JP2014067758A - Reactor, converter, and power converter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a compact reactor when compared with a conventional one.SOLUTION: A reactor 1 includes a combination 10 of a coil 2 formed by connecting a pair of coil elements 2a, 2b each consisting of a winding 2w, and a magnetic core 3. The magnetic core 3 has a pair of inner cores 31 arranged in these coil elements 2a, 2b, respectively, and a pair of outer cores 32 forming a closed magnetic path by coupling these inner cores 31. The upper surface 32u of the outer core 32 is located below the upper surface 31u of the inner core 31.

Description

  The present invention relates to a reactor used as a component of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, a converter including a reactor, and a power conversion device including a converter. In particular, it relates to a reactor having a low height.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. As the reactor, for example, there is one shown in Patent Document 1. The reactor of patent document 1 is provided with the combined body which has a coil which has a pair of coil element, and a magnetic core by which this coil is arrange | positioned. The magnetic core has a pair of inner core portions arranged in each coil element, and a pair of outer core portions that connect the inner core portions. Here, the position of the upper surface of the outer core portion is higher than the position of the upper surface of the inner core portion, and the width of the outer core portion is equal to the width of the coil (FIGS. 3 to 5 of Patent Document 1). And the connection end part to which the terminal of a coil is connected is pulled out above the reactor from the turn formation part of a coil.

JP 2011-119664 A

  Other devices and parts are often arranged around the reactor, particularly on the side opposite to the installation side (usually upward), and it is necessary to secure a space for the arrangement. However, since the connection end portion of the coil is pulled out to the upper side of the reactor, it may be difficult to secure a space for arrangement due to an increase in the height of the reactor. In addition, a part of a coil winding, a terminal, a terminal block, and the like may be provided on the upper surface of the outer core portion. If the outer core portion is high, it may be difficult to secure a space for arranging them.

  The present invention has been made in view of the above circumstances, and one of its purposes is a part of a coil winding or a terminal on the side opposite to the installation target of the outer core portion compared to a conventional reactor, The object is to provide a reactor capable of securing a space for installing a terminal block or the like. Another object of the present invention is to provide a reactor that can reduce the height of at least a part of the reactor as compared with a conventional reactor.

  The other object of this invention is to provide a converter provided with the said reactor, and a power converter device provided with this converter.

  The reactor of the present invention includes a combination of a coil and a magnetic core formed by connecting a pair of coil elements wound with windings. A magnetic core has an inner core part arrange | positioned in a coil element, and an outer core part which connects an inner core part and forms a closed magnetic circuit. When this union is installed on an installation target, the installation target side of the union and each component of the union is the installation side, and the opposite side is the opposing side. In that case, the surface on the opposite side of the outer core portion is positioned on the installation side with respect to the surface on the opposite side of the inner core portion. Here, the phrase “the inner core part is disposed in the coil element” includes the case where a part of the inner core part is exposed from the coil element.

  According to said structure, the said opposing surface of an outer core part is located in the said installation side rather than the said opposing surface of an inner core part, and it is a coil on the said opposing surface of an outer core part. It is possible to easily secure an installation space for a part of the windings, terminals, terminal blocks, and the like. Therefore, the reactor can be reduced in size.

  As one form of the reactor of this invention, the difference of the position of the said opposing surface of an inner core part and the position of the said opposing surface of an outer core part shall be 15% or less of the height of an inner core part. Can be mentioned.

  According to said structure, the magnetic path area in the junction location of an outer core part and an inner core part is securable by making the said difference 15% or less of the height of an inner core part.

  As one form of the reactor of this invention, it is mentioned that the difference of the position of the said opposing surface of an inner core part and the position of the said opposing surface of an outer core part shall be 0.5 mm or more.

  According to said structure, it can be made easy to ensure the arrangement | positioning space of the coil | winding edge part of a coil, or a wiring member because the said difference shall be 0.5 mm or more.

  As one form of the reactor of the present invention, each of the coil elements is a turn forming portion formed by winding a winding, and from one end side of the turn forming portion, the surface on the opposite side of the outer core portion and the above of the turn forming portion. It is possible to provide a connection end portion that is used as a connection portion of the terminal fitting by pulling out the end portion of the winding between the opposite surface.

  According to said structure, the height by the side of a terminal metal fitting can be made low at least. The surface on the opposite side of the outer core portion is positioned on the installation side with respect to the surface on the opposite side of the inner core portion, and the surface on the opposite side of the outer core portion and the surface on the opposite side of the turn forming portion This is because it is possible to secure a space for pulling out the connection end portion between them, and there is no need to project the connection end portion of the coil on the opposite side of the turn forming portion as in the prior art.

  As one form of the reactor of this invention, when a coil element is provided with a turn formation part and a connection end part, providing a terminal metal fitting further connected to a connection end part is mentioned. In that case, it is preferable that the terminal fitting, the connecting end, and the terminal connecting portion formed by connecting the terminal fitting and the connecting end are positioned on the installation side with respect to the surface on the opposite side of the turn forming portion.

  According to said structure, a terminal metal fitting, a connection end part, and a terminal connection part are all located in the installation side rather than the surface of the said opposing side of a turn formation part, The height of a reactor is made into the height of a turn formation part. It can be made lower than the surface on the opposite side.

  As one form of the reactor of this invention, when a coil element is provided with a turn formation part and a connection end part, it is mentioned that the turn formation part of a coil element is comprised by winding the wire which consists of a rectangular wire edgewise. It is done. On the other hand, the connecting end portion of the coil element is drawn out by flat-bending the flat wire so that the width direction of the flat wire is parallel to the horizontal direction of the coil element while being along the axial direction of the coil.

  According to the above configuration, the turn forming portion is edgewise wound, and the connection end portion is flatwise bent as described above, so that the connection end portion is opposed to the surface on the opposite side of the outer core portion and the turn formation portion. It is easy to arrange between the opposing surfaces. In addition, it is easy to secure an arrangement space for terminal fittings connected to the connection end portions between these surfaces. Therefore, even if the terminal fitting is connected to the connection end, the terminal fitting and the terminal connection portion formed by connecting the connection end and the terminal fitting are also opposed to the surface on the opposite side of the outer core portion and the turn forming portion. It can arrange | position between side surfaces and can make the height of a reactor low.

