspective view of a combined body provided in the reactor according to the first embodiment. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of the power converter device of this invention provided with the converter of this invention.

[Embodiment 1]
Hereinafter, the reactor according to the first embodiment will be described with reference to FIGS. The same reference numerals in the figure indicate the same names.

<Overall reactor structure>
A reactor 1 includes a coil 2 formed by winding a winding 2w as shown in FIG. 1, a magnetic core 3 on which the coil 2 is disposed, and a case 4 that houses a combined body 10 of the coil 2 and the magnetic core 3. And a terminal fitting 8 to which the end of the winding 2w is connected. The case 4 includes a bottom plate portion 40 and a side wall portion 41 standing from the bottom plate portion 40. The basic configuration of the reactor 1 is the same as the reactor described in Patent Document 1, and at least a part (here, all) of the side wall part 41 of the case 4 is made of an insulating resin, and a part of the side wall part 41 Provide a terminal block. The feature of the reactor 1 is that the side wall portion 41 is provided with both a positioning portion 417 of the terminal fitting 8 and a swing suppressing portion 416 that restricts swinging of the terminal fitting 8, and the terminal fitting 8 is swung. It is in the point which comprises the latching | locking part 86 latched by the suppression part 416. FIG. Hereinafter, each configuration will be described in more detail.

<Union>
The combination 10 can use a coil and a magnetic core having a known shape and material. Here, the magnetic core 3 includes a pair of columnar inner core portions 31 (FIG. 6) and a pair of columnar outer core portions 32 (FIGS. 3 and 6) assembled to the inner core portion 31 to form an annular body. With The detailed configuration of the magnetic core 3 will be described later.

(coil)
The coil 2 will be described mainly with reference to FIGS. The coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding the winding 2w, and a coil connecting portion 2r that connects both the coil elements 2a and 2b. The coil elements 2a and 2b are hollow cylindrical bodies having the same number of turns, and are arranged in parallel (side by side) so that the axial directions are parallel to each other. On the other end side of the coil 2 (upper side in FIG. 2, right side in FIG. 6), a part of the winding 2w is bent into a U shape to form a coil coupling portion 2r. With this configuration, the winding directions of both coil elements 2a and 2b are the same, and both coil elements 2a and 2b are electrically connected in series.

  Here, one continuous winding 2w having no joint is used. Each coil element is manufactured by separate windings, and one end of each coil element winding is joined via a coil or a connecting member (for example, a plate material) directly joined by welding, soldering, crimping, etc. Coil.

  As the winding 2w, a coated wire having an insulating coating made of an insulating material (typically polyamideimide) on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. Here, a covered rectangular wire having a conductor made of a copper rectangular wire is used. Each of the coil elements 2a and 2b is an edgewise coil in which the covered rectangular wire is wound edgewise. The edgewise coil is (1) easy to form a coil with a higher space factor than when a round wire is used for the winding, so it can be made smaller, (2) because at least a part of the outer peripheral surface can be made flat, A large contact area with the bonding layer 42 (see FIG. 3, which will be described later) provided on the bottom plate 40 can be secured to increase heat dissipation. (3) The end of the winding 2w itself is connected to the terminal fitting 8 (described later). In addition to being usable in various places, there is an advantage that a wide contact area with the terminal fitting 8 can be secured. The end face shape of the coil element is a rectangular frame here, but can be changed as appropriate (for example, an annular shape).

  At both ends of the winding 2w forming the coil 2, the terminal fitting 8 is connected to the conductor portion exposed by peeling off the insulation coating. An external device (not shown) such as a power source for supplying power is connected to the coil 2 via the terminal fitting 8.

  Here, the end of the winding 2w is drawn out along the winding direction of the winding. Here, the end of the winding 2w is drawn out so as to be orthogonal to both the axial direction of the coil 2 and the horizontal direction of the coil elements 2a and 2b. Here, the end of the winding 2w can be pulled out in a desired position and direction by appropriately bending the end of the winding 2w. For example, in Patent Document 1, the winding 2w is edgewise bent in the direction opposite to the winding direction of the winding, and the end of the winding 2w is disposed at the intermediate portion of the coil element 2a (2b). In order to perform edgewise bending in the direction opposite to the winding direction of the winding, it is necessary to completely separate the winding operation and the drawing process, resulting in a decrease in workability. When the winding direction of the winding is the same as the drawing direction of the end of the winding, the drawing process can be performed continuously after the winding operation. Therefore, this form is excellent in the manufacturability of the coil 2.

  Here, one end of the winding 2 w is drawn along the outer peripheral surface of the coil 2. With this configuration, as shown in FIG. 2, the location on the inner surface of the side wall portion 41 of the case 4 in the vicinity of one end of the winding 2w: between the winding proximity location 41a and one end of the winding 2w The interval can be made very small. Here, the shortest distance between the winding proximity point 41a and one end of the winding 2w is 2.0 mm or less. Since the side wall 41 is made of an insulating resin, the insulation between the coil 2 (the end of the winding 2w) and the case 4 (side wall 41) even if the shortest distance is 2.0 mm or less. Can be secured. The shortest distance is 1.0 mm or less, further 0.5 mm or less, particularly 0 mm, that is, the end portion of the coil 2w and the side wall portion 41 may be in contact with each other. The smaller the shortest distance, the smaller the reactor 1 can be made. When the shortest distance is large, it is easy to prevent thermal degradation or damage of the side wall 41 due to heat at the time of soldering for connecting the winding 2w and the terminal fitting 8.

(Terminal bracket)
The terminal fitting 8 will be described with reference to FIG. 2, FIG. 3, and FIG. The terminal fitting 8 is a conductive member formed from a strip material (plate material). Constituent materials include conductive materials such as copper, copper alloys, aluminum, and aluminum alloys. The terminal fitting 8 is formed by punching a material plate made of a conductive material into a desired shape and bending it into the desired shape. As shown in FIG. 5 (B) and the like, the terminal fitting 8 has a joining portion 81 to which the end of the winding 2w is joined on one end side in the longitudinal direction of the belt-like material, and an external power source or the like on the other end side. It has a through hole into which a connecting member (typically a bolt) for connecting the device is fitted, and has a fixing region fixed to the side wall 41 in the middle part. The terminal fitting 8 is directly fixed to the side wall 41 by a fastening member (here, a bolt 419). Therefore, the fixing area includes a fixing hole 85 (FIGS. 3 and 5B) through which the bolt 419 is inserted.

