JP2014096463A - Reactor, converter, power conversion device, and method of manufacturing reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that excels in heat radiation, insulation and producibility, a converter having the reactor, a power conversion device, and a method of manufacturing the reactor.SOLUTION: A reactor 1 includes a coil 2 comprising a helically wound winding 2w, and a magnetic core 3 where the core 2 is arranged, and further includes a metal member (specifically, a baseplate part 40 of a case 4) where the coil 2 is mounted, and a joining layer 42 interposed between the coil 2 and the metal member to fix the coil 2 to the metal member. The joining layer 42 comprises a double adhesive sheet 420 including an insulating sheet 422 made of an insulating material, and a coil side adhesive layer 425 and a metal side adhesive layer 427 formed on obverse and reverse surfaces of the insulating sheet 422 for contact with the coil 2 and contact with the metal member, respectively. A thickness tof the coil side adhesive layer 425 is greater than a thickness tof the metal side adhesive layer 427. The joining of the coil 2 to the metal member enhances heat radiation, and the formation of the joining layer 42 from the double adhesive sheet 420 including the insulating sheet 422 enhances insulation and producibility.

Description

  The present invention relates to a reactor, a converter including a reactor, a power converter including the converter, and a reactor used in a DC-DC converter mounted on a vehicle such as a hybrid vehicle or a component of a power converter. It relates to a manufacturing method. In particular, the present invention relates to a reactor that is excellent in heat dissipation and insulation properties and also in productivity.

  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 discloses a coil having a cylindrical coil element formed by spirally winding a coil as a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, and this coil is arranged. An annular magnetic core and a case that houses a combination of a coil and a magnetic core are disclosed.

  Patent Document 1 discloses a configuration in which a bottom plate portion of a case on which a combined body is placed and a coil are fixed with an adhesive. By fixing the coil to the metal bottom plate with the adhesive, the heat of the coil that can be generated when using the reactor can be efficiently transmitted to the bottom plate, and as a result, the heat of the coil can be transferred to the installation target to which the reactor is attached. . Therefore, this reactor is excellent in heat dissipation.

Japanese Patent No. 4952963

  In addition to excellent heat dissipation and insulation, it is desirable to develop a reactor that is excellent in productivity.

  The reactor described in Patent Document 1 is excellent in heat dissipation as described above by including an adhesive layer made of an adhesive. Further, for example, when the adhesive layer between the coil and the metal bottom plate portion has a multilayer structure, the insulating property can be enhanced. However, when the number of layers is increased, a curing process is required for each layer, resulting in a decrease in productivity.

  When one sheet-like adhesive described in Patent Document 1 is used, the curing process can be performed once. Even with a single sheet-like adhesive, if the thickness is increased, the insulating property can be improved. However, when the thickness is increased, the curing time becomes longer and the productivity is lowered. Moreover, since the reactor is increased in size by increasing the thickness, there is a limit to the improvement in insulation by increasing the thickness of the sheet-like adhesive. Furthermore, since the distance between a coil and a baseplate part becomes large by making the said thickness thick, the fall of heat dissipation is caused depending on the material.

  Accordingly, it is desired to develop a structure that is excellent in heat dissipation and productivity even when the insulation is further improved.

  Then, one of the objectives of this invention is providing the reactor which is excellent also in productivity while being excellent in heat dissipation and insulation. Another object of the present invention is to provide a converter including the reactor and a power conversion device including the converter. Furthermore, another object of the present invention is to provide a reactor manufacturing method capable of manufacturing a reactor excellent in heat dissipation and insulation with high productivity.

  This invention achieves the said objective by providing the joining layer comprised from a specific adhesive sheet.

  The reactor of the present invention includes a coil formed by winding a winding in a spiral shape, a magnetic core on which the coil is disposed, a metal member on which the coil is placed, the coil, and the metal member And a bonding layer for fixing the coil to the metal member. The bonding layer includes both an insulating sheet made of an insulating material, a coil side adhesive layer formed on the front and back surfaces of the insulating sheet and in contact with the coil, and a metal side adhesive layer in contact with the metal member. It is composed of an adhesive sheet. And the thickness of the said coil side contact bonding layer is thicker than the thickness of the said metal side contact bonding layer.

  The reactor according to the present invention generally has a metal member (for example, a metal plate or a bottom plate portion of a case) and a coil that are made of a metal having excellent thermal conductivity, and the coil is bonded by a bonding layer, so that the metal member can be dissipated. It is possible to efficiently transfer the heat of the coil to the outside (for example, a reactor installation target). Therefore, the reactor of this invention is excellent in heat dissipation.

  In the reactor of the present invention, an insulating sheet as a part of the bonding layer is interposed between the coil and the metal member, and the insulating sheet functions as an insulating member to insulate the coil from the metal member. Increases sex. Therefore, the reactor of the present invention is excellent in insulation even if the bonding layer is thin. Specifically, the reactor of the present invention can ensure equivalent or higher insulation as compared with a case where a thick adhesive layer made of a single material adhesive is interposed between the coil and the metal member. Moreover, the reactor of this invention can shorten the distance between a coil and a metal member by thickness reduction of a joining layer. Also from this point, the reactor of this invention is excellent in heat dissipation.