  As one form of the reactor of this invention, when a coil element is provided with a turn formation part and a connection end part, it is mentioned that a coil element winds each two independent windings. In this case, the coil element extends from the other end side of the turn forming portion between the opposing surface of the outer core portion and the opposing surface of the turn forming portion by pulling the end of the coil between the coil elements. A connection end portion as a connection location and a coil connection member for connecting the connection end portions to each other are provided. And a coil connection member and a connection end part are located in the said installation side rather than the surface of the said opposing side of a turn formation part.

  According to said structure, in order to position a coil connection member and a connection end part in the said installation side rather than the said opposing side surface of a turn formation part, not only the terminal metal fitting side of a reactor but the other side also makes the height of a reactor low. it can.

  As one form of the reactor of this invention, when a coil element is provided with a turn formation part and a connection end part, it is further provided with the fixing member which fixes an assembly to an installation object by pressing an outer core part to the above-mentioned installation side. Is mentioned. In that case, it is preferable that the pressing part which presses the said opposing surface of an outer core part is located in the said installation side rather than the said opposing surface of a turn formation part among fixed members.

  According to said structure, a reactor can be fixed to installation object by providing a fixing member. And since the said pressing part is located in the said installation side rather than the said opposing surface of a turn formation part, since it does not protrude from the said opposing surface of a turn formation part, the height of a reactor can be made low.

  As one form of the reactor of this invention, providing the outer side resin part which covers further at least one part of the outer periphery of an assembly is mentioned.

  According to the above configuration, in addition to mechanical protection and protection from the external environment (improvement of corrosion resistance), it is possible to improve heat dissipation, further reduce noise, further reduce vibration, and the like.

  As one form of the reactor of this invention, providing a converter case which accommodates an assembly further is mentioned.

  According to said structure, by storing an assembly in a converter case, the assembly can be united with members other than an assembly, for example, a circuit board provided with a semiconductor element, etc., and it is easy to handle and assembly workability Excellent.

  The reactor of this invention can be utilized suitably for the component of a converter. The converter of this invention is provided with the reactor of the said invention.

  The converter of this invention can achieve size reduction by providing the reactor of this invention.

  The converter of this invention can be utilized suitably for the component of a power converter device. The power converter device of this invention is provided with the converter of the said invention.

  The power converter of the present invention including the converter of the present invention can also be reduced in size.

  The reactor of the present invention can be reduced in size as compared with a conventional reactor.

  The converter of this invention and the power converter device of this invention can achieve size reduction compared with those of the past.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is (II)-(II) sectional drawing of the reactor shown in FIG. It is a disassembled perspective view which shows the outline of the reactor of Embodiment 1. FIG. 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.

  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
[Reactor]
The reactor 1 of Embodiment 1 is demonstrated with reference to FIGS. Here, the installation target side of the reactor 1 is the installation side (lower side), and the opposite side is the opposite side (upper side). The reactor 1 includes a combination 10 of a coil 2 having a pair of coil elements 2 a and 2 b and a magnetic core 3. The coil elements 2a and 2b are composed of a turn forming portion 2t, a connecting end portion 2c, and a connecting end portion 2j (FIG. 3). The magnetic core 3 has a pair of inner core portions 31 disposed in the coil elements 2a and 2b, and a pair of outer core portions 32 that connect the inner core portions 31 to form a closed magnetic path (FIG. 3). . The main feature of the reactor 1 is that the upper surface 32u of the outer core portion 32 is positioned below the upper surface 31u of the inner core portion 31 when the assembly 10 is installed on the installation target. Hereinafter, the characteristic part of the reactor 1 and the structure of the related part and the main effects will be described in order, and then each structure will be described in detail. In the description, the vertical direction of the reactor 1 will be described as the height, and the horizontal direction of the coil elements 2a and 2b will be described as the width.

[Composition of features and related parts]
(Magnetic core)
In the magnetic core 3, both outer core portions 32 are disposed so as to sandwich a pair of spaced apart inner core portions 31, and the end surface 31 e of each inner core portion 31 and the inner end surface 32 e of the outer core portion 32 are brought into contact with each other. To form an annular shape. The inner core portion 31 and the outer core portion 32 form a closed magnetic circuit when the coil 2 is excited. Here, each inner core portion 31 is a columnar body (here, a shape obtained by rounding the corners of a rectangular parallelepiped) having an outer shape along the inner peripheral shape of each coil element 2a, 2b, and each outer core portion 32. Are prismatic bodies. For example, in a reactor mounted on an automobile, the inner core portion 31 has a height of 20 mm to 40 mm. However, it may be smaller than 20 mm or larger than 40 mm depending on the use of the reactor and required performance.

  In the magnetic core 3, as shown in FIG. 2, the upper surface 32 u of the outer core portion 32 is located closer to the installation target than the upper surface 31 u of the inner core portion 31. That is, the height position of the upper surface 32 u of the outer core portion 32 is set lower than the upper surface 31 u of the inner core portion 31. Then, between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t, the connection end 2c and the connection end 2j of the coil 2, the terminal fitting 4 connected to the connection end 2c and the connection It is easy to secure a space for installing a coil coupling member 2r (both described later) connected to the end 2j.

  The larger the difference t between the position of the upper surface 32 u of the outer core part 32 and the position of the upper surface 31 u of the inner core part 31, the easier it is to secure the arrangement space, and the smaller the smaller the difference t is, the junction point between the outer core part 32 and the inner core part 31. It is easy to secure the magnetic path area at. The difference t is preferably 15% or less of the height of the inner core portion 31. If it does so, a magnetic path area can be ensured and leakage magnetic flux can be decreased. The difference t is preferably 10% or less of the height of the inner core portion 31 and particularly preferably 5% or less. Then, the leakage magnetic flux can be further reduced. The difference t is preferably 2.5% or more of the height of the inner core portion 31. Then, it is easy to secure the arrangement space.

  The difference t is preferably 0.5 mm or more. Then, depending on the size of the winding 2w of the coil 2 (for example, the diameter in the case of a round wire, the width and thickness in the case of a flat wire), the size of the terminal fitting 4 (described later), etc. Easy to secure space. The difference t is preferably 1 mm or more, more preferably 2 mm or more, and particularly preferably 3 mm or more. If so, a larger amount of the above-described arrangement space can be secured. The difference t is preferably 6 mm or less. Then, the magnetic path area can be secured.