  The shape of the terminal fitting 8 can be selected as appropriate. Here, the terminal fitting 8 is formed in the shape of a slide so that the other end side region having the through hole is positioned lower than the fixed region (position closer to the installation surface) (FIG. 3). As in Patent Document 1, the step between the one end side region and the other end side region may be small. Also, here, the fixed region to the other end side region is a linear region having a uniform width, and the one end side region to which the end of the winding 2w is connected is the width direction as viewed from the other end side region. (Figs. 3 and 5 (B)). By adjusting the shape of the terminal fitting 8 in this way, the terminal fitting having a predetermined shape can be obtained even if the position of the end of the winding 2w and the position of the connection portion with the external device are not aligned. The end of the winding 2w and the external device can be connected via 8. Therefore, in this embodiment, there is no need to adjust the position of the end of the winding 2w by folding the winding 2w in the direction opposite to the winding direction.

  Here, the joint 81 is a U-shaped member (FIG. 2). The U-shaped joint 81 has the end of the winding 2w interposed in the U-shaped space, and solder is poured into the gap, or the end of the winding 2w is interposed in the U-shaped space. After crimping, the joining portion 81 and the winding 2w can be joined by performing welding such as TIG welding, crimping, or soldering. Since the U-shaped joining portion 81 can be used as a holding member at the end of the winding 2w, a holding jig is not required for joining, and the joining workability is excellent. The terminal fitting 8 is preferably arranged so that the U-shaped opening is directed to the side wall 41 side. For example, when solder is used for joining, molten solder tends to accumulate in the U-shaped portion. When the opening of the U-shaped part is directed toward the side wall 41, the molten solder accumulated in the U-shaped part and the side wall 41 are arranged apart from each other. Therefore, it is possible to prevent the side wall portion 41 (particularly the winding proximity portion 41a) from being damaged or deformed by the heat of the melted solder. The shape of the joint portion 81 can be changed as appropriate. For example, a flat plate shape as described in Patent Document 1 may be used.

  In addition, the terminal fitting 8 includes a latching portion 86, a positioning notch 87, and a positioning hole 87h in the vicinity of the fixing hole 85 (FIGS. 2, 3, and 5B). These details will be described in the terminal block section.

<Case>
The case 4 is a box that includes a flat bottom plate portion 40 on which the combined body 10 is placed and a frame-shaped side wall portion 41 that surrounds the periphery of the combined body 10, and the side facing the bottom plate portion 40 is open. (Figure 1). As shown in FIG. 3, the bottom plate portion 40 and the side wall portion 41 are independent members, and are separately attached by a fixing material. First, a terminal block provided in the side wall portion 41 will be described mainly with reference to FIGS. 2 to 5, and then configurations other than the bottom plate portion 40 and the terminal block of the side wall portion 41 will be described.

(Terminal block)
The side wall portion 41 includes, in the opening side region, a flange portion 410 that covers a portion (here, a part of the upper surface of each outer core portion 32) disposed on the opening side of the case 4 in the assembly 10 (FIG. 2). . One flange 410 (the lower side in FIG. 2 and the left side in FIG. 3) is used as a terminal block. As a main constituent member of the terminal block, the collar portion 410 includes a fastening base portion 415 (FIGS. 3 and 5) for fixing a part of the terminal fitting 8 with a fastening member (bolt 419). In the vicinity of the fastening base part 415, a swing suppression part 416 and a positioning part 417 for positioning the terminal fitting 8 with respect to the fastening base part 415 are provided (FIGS. 3 and 5). The fastening base portion 415, the swing suppression portion 416, and the positioning portion 417 are all integrally formed on the side wall portion 41 by using the main constituent material as an insulating resin constituting the side wall portion 41. .

  Here, the collar portion 410 is provided at a position lower than the opening edge of the side wall portion 41 (FIG. 3). Specifically, the collar portion 410 is provided so as to cover the upper surface of the outer core portion 32 as shown in FIG. 4, and the interval between the inner surface of the collar portion 410 and the upper surface of the outer core portion 32 is narrow. Moreover, the collar part 410 is thin. Therefore, a relatively large space is provided above the outer core portion 32. By using this space, the bulk can be reduced and the size can be reduced while the fastening base 415 is provided. In the embodiment including the sealing resin 100 (FIG. 1), the space for filling the sealing resin 100 (the volume of the case 4) can be reduced. Therefore, the filling time and curing time of the sealing resin 100 can be shortened, and the filling workability is excellent. Furthermore, the amount of the sealing resin 100 used can be reduced, and the cost can be reduced. The interval is preferably about 0.5 mm to 3.0 mm.

  Here, although the wall portion 413 standing on the flange portion 410 is provided and the entire outer periphery of the coil 2 is surrounded by the side wall portion 41, the wall portion 413 can be omitted.

  Two columnar bodies projecting from the surface are provided on the surface of one collar portion 410 (FIG. 3). Each columnar body is referred to as a fastening base 415. Each fastening base 415 is provided with a bolt hole into which a bolt 419 is screwed. Here, the bolt hole is formed by a metal collar including a metal cylinder such as brass, stainless steel, and steel and an annular flange protruding outward from each peripheral edge of the cylinder (FIG. 3). In Fig. 5, the flange and the bolt hole are visible). That is, a part of the fastening base part 415 is made of metal, and the fastening force of the bolt 419 is substantially received by the metal collar and the metal terminal fitting 8, so that the other part of the fastening base part 415 is The constituent resin is difficult to creep. A bolt hole made of a metal collar can be easily formed by insert molding using the metal collar as a core. The fastening base part 415 (bolt hole) can also be made of resin alone.

  The outer shape of the fastening base 415 is not particularly limited. Since the fastening base 415 is mainly made of resin, it can be easily formed into a desired shape by injection molding or the like. Here, it is cylindrical, but it may be rectangular. If the fastening base 415 is small, the amount of resin used can be reduced. Here, as shown in FIG. 5 (B), the width of the end surface of the fastening base part 415 (here, the outer diameter of the cylinder) is larger than the width in the vicinity of the contact area with the fastening base part 415 in the strip material constituting the terminal fitting 8. (Therefore, in FIG. 2, the fastening base 415 is not visible because it is hidden under the terminal fitting 8). Since the end surface of the fastening base part 415 that contacts a part of the terminal metal part 8 and supports the terminal metal part 8 is small, the terminal metal part 8 can be attached to the fixing holes 85 and Centering around the vicinity, the both ends of the terminal fitting 8 in the longitudinal direction are easily rotated so as to be inclined in the vertical direction. That is, the terminal fitting 8 is easy to swing. In order to suppress this swing, the side wall portion 41 includes a swing suppression portion 416, and the terminal fitting 8 includes a hooking portion 86 that is hooked on the swing suppression portion 416.

  Here, a part of the wall part 413 standing from the collar part 410 is slightly thicker than the other part of the side wall part 41 (FIGS. 2 and 5 (A)), and two rectangular shapes are formed in this thick part. Provide a hole. Each hole is referred to as a swing suppression portion 416. The hooking portion 86 of the terminal fitting 8 is inserted into each hole. Here, the latching portion 86 is a bent piece formed by bending a part of the belt-like material as shown in FIG. The shape and depth of the hole may be selected according to the shape and size (width, bending length) of the hooking portion 86. Here, since the cross section of the bent piece is rectangular, the hole is also rectangular. The greater the width (cross section) of the bent piece, the longer the bent length, and the deeper the hole, the easier it is to suppress the swing of the terminal fitting 8. Even if the bent piece is long, if the depth of the hole is shallow, or if the bent piece is short even if the depth of the hole is deep, the bent piece is not sufficiently supported by the hole, and the terminal fitting 8 is likely to swing. However, if the bent piece is too large, the terminal fitting 8 and the hole are increased in size, and as a result, the case 4 and the reactor 1 are increased in size. Accordingly, the length of the bent piece and the depth of the hole are selected in consideration of the positional relationship between the center of gravity of the terminal fitting 8 and the fixing hole, the overall size of the reactor 1 (case 4), and the like.

  The formation position of the latching portion 86 and the formation position of the swing suppression portion 416 can be selected as appropriate. If the latching portion 86 is provided at a position away from the fixing hole 85 of the terminal fitting 8, the swing restraining portion 416 is small as described above, and it is difficult to sufficiently support the terminal fitting 8 only by the end surface of the fastening base portion 415. However, the terminal fitting 8 is easy to stabilize. However, in order to increase the size of the terminal fitting 8, here, the latching portion 86 is provided in the vicinity of the fixing hole 85.

  Further, a plurality of (here, two) protrusions are provided in contact with the outer peripheral surface of the columnar fastening base 415 (FIGS. 3 and 5). These protrusions are referred to as positioning portions 417. The terminal fitting 8 includes a portion (here, a positioning notch 87 and a positioning hole 87h) that engages with the positioning portion 417 at a position corresponding to the positioning portion 417. The shape of the protrusion is a columnar shape here, but it can be appropriately changed such as a prismatic shape. If it is a cylindrical projection, the positioning hole 87h may be a circular hole, and the moldability of the terminal fitting 8 is excellent. When the prismatic protrusion is used, in addition to positioning the terminal fitting 8, it is possible to prevent the terminal fitting 8 from rotating in the horizontal direction. The size of the protrusion (projection length) can be selected as appropriate. If the protruding length is increased as described above, the effect of suppressing the swing of the terminal fitting 8 can be expected, but the size is increased. Accordingly, the protrusion length of the positioning portion 417 (protrusion) is larger than the height at which the head of the bolt 419 protrudes from the surface of the terminal fitting 8 when the bolt 419 is completely tightened as shown in FIG. It is preferable to select the height of the positioning portion 417 (protrusion) protruding from the surface of 8 to be lower.

  The number of protrusions constituting the positioning portion 417 can also be selected as appropriate. Three or more protrusions may be provided. However, if the number is too large, it is necessary to increase the number of positioning holes 87h and the like provided in the terminal fitting 8, which leads to an increase in the size of the terminal fitting 8 and a decrease in moldability. One protrusion may be provided, but a plurality of protrusions are preferable because the positioning accuracy of the terminal fitting 8 can be improved. The formation position of the protrusion can also be selected as appropriate. As shown in this example, when the positioning portion 417 is provided in contact with the fastening base portion 415, the molding die for the side wall portion 41 can be formed in a simple shape, and the productivity is excellent.

  In addition, since the rocking | swiveling suppression part 416 and the latching part 86 of the terminal metal fitting 8 have a positioning function, it is possible to omit the positioning part 417, the positioning hole 87h, and the positioning notch 87. However, by providing the positioning portion 417 and the positioning notch 87 in addition to the swing suppression portion 416 and the latching portion 86, positioning and swing suppression can be performed more reliably. Further, the terminal fitting 8 may be provided with a protrusion (a bent piece or a convex portion provided by press working) and the side wall portion 41 may be provided with a groove or a hole into which the protrusion is fitted. However, when the positioning portion 417 is a protrusion and the terminal fitting 8 is provided with a through hole or a notch as shown in this example, the side wall portion 41 and the terminal fitting 8 are excellent in manufacturability.

  At least a part of the side wall portion 41 is made of a resin, particularly an insulating resin. Specific examples of the resin include polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like. In the present invention, in the side wall portion 41, the winding proximity portion 41a, the fastening base portion 415, the swing suppression portion 416, and the positioning portion 417 are made of an insulating resin. It is preferable that a location close to the coil 2 or the terminal fitting 8 (one flange portion 410 or the like) or a location that may be close is also made of an insulating resin. In this case, insulation between the coil 2 and the side wall 41 can be ensured even if the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 are brought close to each other. Furthermore, when a resin containing a ceramic filler (for example, silicon nitride, alumina, silicon carbide, or the like) is used as a constituent material of the side wall portion 41, heat dissipation and insulation can be improved. Here, the side wall 41 is made of PPS resin.

  The portion of the terminal fitting 8 that engages with the positioning portion 417 (here, a plurality of protrusions) can be all through holes or all cutouts. When all the through holes are formed, the engaging portion can be provided at an arbitrary position of the belt-like material. It should be noted that if a through hole is provided in the inner region away from the periphery of the terminal fitting 8, the manufacturability of the terminal fitting 8 is excellent. If all are notched, the formation position of the engaging portion is limited in the vicinity of the periphery of the belt-like material, but it is easy to fit into the positioning portion 417, and the arrangement workability of the terminal fitting 8 is excellent. Here, the terminal fitting 8 includes both a through hole through which one protrusion is inserted: a positioning hole 87h, and a notch into which the other protrusion is fitted: a positioning notch 87. In particular, here, the joint 81 is formed in one of the two sections forming the positioning notch 87, and the other section is bent to form a bent piece constituting the latching portion 86. With this configuration, it is easy to form a bent piece that becomes the hooking portion 86, and the productivity of the terminal fitting 8 is excellent. Also, with this configuration, the latching portion 86 is provided in the vicinity of the positioning notch 87. That is, since the fixing hole 85, the latching portion 86, and the positioning notch 87 are all provided close to each other, the terminal fitting 8 can be reduced in size.