  The width of the outer core portion 32, that is, the distance in the direction in which the coil elements 2 a and 2 b in the outer core portion 32 are arranged in parallel can be made equal to the width of the coil 2. In the present invention, as described above, the height of the upper surface 32 u of the outer core portion 32 is set lower than the position of the upper surface 31 u of the inner core portion 31. Thereby, even if the width of the outer core portion 32 and the width of the coil 2 are equal, the connection end portion 2c and the connection of the coil 2 are connected between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t. A space for arranging (drawing out) the end 2j can be secured. This is because the height of the reactor 1 can be lowered without increasing the width of the reactor 1. As described above, in the case of a conventional reactor, when the width of the outer core portion is made equal to the width of the coil, if the connection end portion of the coil is to be pulled out, it is pulled out from above the turn forming portion or the combined body is flat. It is necessary to draw outside the outline of the combination when viewed (outside in the width direction of the combination). However, in the former case, since the position of the upper surface of the outer core portion is not lower than the position of the upper surface of the inner core portion, there is no space for arranging the connection end portion between the upper surface of the outer core portion and the upper surface of the turn forming portion. . Therefore, it is necessary to pull out the connection end portion above the upper surface of the turn forming portion, and the height of the reactor is increased. On the other hand, in the latter case, the width of the reactor is increased.

(coil)
The coil 2 is a pair of coil elements 2a and 2b formed by spirally winding two independent windings 2w, and the coil elements 2a and 2b are independent members, and the coils 2a and 2b are connected to each other. And a coil connecting member 2r. Here, each coil element 2a, 2b is a hollow cylindrical body having the same number of turns, and is arranged in parallel (side by side) so that the respective axial directions are parallel. The end face shape (FIG. 3) of each coil element 2a, 2b is a shape obtained by rounding the corners of a rectangle, but it can be appropriately changed such as a circular shape. In addition, it has a pair of coil elements formed by spirally winding one continuous winding without a joint part, and a coil connection part that connects both coil elements, and the coil connection part is wound on one end side of the coil. It can also be set as the coil comprised by bending a part of line | wire in U shape. Also in this case, it is preferable that the U-shaped bent portion does not protrude upward from the upper surface of the turn forming portion.

  Each of the coil elements 2a and 2b includes a turn forming portion 2t, a connecting end portion 2c to which the terminal fitting 4 is connected, and a connecting end portion 2j to which the coil connecting member 2r is connected (FIG. 3). The turn forming portion 2t is configured by edgewise winding a winding 2w made of a covered rectangular wire. The connecting end 2c is pulled out from one end side of the turn forming portion 2t, and the connecting end 2j is pulled out from the other end side of the turn forming portion 2t.

  The position where the connecting end 2c is pulled out is preferably between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t. During this time, the uppermost surface of the connection end 2c may be flush with the upper surface 2u of the turn forming portion 2t, or the uppermost surface of the connection end 2c may be lower than the upper surface 2u of the turn forming portion 2t. In the former case, the height of the reactor 1 can be reduced as compared with the conventional case where the connecting end is pulled out above the turn forming portion. In particular, in the latter case, since the terminal fitting 4 is also easily made lower than the upper surface 2u of the turn forming portion 2t, the height of the reactor 1 on the connection end portion 2c side can be further reduced.

  On the other hand, the position where the connecting end 2j is pulled out is preferably between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t, like the connection end 2c. During this time, similarly to the connection end 2c, the uppermost surface of the connection end 2j may be flush with the upper surface 2u of the turn forming portion 2t, and the uppermost surface of the connection end 2j is higher than the upper surface 2u of the turn formation 2t. It may be lowered. In particular, the latter case is preferable because the coil connecting member 2r can be easily made lower than the upper surface 2u of the turn forming portion 2t, so that not only the connection end portion 2c side but also the connection end portion 2j side height can be reduced.

  The connecting end portion 2c and the connecting end portion 2j are pulled out along the axial direction of the coil 2 on the upper surface side of the combined body 10, and the covering flat angle is such that the width direction of the covering flat wire is along the height direction of the reactor 1. A method of bending the wire flatwise may be used, or a method of bending the coated flat wire flatwise so that the width direction of the covered flat wire is parallel to the horizontal direction of the coil elements 2a and 2b. In particular, in the latter case, since the height of the upper surface 32u of the outer core portion 32 is lower than the upper surface 31u of the inner core portion 31 as described above, the connection end portion 2c and the coupling end portion 2j are connected to the upper surface 32u of the outer core portion 32. And the upper surface 2u of the turn forming portion 2t. In addition, since it is easy to secure a space for arranging the terminal fitting 4 and the coil coupling member 2r between these surfaces, the positions of the terminal fitting 4 and the coil coupling member 2r are also lower than the upper surface 2u of the turn forming portion 2t. Easy to do. Here, the method of pulling out the connection end 2c and the connection end 2j is the latter, and the positions of the upper surfaces of the connection end 2c and the connection end 2j are lower than the upper surface 2u of the turn forming portion 2t.

  The coated rectangular wire includes an insulating coating made of an insulating material on the outer periphery of a flat conductor made of a conductive material such as copper, aluminum, or an alloy thereof. The flat wire has an advantage that the space factor is high and it is easy to secure a wide contact area with the terminal fitting 4. Here, the coated rectangular wire is formed by coating a copper conductor with enamel (typically polyamideimide). In addition to the flat angle, the shape of the conductor can be various shapes such as a circular shape, an elliptical shape, and a polygonal cross section.