(Bottom plate)
The bottom plate portion 40 is a plate material fixed in contact with the installation target when the reactor 1 is installed on the installation target (FIG. 3), and is made of metal here. Since the bottom plate portion 40 is a separate member from the side wall portion 41, the material of the bottom plate portion 40 and the material of the side wall portion 41 can be different. Examples of the metal include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron and austenitic stainless steel. Aluminum, magnesium, and their alloys can be made into lightweight cases. The thickness of the bottom plate portion 40 is, for example, about 2 mm to 5 mm in consideration of strength, shielding properties, heat dissipation properties, noise characteristics, and the like. Here, the bottom plate portion 40 is made of an aluminum alloy. Therefore, the thermal conductivity of the bottom plate portion 40 is sufficiently higher than the thermal conductivity of the side wall portion 41.

  The outer shape of the bottom plate portion 40 can be selected as appropriate. Here, the bottom plate portion 40 has a rectangular shape as shown in FIG. 3, and has mounting portions 400 protruding from the four corners. The side wall portion 41 also has an attachment portion 411. When the case 4 is formed by combining the bottom plate portion 40 and the side wall portion 41, the attachment portion 400 and the attachment portion 411 of the side wall portion 41 overlap. Bolt holes 400h and 411h are provided in the attachment portions 400 and 411 so as to communicate with each other. Bolts (not shown) for fixing the case 4 to the installation target are inserted into the bolt holes 400h and 411h. The shape, the number, etc. of the attachment parts 400, 411 can be selected as appropriate. The bolt hole 411h of the side wall portion 41 is constituted by the above-described metal collar. In particular, here, one flange of the metal collar is interposed between the resin constituting the attachment portion 411 in the side wall portion 41 and the attachment portion 400 of the bottom plate portion 40. With this configuration, the tightening force of the bolt (not shown) for fixing the case 4 is substantially received by the metal collar and the metal bottom plate portion 40, so that the resin constituting the other portion of the mounting portion 411 creeps. Difficult to deform.

  Here, an installation state in which the bottom plate portion 40 is downward is shown, but there may be an installation state in which the bottom plate portion 40 is upward or lateral.

  The bottom plate portion 40 includes a bonding layer 42 on one surface thereof (one surface disposed inside when the case 4 is assembled). The coil 2 is fixed to the bottom plate portion 40 by the bonding layer 42.

  The bonding layer 42 is preferably made of an insulating material on at least the side on which the surface on the installation side of the coil 2 is in contact. In addition, if the bonding layer 42 is made of a material having a thermal conductivity of 0.1 W / m · K or more, further 1 W / m · K or more, particularly 2.0 W / m · K or more, the heat dissipation is excellent. preferable.

  For example, the bonding layer 42 may have a multilayer structure including an insulating layer and an adhesive layer. As the insulating layer, for example, a commercially available insulating sheet can be used. By providing adhesive layers on the top and bottom so as to sandwich the insulating sheet, the insulating sheet can be fixed to the bottom plate portion 40. Examples of the material of the adhesive layer include a thermosetting resin such as an epoxy resin, a silicone resin, and an unsaturated polyester, and a thermoplastic insulating resin such as a PPS resin and a liquid crystal polymer (LCP). The insulating layer can also be formed by screen printing the listed resins. Further, if the resin contains the ceramic filler described in the section of the material of the side wall portion 41, the heat dissipation can be improved. An adhesive having excellent heat dissipation, for example, an insulating adhesive such as an epoxy adhesive or an acrylic adhesive may be used as a constituent material of the adhesive layer. The adhesive layer can be formed by using, for example, a commercially available adhesive sheet or screen printing.

  The total thickness of the bonding layer 42 is, for example, less than 2 mm, further 1 mm or less, particularly 0.5 mm or less. As the bonding layer 42 is thinner, heat dissipation can be improved and the size can be reduced. Here, the thickness of the bonding layer 42 is the thickness immediately after formation. After the combination 10 is placed, the thickness of the bonding layer 42 may become thin (for example, about 0.1 mm).

  The shape of the bonding layer 42 is not particularly limited as long as at least the surface on the installation side of the coil 2 has an area that can be sufficiently contacted. Here, as shown in FIG. 3, the bonding layer 42 has a shape along a contour formed by a surface on the installation side of the assembly 10 (here, surfaces on the installation side of both the coil 2 and the outer core portion 32). . Therefore, both the coil 2 and the outer core portion 32 can sufficiently come into contact with the bonding layer 42, and heat dissipation can be improved. Here, the bonding layer 42 includes an insulating layer and an adhesive layer, and each layer is configured by a screen-printed epoxy adhesive.

(Sidewall)
The side wall portion 41 is a frame-like body (here, rectangular shape), and includes the flange portion 410 on the opening side as described above. In addition to the use of the terminal block, by providing the collar 410, (1) improved vibration resistance, (2) improved rigidity of the case 4 (side wall 41), (3) magnetic core 3 (outer core) Various effects such as protection of the part 32) from the external environment and mechanical protection, and (4) prevention of the assembly 10 from falling off can be obtained. Further, here, the other hook part 410 (upper side in FIG. 2) hooks the wiring hooking part 43 for hooking the wiring 71 of the sensor 7 and the connector part 72 provided at the end of the wiring 71. And a connector latch 44. When the sensor 7 is not provided, the wiring hooking portion 43 and the connector hooking portion 44 can be omitted.

  Here, since the entire side wall 41 is made of an insulating resin, the entire coil 3 can be disposed close to the side wall 41. Specifically, the distance between the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall 41 is about 0 mm to 1.0 mm, which is very narrow. Further, by making the entire side wall 41 made of resin, it is easier to manufacture the side wall 41 and the case 4 can be made lighter than a case where a part of the side wall 41 is made of a different material. . If a part of the side wall 41 is made of a metal (particularly a nonmagnetic metal such as aluminum or magnesium), an improvement in heat dissipation and a shielding function can be expected.

  Here, the above-described sensor 7 is a temperature sensor including a thermal element such as a thermistor or a thermocouple. Other sensors include a current sensor having a magnetoelectric conversion element such as a Hall element. A wire 71 is connected to the sensor 7, and a connector portion 72 is provided at the end of the wire 71. Information sensed by the sensor 7 is sent to an external measurement apparatus main body (not shown), and various physical quantities (such as temperature and current) can be measured from the information. A connector portion (not shown) connected to the measuring apparatus main body is connected to the connector portion 72 of the sensor 7. The wiring latching portion 43 is a member for latching the wiring 71 in order to suppress disturbance of the wiring 71. Here, the wiring latching portion 43 includes an L-shaped member that supports the wiring 71 and a claw portion that prevents the wiring 71 from floating from the L-shaped member (FIG. 3). Further, a rod-like body 435 standing from the end face of the wall portion 413 is also used as a wiring latching portion. The connector hooking portion 44 includes a slide rail that hooks a slide groove provided on the outer peripheral surface of the connector portion 72 (FIG. 2). The shape, number, and arrangement position of the wiring latching portion 43 can be selected as appropriate.

(Consolidation method)
Here, the bottom plate portion 40 and the side wall portion 41 are respectively provided with connecting holes 40h and 41h (two here), and are integrated by screwing a connecting bolt 4b into the connecting holes 40h and 41h (FIGS. 2 and 2). 3). An adhesive may be used together with the connecting bolt 4b. Or you may connect the baseplate part 40 and the side wall part 41 only using an adhesive agent.

(Magnetic core)
The magnetic core 3 will be described with reference to FIG. Here, the magnetic core 3 includes core parts 5A and 5B which are integrally molded with the outer peripheral surface of the inner core portion 31 covered with an insulating resin.

  The core parts 5A and 5B are members having the same shape. When one core part 5A is rotated 180 ° in the horizontal direction, the other core part 5B is obtained. Hereinafter, the core component 5A will be described as an example. Constituent elements common to both core parts 5A and 5B are denoted by the same reference numerals.

  As shown in the broken-line circle in FIG. 6, the core component 5A includes a laminated columnar body including a plurality of core pieces 31m and a gap material 31g, and a coating resin that integrally covers the laminated columnar body. In short, the core component 5A includes an inner core portion 31, a cylindrical portion of a conventional insulator (resin constituting a peripheral surface covering portion 51o described later), and a frame plate portion of a conventional insulator (frame plate described later). And the resin constituting the portion 52 are integrally formed. The coating resin has a function similar to that of the conventional insulator and also functions as a binding material for the components of the inner core portion 31.

  The laminated columnar body is a laminated body in which core pieces 31m and gap members 31g are alternately arranged. Here, since the number of core pieces 31m and the number of gap members 31g are the same, one end face of the laminated columnar body is constituted by the gap member 31g and the other end face is constituted by the core piece 31m. The core piece 31m and the gap material 31g can be integrated by an adhesive, an adhesive tape, or the like. Since the core piece 31m and the gap material 31g can be completely integrated by the coating resin, the adhesive or the like can be omitted, or temporary fixing until the coating resin is formed can be achieved. When the core piece 31m and the gap material 31g are joined by an adhesive, it is easy to handle and noise can be easily reduced.

  The core component 5A includes a peripheral surface covering portion 51o that covers the peripheral surface of the inner core portion 31, and a frame plate portion 52 on which the peripheral surface covering portion 51o is projected. Further, the core component 5A includes an engagement cylinder portion 53A that protrudes from one surface of the frame plate portion 52 and is arranged in parallel with the peripheral surface covering portion 51o.

  Most of the peripheral surface covering portion 51o is made of a thin resin, and protrusions are appropriately provided on the surface. The coil element 2b is supported by these protrusions. The tip side portion of the peripheral surface covering portion 51o is formed by a flat surface that is thinner than the other portions and does not have protrusions. This thin flat portion: the engaging portion 517A functions as an insertion portion into the engaging tube portion 53B provided in the other core part 5B. The engagement part 517A of the core part 5A and the engagement cylinder part 53B of the other core part 5B are fitted together, and the engagement cylinder part 53A of the core part 5A and the engagement part 517B of the other core part 5B are fitted together. Both core parts 5A and 5B are connected in an annular shape.

  The frame plate portion 52 includes an end cover portion 51e that covers one end surface 31e of the inner core portion 31 provided with the peripheral surface cover portion 51o. Therefore, the end covering portion 51e is interposed between one end surface 31e (here, the core piece 31m) of the inner core portion 31 of the core component 5A and the inner end surface 32e of the one outer core portion 32, and both surfaces 31e 32e is not in direct contact. That is, the end covering portion 51e is interposed between the inner core portion 31 and the outer core portion 32 and functions as a gap.

  A portion of the frame plate portion 52 where the engagement cylinder portion 53A is connected is provided with a through hole 530 having a size capable of inserting the inner core portion 31 of the other core component 5B. The through hole 530 is a hole (here, a rectangular hole) having a shape corresponding to the outer shape of the engaging portion 517B. Here, in the other core part 5B inserted into the engagement cylinder part 53A of the core part 5A, the other end face 31e of the inner core part 31 is constituted by the gap material 31g. Therefore, the other end of the inner core portion 31 of the other core component 5B is connected to the one outer core portion 32 via the gap material 31g.

  Here, the core component 5A includes a partition 56 between the peripheral surface covering portion 51o and the engaging cylinder portion 53A in the frame plate portion 52. The partition 56 is disposed between the coil elements 2a and 2b of the coil 2 to which the core components 5A and 5B are assembled, and functions as an insulating material between the coil elements 2a and 2b. Further, here, the frame plate portion 52 includes a pedestal 54 on which the coil connecting portion 2r is placed, a positioning protrusion of the outer core portion 32, an inclined portion corresponding to the end surface shape of the coil 2, and the like. If at least one of the pedestal 54, the partition 56, the positioning protrusion, and the inclined portion is omitted, the shape becomes simple and the core part is excellent in manufacturability.

  Examples of the coating resin include thermoplastic resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, LCP, nylon 6, nylon 66, and PBT resin. Here, the coating resin is PPS resin.

  Instead of the core components 5A and 5B, the inner core portion 31 and the insulator (the cylindrical portion and the frame plate portion) may be separate members. For example, the insulator includes a pair of frame plate portions and a pair of cylindrical portions, each having an independent form, or two members in which a part of the cylindrical portion is integrated with one frame plate portion. It can be a form or the like. For example, when the cylindrical part is formed in a form that forms a cylindrical shape by combining two divided pieces having a cross-sectional shape, the cylindrical part is easily arranged on the outer periphery of the inner core part 31. When the inner core portion 31 and the insulator are separate members, it is easy to handle if the constituent members of the inner core portion 31 are integrated with an adhesive or the like.