  The size of the flat wire can be selected as appropriate. For example, the ratio of the width to the thickness of the flat wire (width / thickness) may be small. As described above, since the height of the upper surface 32u of the outer core portion 32 is set lower than the upper surface 31u of the inner core portion 31, the positions of the connection end portion 2c and the connecting end portion 2j are positioned from the upper surface 2u of the turn forming portion 2t. It is because it is easy to make it low. In particular, when the turn forming portion 2t is configured by edgewise winding as described above, and the connection end portion 2c and the coupling end portion 2j are pulled out by flatwise bending as described above, the ratio (width / thickness) is small. Even so, the positions of the connecting end 2c and the connecting end 2j can be made lower than the upper surface 2u of the turn forming portion 2t. Therefore, even if the ratio (width / thickness) is small, the terminal fitting 4 and the coil connecting member 2r can be connected to the connecting end 2c and the connecting end 2j, respectively, at a position lower than the upper surface 2u of the turn forming portion 2t. Specifically, the ratio (width / thickness) can be 6 or less. And the width | variety of a flat wire can be 8 mm or less. Of course, as the ratio (width / thickness) is larger, the positions of the connecting end 2c and the connecting end 2j can be made lower than the upper surface 2u of the turn forming portion 2t, and the upper surface 32u of the outer core portion 32 and the turn It is easy to secure a space for arranging the terminal fitting 4 and the coil coupling member 2r between the upper surface 2u of the forming portion 2t.

  Here, the coil connecting member 2r is formed of a flat bar. The thickness of the coil connecting member 2r is preferably equal to or less than the thickness of the winding 2w. Then, the coil connecting member 2r can be easily disposed between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t, and the upper surface of the coil connecting member 2r is positioned more than the position of the upper surface 2u of the turn forming portion 2t. Can be lowered. Here, the thickness and width of the flat bar are set to be substantially the same as those of the winding 2w. Both ends of the flat bar are connection points connected to the coupling ends 2j of the coil elements 2a and 2b, and are bent into a U shape so as to cover substantially the entire circumference of the outer periphery of the coupling end 2j. It is formed (FIG. 3).

  The position of the uppermost surface of the coil connecting member 2r is preferably flush with the upper surface 2u of the turn forming portion 2t, and particularly preferably lower than the upper surface 2u of the turn forming portion 2t. By doing so, since the uppermost surface of the coil connecting member 2r does not protrude from the upper surface 2u of the turn forming portion 2t, the height of the reactor 1 on the coil connecting portion 2r side can be reduced. Here, the position of the uppermost surface of the coil coupling member 2r (the connection portion with the coupling end 2j) is set lower than the upper surface 2u (FIG. 2). The height of the upper surface 32u of the outer core portion 32 is made lower than the upper surface 31u of the inner core portion 31, and the connecting end portion 2j is pulled out by flatwise bending as described above, thereby forming a turn with the upper surface 32u of the outer core portion 32. This is because an arrangement space for the coil connecting member 2r can be secured between the upper surface 2u of the portion 2t.

  As the material of the coil connecting member 2r, a conductor made of a conductive material such as copper, aluminum, or an alloy thereof, a plated conductor obtained by plating (for example, Sn plating) on these conductors, or the like can be used.

  Various means such as fusing (thermal caulking), welding such as TIG welding, soldering, brazing, and caulking can be used to connect the coupling end portions 2j of the coil elements 2a and 2b and the coil coupling member 2r. In particular, fusing can reduce the thermal influence on the winding 2w as compared with welding or soldering.

(Terminal bracket)
The reactor 1 is connected to each connection end 2c of the coil 2 and includes a terminal fitting 4 that supplies power to the coil 2 from an external device such as a power source.

  Here, the terminal metal fitting 4 is a metal fitting formed by bending a flat metal piece, and includes a coil side connection piece 41 on one end side and a lead side connection piece on the other end side. The coil side connection piece 41 is connected to the connection end 2c of the coil elements 2a and 2b. The lead side connection piece is provided with a through hole 42h. The through hole 42h is fitted with a connecting member such as a bolt for connecting a lead wire connected to an external device such as a power source to the terminal fitting 4. Specifically, as shown in FIG. 2, the shape of the terminal fitting 4 is a stepped vertical cross section, and the flat plate is moved from the connection piece 41 toward the lead side connection piece from the middle to the lower surface side of the reactor 1. It is bent so as to be directed, and further bent so as to be parallel to the lower surface of the reactor 1 on the lead side connection piece side.

  The thickness of the terminal fitting 4 is preferably equal to or less than the thickness of the winding 2w. If it does so, it will be easy to arrange | position the terminal metal fitting 4 between the upper surface 32u of the outer core part 32, and the upper surface 2u of the turn formation part 2t, and make the upper surface of the terminal metal fitting 4 lower than the position of the upper surface 2u of the turn formation part 2t. easy. Here, the thickness of the terminal fitting 4 is substantially the same as that of the winding 2w.

  The position of the uppermost surface of the terminal fitting 4 is preferably flush with the upper surface 2u of the turn forming portion 2t, and particularly preferably lower than the upper surface 2u of the turn forming portion 2t. If it does so, the height of the reactor 1 can be made low. Of course, here, it is set lower than the position of the upper surface 2u of the turn forming portion 2t (FIG. 2). In addition to making the height of the upper surface 32u of the outer core portion 32 lower than that of the upper surface 31u of the inner core portion 31, the connecting end portion 2c is pulled out by flatwise bending as described above. An arrangement space for the terminal fitting 4 can be secured between the upper surface 32u and the upper surface 2u of the turn forming portion 2t. It is because it can arrange.

  The shape of the connection piece 41 can be appropriately selected as long as it can be connected by the connection method with the connection end 2c described above. Here, the shape of the connection piece 41 is U-shaped. With the connection end 2c interposed in the U-shaped space, for example, the connection piece 41 and the connection end are utilized by using the same means as the connection between the coil elements 2a and 2b and the coil coupling member 2r. The part 2c can be connected.

  The constituent material of the terminal fitting 4 includes a conductive material so that electric power can be supplied to the coil 2 from an external device. For example, copper, a copper alloy, aluminum, an aluminum alloy, etc. are mentioned.

  In addition, the shape of the terminal metal fitting 4 is an example, and can be appropriately changed as long as the entire terminal metal fitting 4 has a shape lower than the position of the upper surface 2u of the turn forming portion 2t.