  The outer core portion 32 is a columnar core piece having a pair of dome-shaped planes whose cross-sectional area decreases outward from the inner end surface 32e. Here, the size of the outer core portion 32 is adjusted so that the installation-side surface (the lower surface in FIG. 6) of the outer core portion 32 is flush with the installation-side surface (the lower surface in FIG. 6) of the coil 2. Yes. The shape of the outer core portion 32 can be changed as appropriate. For example, it can be a rectangular parallelepiped.

  The core pieces constituting the inner core portion 31 and the outer core portion 32 are formed of a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, or a magnetic thin plate having an insulating film (for example, silicon A laminated body in which a plurality of electromagnetic steel sheets represented by steel sheets) are laminated. Examples of the molded body include a compacted body, a sintered body, and a composite material obtained by injection molding or cast molding a mixture including soft magnetic powder and resin. Here, each core piece is a compacted body of soft magnetic metal powder containing iron such as iron or steel.

  The gap material 31g is made of a material having a lower magnetic permeability than the core piece 31m. Specific examples include nonmagnetic materials such as alumina and unsaturated polyester, and mixtures containing nonmagnetic materials such as PPS resin and magnetic powder (for example, soft magnetic powder such as iron powder). Here, the gap material 31g is composed of a mixture containing PPS resin and iron powder (relative magnetic permeability: about 1.15).

  The inner core portion 31 and the outer core portion 32 can have different magnetic characteristics. In order to make the magnetic characteristics different, for example, a form in which the materials used for the core piece 31m and the outer core part 32 of the inner core part 31 are different, the core piece 31m of the inner core part 31 is a composite material, and the outer core part 32 is made different. In the form of powder compacts and laminates, the core pieces have different specifications, all core pieces are composite materials, and the soft magnetic powder material and ratio are between the core piece 31m of the inner core part 31 and the outer core part 32. There are different forms. In general, composite materials tend to contain more resin and less magnetic powder than compacted bodies. Therefore, it can be set as the relative magnetic permeability of the composite material ≦ the relative magnetic permeability of the green compact. The form in which the core piece 31m of the inner core portion 31 is a composite material and the outer core portion 32 is a compacted body is a magnetic core 3 (reactor 1) that is difficult to be magnetically saturated due to the presence of the composite material even when used at a large current. It can be. Moreover, this form is easy to reduce the leakage magnetic flux from the outer core portion 32. Furthermore, this form can reduce the gap material 31g. For example, the gap member 31g may be omitted, or the inner core portion 31 may be formed by one core piece 31m made of a composite material and one gap member 31g bonded to one end side of the core piece 31m.

<Sealing resin>
The case 4 may be filled with the sealing resin 100 (FIG. 1). Sealing resin 100 is intended to fix the position of combination 10 and sensor 7 stored in case 4, mechanical protection of combination 10 and sensor 7 and protection from the external environment (improvement of corrosion resistance), etc. Can do. In this embodiment, when the end of the winding 2w is exposed from the sealing resin 100, it is easy to join the end of the winding 2w and the joint 81 of the terminal fitting 8. Examples of the sealing resin 100 include insulating resins such as an epoxy resin, a urethane resin, and a silicone resin. Furthermore, if the resin contains the ceramic filler described in the section of the material of the side wall portion 41, heat dissipation and insulation can be improved.

  In the form including the sealing resin 100, if a packing (not shown) is provided between the bottom plate portion 40 and the side wall portion 41, uncured resin leaks from the gap between the bottom plate portion 40 and the side wall portion 41. Can be prevented. When the bottom plate portion 40 and the side wall portion 41 are integrated with an adhesive, the adhesive can be sealed between the two to prevent leakage of uncured resin, so that packing can be omitted.

<Lid>
The reactor 1 can be configured to include a lid 9 that covers the opening of the case 4 (FIG. 1). Examples of the constituent material of the lid 9 include the insulating resin described in the section of the material of the side wall portion 41. In the form including the lid 9, mechanical protection of the assembly 10 and protection from the external environment (improvement of corrosion resistance), contact avoidance with external parts, insulation, etc. can be achieved.

  Here, the lid 9 is made of an insulating resin. The lid 9 is integrally provided with a terminal cover 90 that covers an upper portion of a joint portion (the vicinity of the bolt 419) between the fastening base 415 and the terminal fitting 8. The lid 9 includes an annular fastener 9C so as to be firmly held by the case 4. An engaging claw 41C is provided on the outer peripheral surface of the side wall 41 of the case 4. A so-called snap-fit structure is constructed by the annular fastener 9C and the engaging claw 41C, and the case 4 and the lid 9 are firmly fixed to each other.

  The lid 9 may be omitted. When the lid 9 is omitted, a plate-like terminal fixing member made of an insulating material is provided, and the joint between the fastening base 415 and the terminal fitting 8 is covered. It is preferable to ensure insulation.

<Reactor manufacturing method>
The reactor 1 can be basically manufactured by the process described in Patent Document 1. Specific steps include production of the combined body 10, housing of the combined body 10 in the case 4, joining of the terminal fitting 8 and the winding 2w, and filling of the sealing resin 100.

(Production of union 10)
The core components 5A and 5B and the outer core portion 32 are produced (FIG. 6). The core components 5A and 5B can be manufactured by insert molding using a laminated columnar body as a core. The core parts 5A and 5B and the coil 2 are assembled, and the outer core portion 32 is further assembled to form the magnetic core 3 that forms an annular closed magnetic path. Moreover, the combined body 10 is formed by this process.

  A bottom plate portion 40 formed in a predetermined shape is prepared (FIG. 3). A bonding layer 42 having a predetermined shape is formed on one surface of the bottom plate portion 40. The assembled assembly 10 is placed on the bonding layer 42, and then the bonding layer 42 is appropriately cured to fix the combination 10 to the bottom plate portion 40. Since the formation of the bonding layer 42 and the arrangement of the combined body 10 can be performed with the side wall 41 removed, the workability is excellent.

  A side wall portion 41 and a terminal fitting 8 formed in a predetermined shape are prepared (FIG. 3). Here, the side wall portion 41 can be manufactured by partially performing insert molding using a metal collar as a core. The terminal fitting 8 is disposed on the end face of the fastening base part 415 of the side wall part 41. At this time, the positioning holes 87h and the positioning notches 87 of the terminal fitting 8 are fitted into the protrusions constituting the positioning portion 417, and the bent pieces constituting the latching portion 86 are inserted into the swing suppression portion 416 (FIG. 5). Such). By doing so, the terminal fitting 8 is positioned on the side wall 41 so that the bolt hole of the fastening base 415 and the fixing hole 85 of the terminal fitting 8 communicate with each other. Can maintain an independent state. Therefore, when the bolt 419 is inserted into the bolt hole and the fixing hole 85 and tightened, the terminal fitting 8 can be prevented from swinging or rotating in the horizontal direction. Therefore, the bolt 419 can be tightened without separately supporting the terminal fitting 8. By this process, the side wall portion 41 including the terminal fitting 8 can be formed.