[Operational effects in the characteristic part of the reactor]
According to the reactor 1 having the above configuration, since the height of the upper surface 32u of the outer core portion 32 is lower than the upper surface 31u of the inner core portion 31, the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t In the meantime, it is possible to secure an arrangement space for the connecting end 2c and the connecting end 2j of the coil 2 and the terminal fitting 4 and the coil connecting member 2r connected thereto. Therefore, any of the connection end 2c, the connection end 2j, the terminal fitting 4, and the coil connection member 2r can be disposed between the upper surface 32u of the outer core portion 32 and the upper surface 2u of the turn forming portion 2t. Accordingly, unlike the prior art, it is not necessary to project the connecting end 2c and the connecting end 2j of the coil 2 above the upper surface 2u of the turn forming portion 2t, so that the height of the reactor 1 can be reduced.

[Description of each configuration]
(Magnetic core)
The inner core portion 31 of the magnetic core 3 is a laminate in which a plurality of core pieces 31m made of a soft magnetic material and gap members 31g made of a material having a relative permeability smaller than that of the core piece 31m are alternately laminated. The outer core portion 32 is a core piece made of a magnetic material. For the integration of the core piece 31m and the gap material 31g, it is easy to handle especially when an adhesive is used, and the core piece 31m is made of a material that vibrates due to magnetostriction, and the gap material 31g is made of a material having high rigidity such as alumina. It is expected that the noise associated with the contact / non-contact between the core piece 31m and the gap material 31g can be reduced even in the case where it is configured. In addition, an adhesive tape or the like can be used to integrate the core piece 31m and the gap material 31g. Here, the core piece 31m and the gap material 31g are integrated by an adhesive.

  The core piece constituting the inner core portion 31 and the outer core portion 32 has a molded body using an insulating group and a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, an oxide containing iron, or the like. The laminated body which laminated | stacked multiple magnetic thin plates (For example, the electromagnetic steel plate represented by the silicon steel plate) is mentioned. 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 made of the same composite material. The composite material has a magnetic powder content of 40% by volume to 75% by volume, a saturation magnetic flux density of 0.6T or more, a relative magnetic permeability of 5 to 50, preferably 10 to 30 and more preferably 20 to 30. The following may be mentioned. In this case, since the relative permeability is relatively low, the gap material 31g can be omitted. The relative magnetic permeability of the entire magnetic core (when the gap material is included, the total relative permeability including the gap material) is preferably 5 or more and 50 or less. As described above, all the core pieces constituting the magnetic core 3 are made of the same composite material, but each core piece is compacted with a soft magnetic metal powder containing iron such as iron or steel. It can also be a body.

  Specific materials for the gap material 31g include nonmagnetic materials such as alumina and unsaturated polyester, nonmagnetic materials such as polyphenylene sulfide (PPS) resin, and magnetic materials (examples of magnetic materials include soft magnetic powder such as iron powder). And the like. When the gap material 31g is composed of the above mixture, the relative permeability of the gap material 31g is preferably 1.05 or more and 2 or less. Here, the gap material 31g is composed of a mixture (relative magnetic permeability: about 1.15) containing PPS resin and iron powder.

  Further, the magnetic characteristics can be made different between the inner core portion 31 and the outer core portion 32. For example, (1) all core pieces are made of a composite material, and the core pieces 31m of the inner core portion 31 and the outer core portion 32 have different materials and ratios of magnetic powder, and (2) all the core pieces are pressed. It is a powder molded body, in which the material is different between the core piece 31m of the inner core portion 31 and the outer core portion 32. (3) The core piece 31m of the inner core portion 31 is a composite material, and the outer core portion 32 is a powder molded body. The inner core portion 31 and the outer core portion 32 can have different magnetic characteristics by adopting a form such as a laminated plate body. If the saturation magnetic flux density of the core piece 31m of the inner core portion 31> the saturation magnetic flux density of the outer core portion, the area of the inner core portion 31 through which the magnetic flux passes can be easily reduced, and the reactor can be downsized. If the relative permeability of the core piece 31m of the inner core portion 31 is smaller than the relative permeability of the outer core portion 32, the leakage flux in the outer core portion 32 is reduced because the relative permeability of the outer core portion 32 is relatively high. Easy to do.

  In the form of (1) above, the composite material constituting the core piece 31m of the inner core portion 31 and the outer core portion 32 are both magnetic powder content: 40 vol% or more and 75 vol% or less, saturation magnetic flux density: 0.6 T or more, relative magnetic permeability: 5 or more and 50 or less, preferably 10 or more and 30 or less, more preferably 20 or more and 30 or less, relative permeability of the entire magnetic core (when including a gap material, the entire permeability including the gap material) Specific permeability): those satisfying 5 or more and 50 or less. By adjusting the material and content of the magnetic powder, for example, (a) a form in which the saturation magnetic flux density of the inner core part is high and the relative permeability of the outer core part is low, and (b) the relative permeability of the inner core part. In which the outer core portion has a high relative magnetic permeability and (c) the saturation magnetic flux density and the relative magnetic permeability of both the inner core portion and the outer core portion are the same. The form (a) can reduce the size of the reactor as described above, and the form (b) can easily reduce the leakage magnetic flux in the outer core portion 32. The form (c) is easy to prepare the raw material and is excellent in the productivity of the core piece.

  The shape of the inner core portion 31 is a rectangular parallelepiped, and the shape of the outer core portion 32 is a prismatic shape. The shape of the inner core portion 31 (core piece 31m / gap material 31g) and the shape of the outer core portion 32 are appropriately selected. be able to. As the shape of the outer core portion 32, for example, the upper surface 32 u and the lower surface 32 d can be a dome-shaped columnar body (a deformed trapezoidal shape in which the cross-sectional area decreases outward from the inner end surface 32 e).

  The axial length of the inner core portion 31 may be longer than the axial length of the coil elements 2a and 2b. That is, the end surface of the inner core portion 31 and the vicinity thereof may be exposed by protruding from the end surfaces of the coil elements 2a and 2b.

  The size of the outer core portion 32 is adjusted so that the lower surface 32d of the outer core portion 32 is flush with the lower surface 2d of the coil 2 (FIG. 2). Therefore, when the magnetic core 3 is formed in an annular shape, the lower surface 32 d of the outer core portion 32 protrudes from the lower surface 31 d of the inner core portion 31. Then, when the size of the inner core portion 31 in the reactor 1 of the present invention is the same as the inner core portion in the conventional reactor, the reactor 1 of the present invention has a magnetic core 3 (outer core portion 32) as compared with the conventional reactor. The amount of the constituent material can be reduced, contributing to cost reduction and weight reduction. Further, the lower surface of the combined body 10 is mainly composed of the lower surfaces 32 d of the two outer core portions 32 and the lower surface 2 d of the coil 2.