(Storage in case)
The side wall portion 41 is placed on the bottom plate portion 40 by covering the side wall portion 41 from above the combination body 10 so as to surround the outer peripheral surface of the combination body 10. Here, the side wall portion 41 can be disposed on the bottom plate portion 40 so that the U-shaped joint portion 81 of the terminal fitting 8 is fitted into the end portion of the winding 2w (FIG. 4 and the like). That is, the end portion of the winding 2w and the U-shaped joint portion 81 can be used for the guide and the positioning of the side wall portion 41 with respect to the bottom plate portion 40. Here, the U-shaped joining portion 81 includes a guide portion extending from the joining portion 81 on the insertion side (the lower side in FIGS. 3 and 4) of the winding 2w. The invitation part is composed of an inclined piece 810 extending obliquely from one surface of the U-shaped portion, and a parallel piece 812 extending straight from the opposite other surface of the U-shaped portion and arranged in parallel to the end of the winding 2w. Composed. As shown in FIG. 4, the inclined piece 810 is provided so that the distance between the two pieces 810 and 812 increases toward the lower side. Therefore, the interval between the two pieces 810 and 812 is wider than the interval between the U-shaped portions (the thickness of the winding 2w + the likelihood). That is, the distance between the two pieces 810 and 812 is sufficiently wider than the thickness of the winding 2w. Therefore, when the side wall 41 is covered from above the combined body 10, the end of the winding 2w hits the inclined piece 810 and can be inserted into the U-shaped portion along the parallel piece 812, and the end of the winding 2w is inserted. Excellent in properties.

  Here, a linear groove into which the frame plate portion 52 is fitted is provided on the inner surface of the side wall portion 41 (see FIG. 3). This linear groove also functions as a guide and a positioning portion of the combined body 10 with respect to the side wall portion 41. Further, here, the side wall portion 41 includes a protrusion (not shown) protruding from the surface (lower surface) of the mounting portion 411 on the bottom plate portion 40 side, and the bottom plate portion 40 includes a through hole into which the protrusion is fitted ( Figure 3. Two here). These protrusions and through holes also function as positioning portions of the side wall portion 41 with respect to the bottom plate portion 40. These positioning portions may be omitted.

  Next, the connecting bolt 4b is inserted into the connecting hole 40h of the bottom plate portion 40 and the connecting hole 41h of the side wall portion 41 and tightened, so that both portions 40 and 41 are integrated. By this process, the case 4 is assembled, and the combined body 10 is stored in the case 4.

(Junction of terminal fittings)
The U-shaped connecting portion 81 of the terminal fitting 8 and the end of the winding 2w are joined. By this step, the reactor 1 that does not include the sealing resin can be manufactured. When the reactor 1 includes the sensor 7, the sensor 7 is disposed at an appropriate position (here, between the coil elements 2a and 2b). Further, the wiring 71 and the connector part 72 are attached to the wiring hooking part 43 and the connector hooking part 44.

(Filling with sealing resin)
The reactor 1 including the sealing resin 100 can be manufactured by filling the case 4 with the sealing resin and curing it. In this embodiment, it is preferable that the terminal fitting 8 be bonded first because the sealing resin 100 is hardly damaged or deformed by heat such as solder.

  After the terminal fitting 100 is joined or after the sealing resin 100 is filled, the reactor 9 including the lid 9 can be manufactured by covering the lid 9 further.

<Application>
The reactor 1 described above is used in applications where the energization conditions are, for example, maximum current (DC): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically an electric vehicle or a hybrid It can be suitably used for a component part of an in-vehicle power converter such as an automobile.

<Effect>
When the reactor 1 is fixed to the side wall portion 41 with the bolts 419, the reactor 1 is disposed on the fastening base 415. Can be effectively suppressed. In particular, in the reactor 1 of this example, the fastening base portion 415 is smaller than the terminal fitting 8 and is easy to swing. However, the swinging can be suppressed as described above, and the terminal fitting 8 can be sufficiently independent. . Further, the reactor 1 can accurately position the terminal fitting 8 by the positioning portion 417. From these points, the reactor 1 is easy to perform the tightening operation of the bolt 419 when fixing the terminal fitting 8 (formation of the terminal block), and thus excellent in assembling workability.

[Modification 1]
In the first embodiment described above, a configuration has been described in which the hooking portion 86 is a bent piece and the swing suppressing portion 416 is a hole into which the bent piece is inserted. As another form, the above-mentioned hole is not provided in the end face of the wall part 413, but it protrudes from the inner surface of the wall part 413 into the internal space of the case 4 so that the bent piece can be locked (for example, a C-shaped member, or There is an embodiment in which an L-shaped member) is provided, and this locking member is used as a swing suppressing portion. In this embodiment, the bent piece: the hooking portion 86 is inserted into a gap formed between the C-shaped or L-shaped member and the inner surface of the wall portion 413. When the L-shaped member is used as the swing suppressing portion, even if it is a wide bent piece, a part of the bent piece is pressed by the section of the L-shaped member, so that the degree of freedom of the size of the bent piece can be increased. On the other hand, when the above-described hole or C-shaped member is used as the swing suppressing portion, the bent piece can be held more reliably by matching the size of the bent piece with the size of the above-described hole or C-shaped member.