(Insulator)
It is preferable that the reactor 1 further includes an insulator 5 between the coil 2 and the magnetic core 3 in order to improve both insulation and positioning reliability.

  Here, the insulator 5 is formed by combining each of the coil elements 2a and 2b with a pair of split pieces 50a and 50b that can be split in the axial direction of the coil elements 2a and 2b (FIG. 3). Each of the divided pieces 50a and 50b includes a peripheral wall portion 51 that houses the inner core portion 31, and a frame plate portion 52 that is interposed between the end surface of the coil element 2a (2b) and the inner end surface 32e of the outer core portion 32. Prepare. Here, the frame plate portion 52 and the peripheral wall portion 51 are integrally connected.

  The peripheral wall portion 51 is interposed between the inner peripheral surface of the coil element 2a (2b) and the outer peripheral surface of the inner core portion 31, and insulates the coil element 2a (2b) from the inner core portion 31. The peripheral wall portion 51 is configured by a plurality (four in this case) of plate-like bodies arranged along each surface of the inner core portion 31 so that the corner portion of the inner core portion 31 and its periphery are exposed. . If it does so, for example, in the form provided with outside resin part 7 mentioned below, while being able to increase the contact area of inner core part 31 and outside resin part 7, it is easy to deaerate at the time of filling with outside resin part 7, and it is manufacturability. Excellent. The outer peripheral surface of this plate-like body is formed along the inner peripheral surface of the coil 2.

  The length of the plate-like body along the axial direction of the coil 2 may be selected as long as the insulation between the coil 2 and the inner core portion 31 can be secured when the split pieces 50a and 50b are combined with the coil 2. . Here, when the split pieces 50a and 50b are combined with the coil element 2a (2b), it is mentioned that the length is substantially the entire length in the axial direction of the inner core portion 31, and each of the split pieces 50a and 50b. The length of the plate-like body is approximately half the length of the inner core portion 31 in the axial direction.

  The peripheral wall portion 51 may be configured by a plurality of plate-like bodies disposed at each corner of the inner core portion 31, or a cylindrical body that covers the entire circumference in the circumferential direction of the outer peripheral surface of the inner core portion 31. It may be configured. In the latter case, the outer peripheral surface of the cylindrical body is formed along the inner peripheral surface of the coil 2, and the inner peripheral surface of the cylindrical body is formed substantially along the outer peripheral surface of the inner core portion 31.

  Each frame plate part 52 is interposed between the end face of the coil element 2a (2b) and the end face 31e of the inner core part 31 and the inner end face 32e of the outer core part 32, and the coil element 2a (2b) and the outer core part. It insulates between 32 and functions as a gap between the inner core part 31 and the outer core part 32. Each of the frame plate portions 52 is formed of a rectangular flat plate.

  Examples of the constituent resin of the insulator 5 include thermoplastic resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6, nylon 66, and polybutylene terephthalate (PBT) resin. Here, PPS resin is used.

(Fixing member)
The reactor 1 preferably further includes a fixing member 6 that fixes the combined body 10 to an installation target by pressing the outer core portion 32 toward the installation side.

  Here, the fixing member 6 is a member formed by appropriately bending a thin plate. The fixing member 6 connects a pair of leg portions 6l having a fixing portion 6f fixed to an installation target and both the leg portions 6l, and is placed on the upper surface 32u of the outer core portion 32, so that the outer core portion 32 is mounted. And a pressing portion 6v that presses against the installation target side.

  The fixing portion 6f is configured at a tip end where each leg portion 61 is bent outward, and includes an insertion hole 6h through which a bolt 6b for fixing the fixing member 6 to an installation target is inserted. Bolts 6b are inserted into the insertion holes 6h and screwed to the installation target to fix the combined body 10 to the installation target.

  The pressing portion 6v may be disposed at a position directly below the connection end 2c (the coupling end 2j) on the upper surface 32u of the outer core portion 32, or from the position directly below the connection end 2c (the coupling end 2j). It is good also as a position shifted in the direction of 2 axes. In particular, in the latter case, it is not necessary to secure a space for disposing the pressing portion 6v between the connection end 2c (the connection end 2j) and the outer core portion 32. Therefore, the connection end 2c (the connection end 2j ) In the vicinity of the upper surface 32u side of the outer core portion 32, and it is easy to secure an arrangement space for the terminal fitting 4 and the coil coupling member 2r.

  Furthermore, it is preferable that the fixing member 6 includes a protrusion 6p for limiting the movement (vibration) in the axial direction of the coil 2 as well as pressing the combination 10 against the installation target. Here, a plurality of protrusions 6p are provided on the pressing portion 6v and the leg portion 61 so as to follow the outer end surface 32o of the outer core portion 32.

  Examples of the material of the fixing member 6 include SUS304.

(Outside resin part)
The reactor 1 preferably further includes an outer resin portion 7 that covers at least a part of the outer periphery of the combined body 10. The outer resin part 7 reduces vibration, mechanically protects the assembly 10 and protects from the external environment (improves corrosion resistance), improves heat dissipation, further reduces noise, further reduces vibration, etc. Can be achieved. In addition, the fixing member 6 can be fixed integrally with the combined body 10.

  The covering region of the outer resin portion 7 can be selected as appropriate. For example, the region excluding this lower surface so that the lower surface of the assembly 10 (the lower surface 2d of the coil 2 and the lower surface 32d of the outer core portion 32) is exposed. It is good also as the perimeter of the union 10. In the former case, heat dissipation can be improved by bringing the lower surface of the combined body 10 exposed from the outer resin portion 7 into contact with, for example, a sheet having excellent thermal conductivity. In the latter case, it is easy to reduce the vibration associated with the magnetostriction of the magnetic core 3 and to reduce noise. Here, the entire periphery of the combined body 10 is covered with the outer resin portion 7 except for the through hole 42 h of the terminal fitting 4 and the fixing portion 6 f of the fixing member 6.

  Examples of the constituent resin of the outer resin portion 7 include an insulating resin such as an epoxy resin, a urethane resin, and a silicone resin. Furthermore, when the filler which is excellent in insulation and heat dissipation is contained, heat dissipation (thermal conductivity) and insulation can be improved. When the outer resin portion 7 is provided, it is also possible to adjust the material and the thickness (for example, use a material having elasticity capable of absorbing vibration due to magnetostriction, or a thickness capable of absorbing vibration due to magnetostriction). It is expected that noise can be effectively reduced.

(Case)
The reactor 1 preferably further includes a converter case 8 that houses a combination 100 of the combined body 10, the fixing member 6, and the outer resin portion 7. In this case, the converter case 8 is an installation target of the combined body 10. The converter case 8 accommodates a circuit board (not shown) including a semiconductor element in addition to the combination 10.

  The converter case 8 has a bottomed box shape. The converter case 8 has four protrusions 81 on the bottom surface of which female threads are processed. The protrusion 81 is for fixing the assembly 100 to the converter case 8 by screwing the bolt 6 b of the fixing member 6.

  As the material of the converter case 8, a material excellent in heat dissipation and a material excellent in magnetic shield characteristics can be suitably used. Typical materials include metals such as aluminum and alloys thereof, magnesium and alloys thereof, copper and alloys thereof, silver and alloys thereof, iron and austenitic stainless steel. In particular, aluminum, magnesium, and alloys thereof are lightweight and can be expected to have a shielding function. Aluminum and its alloys are also excellent in heat dissipation.

(Anti-vibration member)
The reactor 1 preferably further includes a vibration isolating member 9 between the assembly 100 and the converter case 8 for mitigating and absorbing the vibration of the reactor 1 (FIGS. 1 and 2).

  The shape (area) of the vibration isolating member 9 is at least the shape (size) along the contour shape formed by the lower surface 32 d of the pair of outer core portions 32 and the lower surface 2 d of the coil 2. It is preferable. If it does so, the vibration of the reactor 1 can be relieve | moderated and absorbed effectively. Here, the shape of the vibration isolating member 9 is a shape along the contour shape of the lower surface of the outer resin portion 7 (FIG. 1).

  As the thickness of the vibration-proof member 9 is thicker, the vibration absorption is better, and as the thickness is thinner, the heat dissipation through the converter case 8 tends to be improved. The specific thickness depends on the constituent material, but is preferably 0.5 mm or more and 2.0 mm or less, for example.

  Examples of the constituent material of the vibration isolation member 9 include materials having excellent vibration absorption, such as rubber. The constituent material of the vibration isolation member 9 is more preferably a material that is excellent in heat dissipation in addition to vibration absorption. Examples of the constituent material include silicone rubber.

(Use)
For example, the reactor 1 has an energization condition of, for example, a maximum current (direct current): about 100 A to 1000 A, an average voltage: about 100 V to about 1000 V, a use frequency: about 5 kHz to about 100 kHz, typically an electric vehicle, a hybrid vehicle, or the like. It can utilize suitably for the component of the vehicle-mounted power converter device.

  According to the reactor 1 described above, the following effects are further achieved.

  (1) Since the peripheral wall portion 51 of the insulator 5 is arranged along each surface of the inner core portion 31 and the corner portion of the inner core portion 31 and its periphery are exposed, the inner core portion 31 and the outer side are exposed. The contact area with the resin portion 7 can be increased, and vibration and noise associated with magnetostriction of the magnetic core 3 can be reduced.

  (2) Since the fixing member 6 that holds the outer core portion 32 is integrated with the combined body 10 by the outer resin portion 7 and is firmly fixed to the converter case 8 by bolting, external impact and vibration This makes it difficult for the assembly 100 to come off the converter case 8.

  (3) Since the bolt 6b is used for fixing the assembly 100 and the converter case 8, it is easy to fix the assembly 100 to the converter case 8. Therefore, the assembly workability is excellent.

  (4) By interposing the vibration isolating member 9 between the assembly 100 and the converter case 8, in addition to being able to relieve and absorb the vibration of the reactor 1, it is difficult to transmit external vibration to the reactor 1.

[Reactor manufacturing method]
The reactor 1 can be manufactured through the steps of integration of the coil 2 and the terminal fitting 4 → assembly of the assembly 10 → production of the outer resin portion 7 (assembly 100) → storage in the converter case 8.

  First, the coil elements 2a and 2b, the coil connecting member 2r and the terminal fitting 4 are prepared, and the coil elements 2a and 2b, the coil connecting member 2r and the terminal fitting 4 are integrally connected. The coil connecting member 2r is fitted to the connecting end 2j of the coil elements 2a and 2b, and the coil connecting member 2r and the coil elements 2a and 2b are integrally connected by the above-described connecting means, for example, fusing, and the coil 2 is connected. Make it. Subsequently, a terminal fitting 4 having a connection piece 41 bent in a U-shape is prepared, the connection piece 41 and the connection end 2c are fitted together, and the connection piece 41 is connected to the connection piece 41 by fusing as described above. The end 2c is integrally connected. Note that either the connection between the connection end 2j and the coil connection member 2r or the connection between the connection end 2c and the terminal fitting 4 may be performed first or simultaneously.

  Next, the combined body 10 is produced by combining the coil 2 and the magnetic core 3. The insulator 5 is fitted to one end side of the inner core portion 31 and inserted into the coil 2. In that case, the inner core part 31 is inserted into each coil element 2a, 2b from the connection end part 2j side of each coil element 2a, 2b. Then, the other insulator 5 is fitted to the other end side of the inner core portion 31, and the inner core portion 31 is sandwiched between the pair of outer core portions 32.

  Next, the outer resin portion 7 is formed on the outer periphery of the combined body 10. The fixing member 6 is placed on the upper surface 32u of the outer core portion 32 and placed in the molding die, and the constituent resin of the outer resin portion 7 is filled and cured in the die to produce the assembly 100. At that time, the outer resin portion 7 is formed so that the fixing portion 6 f of the fixing member 6 is exposed from the outer resin portion 7. Here, it is preferable to fill the resin by vacuum injection molding. If it does so, the outer side resin part 7 with few voids can be formed.