[Modification 2]
In the first embodiment described above, a configuration has been described in which the hooking portion 86 is a bent piece and the swing suppressing portion 416 is a hole into which the bent piece is inserted. As another form, there is a form in which the terminal fitting 8 does not have a bent piece, the side wall 41 does not have the hole, and has a holding piece that presses a part of the vicinity of the periphery of the belt-like material from above. It is done. In this form, a part near the periphery of the belt-like material serves as a latching portion, and the presser piece serves as a swing suppressing portion. The pressing piece is, for example, a Γ-shaped strip, provided so as to protrude from the end surface of the wall portion 413, and further provided so that the upper piece of the Γ shape is parallel to the end surface of the wall portion 413. And a part of one peripheral part in the width direction of a strip | belt-shaped material is inserted in a Γ-shaped strip | belt piece. At this time, the belt-like material is inserted obliquely so that the one peripheral portion in the width direction of the belt-like material is low and the other peripheral portion is high, and the other peripheral portion is in a floating state. After inserting the belt-like material as described above, the other peripheral portion is lowered to the fastening base portion side, and the positioning hole of the belt-like material is inserted into the positioning portion (projection). In this way, the upper Γ-shaped piece (protruding portion) is arranged so as to cover a part near one peripheral edge in the width direction of the belt-like material from above. This Γ-shaped projecting portion can suppress part of the floating in the vicinity of the peripheral edge. Therefore, this form can also prevent the terminal fitting from swinging when the bolt is tightened. However, the combination of the bent piece and the hole in the first embodiment is the same as the operation of inserting the positioning hole 87h into the positioning portion 417 (projection) or the operation of fitting the positioning notch 87, and bends into the swing suppression portion 416 (hole). You can insert a piece. Therefore, the first embodiment is more excellent in the workability of arranging the terminal fitting 8.

[Embodiment 2]
The reactor according to the first embodiment and the first and second modifications can be used, for example, as a component part of a converter mounted on a vehicle or the like, or a component part of a power conversion device including the converter.

  For example, a vehicle 1200 such as a hybrid car or an electric car is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. Motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 includes an engine in addition to the motor 1220. In FIG. 7, although an inlet is shown as a charging point of the vehicle 1200, a form including a plug may be adopted.

  The power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current. Converter 1110 shown in this example boosts the DC voltage (input voltage) of main battery 1210 of about 200 V to 300 V to about 400 V to 700 V and feeds power to inverter 1120 when vehicle 1200 is traveling. In addition, converter 1110 steps down DC voltage (input voltage) output from motor 1220 via inverter 1120 to DC voltage suitable for main battery 1210 during regeneration, and causes main battery 1210 to be charged. The inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current when the vehicle 1200 is running and supplies power to the motor 1220. During regeneration, the alternating current output from the motor 1220 is converted into direct current and output to the converter 1110. doing.

  As shown in FIG. 8, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation) (In this case, step-up / down). For the switching element 1111, a power device such as FET or IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that tends to prevent the change of the current to flow through the circuit. The reactor L includes the reactors of the first embodiment and the first and second modifications. By providing the reactor 1 having excellent assembly workability, the power conversion device 1100 and the converter 1110 also have excellent assembly workability.

  Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting high voltage to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some converters 1150 for power feeding devices perform DC-DC conversion. The reactor of the power supply device converter 1150 and the auxiliary power supply converter 1160 has the same configuration as the reactor of the first embodiment and the first and second modifications, and uses a reactor whose size and shape are appropriately changed. Can do. Further, the reactor according to the first embodiment, the first and second modifications, and the like can be used for a converter that performs conversion of input power, that is, a converter that performs only step-up or a converter that performs only step-down.

  Note that the present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the gist of the present invention. For example, the configuration of the present invention can be applied to a reactor having only one coil element.

  The reactor of the present invention is an in-vehicle converter (typically a DC-DC converter) mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, or a fuel cell vehicle, or a power converter such as an air conditioner converter. It can utilize suitably for a component.

1 Reactor 10 Combination 100 Sealing resin
2 coils
2a, 2b Coil element 2r Coil connection part 2w Winding
3 Magnetic core
31 Inner core 31e End face 31m Core piece 31g Gap material
32 Outer core part 32e Inner end face
4 cases
40 Bottom plate part 41 Side wall part 42 Bonding layer
40h, 41h Connection hole 4b Connection bolt 41C Engagement claw 41a Winding proximity
400,411 Mounting part 400h, 411h Bolt hole
410 ridge part 413 wall part 415 tightening base part 416 swing restraint part
417 Positioning part 419 Bolt
43 Wiring latch 435 Rod 44 Connector latch
5A, 5B core parts
51o Peripheral cover 51e End cover 517A, 517B Engagement 52 Frame plate
53A, 53B Engagement cylinder part 54 Base 56 Partition 530 Through hole
7 Sensor 71 Wiring 72 Connector
8 Terminal bracket
81 Joint 810 Inclined piece 812 Parallel piece 85 Fixing hole 86 Hook
87 Positioning notch 87h Positioning hole
9 Lid
90 Terminal cover 9C Annular fastener
1100 Power converter 1110 Converter 1111 Switching element
1112 Drive circuit L Reactor 1120 Inverter
1150 Power supply converter 1160 Auxiliary power converter
1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery
1240 Auxiliary 1250 Wheel

Claims (7)

A coil formed by winding a winding; a magnetic core in which the coil is disposed; a case that houses a combination of the coil and the magnetic core; and a terminal fitting to which an end of the winding is connected. A reactor that has
The case includes a bottom plate portion on which the combination is placed, and a side wall that surrounds the combination.
At least a part of the side wall portion is made of an insulating resin;
The side wall portion is
A fastening base portion for fixing a part of the terminal fitting by a fastening member;
A swing suppressing portion that restricts swinging of the terminal fitting when tightening the fastening member;
A positioning part for positioning the terminal fitting with respect to the fastening base part;
The fastening base part, the swing suppression part, and the positioning part are integrally formed on the side wall part by the insulating resin,
The terminal fitting is
Formed from a strip of material,
A reactor that is formed from a part of the belt-like material and includes a latching portion that is latched by the swing suppression portion. The hooking portion is a bent piece formed by bending a part of the belt-like material,
2. The reactor according to claim 1, wherein the swing suppressing portion is a hole into which the bent piece is inserted. The positioning portion is at least one protrusion;
The terminal fitting has a positioning notch into which the at least one protrusion is fitted;
3. The reactor according to claim 2, wherein at least one section that forms the positioning notch in the strip is bent to form the bent piece. The side wall portion includes a collar portion that covers a portion disposed on the opening side of the case in the assembly,
The fastening base part is provided so as to protrude from the flange part, and the width of the end surface of the fastening base part is smaller than the width in the vicinity of the contact area with the fastening base part in the strip-shaped material. The reactor according to any one of the above items. The end of the winding is drawn along the winding direction of the winding,
In the inner surface of the side wall portion, the winding proximity portion arranged in the vicinity of the end portion of the winding is composed of the insulating resin,
The reactor according to any one of claims 1 to 4, wherein a shortest distance between the winding adjacent portion and an end of the winding is 2.0 mm or less.   A converter comprising the reactor according to any one of claims 1 to 5.   A power converter comprising the converter according to claim 6.

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