  Next, the assembly 100 is stored in the converter case 8. An anti-vibration member 9 is arranged on the converter case 8, and the assembly 100 is placed on the anti-vibration member 9. Then, the fixing portion 6 f of the fixing member 6 exposed from the outer resin portion 7 is fixed to the protrusion 81 provided on the converter case 8 with the bolt 6 b.

  According to the reactor manufacturing method described above, the following effects can be obtained.

  (1) Since the outer resin portion 7 that covers the combined body 10 is formed not in the converter case 8 but in the molding die, the constituent resin of the outer resin portion 7 is not poured into the converter case 8, so the resin is poured. The weir for molding becomes unnecessary, and the converter case 8 can be downsized. In addition, since heat at the time of forming the outer resin portion 7 is not applied to the converter case 8, deformation of the converter case 8 due to heat can be prevented.

  (2) By forming the outer resin part 7 by vacuum injection molding, the outer resin part 7 with less voids can be formed. Therefore, in addition to being hard to generate | occur | produce in the magnetic core 3, the reactor 1 with few vibration and noise accompanying the magnetostriction of the magnetic core 3, etc. can be manufactured.

<< Embodiment 2 >>
The reactor 1 of Embodiment 1 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 this converter.

  For example, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is 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. The motor (load) 1220 is provided. 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, vehicle 1200 includes an engine in addition to motor 1220. In addition, in FIG. 4, although an inlet is shown as a charge location of the vehicle 1200, it is good also as a form provided with a plug.

  Power conversion device 1100 includes converter 1110 connected to main battery 1210 and inverter 1120 connected to 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 200V to 300V to about 400V to 700V and supplies 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 the motor 1220 with electric power. 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. 5, 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 pressure) is performed. 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 prevents the change of the current to flow through the circuit. As the reactor L, the reactor described in the first embodiment is used. By using a reactor having a low height, the power converter 1100 (including the converter 1110) can be downsized.

  Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary machinery 1240, and main battery 1210. Auxiliary power supply 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 power supply device converters 1150 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 above-described embodiment, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactor of the first embodiment can be used for a converter that performs conversion of input power and that only performs step-up or a step-down operation.

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

  The reactor of the present invention is a configuration of a power conversion device such as an in-vehicle converter (typically a DC-DC converter) or an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, or a fuel cell vehicle. Available for parts.

DESCRIPTION OF SYMBOLS 1 Reactor 10 Combination 100 Assembly 2 Coil 2t Turn formation part 2u Upper surface 2d Lower surface 2c Connection end part 2j Connection end part 2a, 2b Coil element 2r Coil connection member 2w Winding 3 Magnetic core 31 Inner core part 31m Core piece 31g Gap Material 31e End surface 31u Upper surface 31d Lower surface 32 Outer core portion 32e Inner end surface 32o Outer end surface 32u Upper surface 32d Lower surface 4 Terminal fitting 41 Connection piece 42h Through-hole 5 Insulator 50a, 50b Dividing piece 51 Peripheral wall portion 52 Frame plate portion 6 Fixing member 6l Leg portion 6f Fixing part 6h Insertion hole 6v Pressing part 6p Protrusion 6b Bolt 7 Outer resin part 8 Converter case 81 Protrusion 9 Vibration isolator 1100 Power converter 1110 Converter 1111 Switching element 1112 Drive circuit L Reactor 1120 Inverter 1150 Supply Converter for electric device 1160 Converter for auxiliary power supply 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery 1240 Auxiliary equipment 1250 Wheel

Claims (12)

A reactor comprising a combination of a coil and a magnetic core formed by connecting a pair of coil elements wound with windings,
The magnetic core has an inner core portion disposed in the coil element, and an outer core portion that connects the inner core portions to form a closed magnetic path,
When the union is installed on the installation target, when the installation target side of each component of the union and the union is the installation side, and the opposite side is the opposite side,
A reactor in which a surface on the opposite side of the outer core portion is located closer to the installation side than a surface on the opposite side of the inner core portion.   2. The reactor according to claim 1, wherein a difference between a position of an opposing surface of the inner core portion and a position of an opposing surface of the outer core portion is 15% or less of the height of the inner core portion.   The reactor according to claim 2, wherein a difference between a position of a surface on the opposite side of the inner core portion and a position of a surface on the opposite side of the outer core portion is 0.5 mm or more. Each of the coil elements is
A turn forming portion formed by winding the winding;
A connecting end portion that draws an end portion of the winding from the one end side of the turn forming portion between the opposing surface of the outer core portion and the opposing surface of the turn forming portion to serve as a connection portion of the terminal fitting The reactor of any one of Claims 1-3 provided with these. Furthermore, a terminal fitting connected to the connection end is provided,
The terminal fitting, the connection end portion, and the terminal connection portion formed by connecting the terminal fitting and the connection end portion are located closer to the installation side than the surface on the opposite side of the turn forming portion. The described reactor. The coil element turn forming portion is configured by edgewise winding the winding consisting of a rectangular wire,
The connection end of the coil element extends along the axial direction of the coil, and is drawn out by flatwise bending the rectangular wire so that the width direction of the rectangular wire is parallel to the horizontal direction of the coil element. The reactor according to 4 or 5. The coil element is
It is composed by winding two independent windings,
From the other end side of the turn forming portion, an end portion of the winding is drawn between a surface on the opposite side of the outer core portion and a surface on the opposite side of the turn forming portion to connect the coil elements to each other. Connecting end to
The pair of coil elements is composed of an independent member, and includes a coil connection member that connects the connection ends.
The reactor according to any one of claims 4 to 6, wherein the coil coupling member and the coupling end are located on an installation side with respect to a surface on the opposite side of the turn forming unit. Furthermore, it comprises a fixing member that fixes the combination to an installation object by pressing the outer core part on the installation side,
8. The pressing member according to claim 4, wherein a pressing portion that presses a surface on the opposite side of the outer core portion among the fixing members is located on an installation side with respect to a surface on the opposite side of the turn forming portion. Reactor.   Furthermore, the reactor of any one of Claims 1-8 provided with the outer side resin part which covers at least one part of the outer periphery of the said assembly.   Furthermore, the reactor of any one of Claims 1-9 provided with the converter case which accommodates the said assembly.   A converter provided with the reactor of any one of Claims 1-10.   A power converter device comprising the converter according to claim 11.

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