  Furthermore, the reactor according to the present invention uses a double-sided adhesive sheet as a constituent member of the bonding layer, so that a single curing step is required when fixing the coil and the metal member, and the productivity is excellent. Moreover, when the bonding layer (double-sided adhesive sheet) is thinned as described above, the curing time can also be shortened. Also from this point, the reactor of the present invention is excellent in productivity.

  In addition, since the thickness of the coil-side adhesive layer is larger than that of the metal-side adhesive layer, the reactor of the present invention has an inevitable variation in the outer shape of the turns that can occur when the winding is wound in a spiral shape. Can be absorbed by the layer. That is, each of the turns in the coil and the constituent material of the coil-side adhesive layer can be sufficiently contacted, and the coil and the metal member are firmly bonded. Also from this point, the reactor of this invention is excellent in heat dissipation. Moreover, it can also be set as the reactor which is excellent in shape precision and dimensional precision by absorption of the above-mentioned dispersion | variation.

  As one form of the reactor of this invention, the form whose thickness of the said coil side contact bonding layer is more than 30 micrometers and 350 micrometers or less is mentioned.

  The above-mentioned form in which the thickness of the coil-side adhesive layer is in the above-mentioned range is that the coil and the metal member are firmly joined, and further, the heat dissipation is deteriorated and the reactor is enlarged due to excessive thickness of the adhesive layer. Can be suppressed. Therefore, the said form can be made into a small reactor while being excellent in heat dissipation.

  As one form of the reactor of this invention, the form which the adhesive agent which comprises the said coil side contact bonding layer interposed between the adjacent turns in the said coil is mentioned.

  By interposing the adhesive between the turns, the contact area between each of the turns and the adhesive is large, and the coil and the metal member are more firmly joined. Therefore, the said form is more excellent by heat dissipation.

  As one form of the reactor of this invention, the said coil | winding is provided with the conductor comprised from the flat wire, and the form whose said coil is an edgewise coil is mentioned.

  The edgewise coil is easy to increase the space factor and can be a small coil. In particular, in the above-described configuration in which an adhesive is interposed between the turns, the coil and the metal member are further firmly bonded by the anchor effect of the adhesive interposed between the turns. Therefore, the said form is further excellent in heat dissipation while being small.

  As one form of the reactor of this invention, it further has the case which accommodates the assembly of the said coil and the said magnetic core, and the said case is independent of the baseplate part in which the said assembly is mounted, and the said baseplate part. It can be made into the form which comprises the side wall part which is the member which encloses the circumference | surroundings of the said assembly. In this embodiment, it is preferable that the metal member is the bottom plate portion and the side wall portion is made of an insulating resin.

  The said form can mount the double-sided adhesive sheet which comprises an assembly and a joining layer on the baseplate part of the state which removed the side wall part, and is excellent in assembly workability | operativity. In addition, in the above embodiment, the insulation between the coil and the bottom plate portion can be enhanced by the double-sided adhesive sheet (particularly the insulating sheet), and the coil and the side wall portion are brought close to each other by the side wall portion made of insulating resin However, insulation between the coil and the side wall can be ensured. Therefore, the said form is excellent in productivity, and also is excellent in the insulation between a coil and a case. Furthermore, the said form is excellent also in heat dissipation by making a part (bottom plate part) of a case function as a heat radiating member.

The reactor of the present invention can be manufactured, for example, by the following manufacturing method. The method for manufacturing a reactor according to the present invention relates to a method for manufacturing a reactor by assembling a coil formed by winding a winding spirally and a magnetic core on which the coil is arranged, and the following preparation steps: It includes a sheet placement process, an assembly placement process, and a joining process.
Preparation step: A step of preparing a double-sided adhesive sheet comprising an insulating sheet made of an insulating material and an adhesive layer formed on each of the front and back surfaces of the insulating sheet.
Sheet placement step: a step of placing the double-sided adhesive sheet on a metal member on which a combination of the coil and the magnetic core is placed.
Combined body mounting step: a step of mounting the combined body on the double-sided adhesive sheet.
Bonding step: a step of curing the adhesive layer provided on the double-sided adhesive sheet, and joining the coil and the metal member via the double-sided adhesive sheet.
In the double-sided adhesive sheet, the thickness of one adhesive layer in contact with the coil is thicker than the thickness of the other adhesive layer in contact with the metal member.

  The reactor manufacturing method of the present invention uses a double-sided adhesive sheet for joining the coil and the metal member, so that the constituent material of the joining layer is placed on the metal member and cured between the coil and the metal member. The process can be performed once. Therefore, the reactor manufacturing method of the present invention can manufacture the reactor of the present invention, which has excellent heat dissipation and insulating properties, with high productivity.

  Also, as a double-sided adhesive sheet, by using a thin one adhesive layer (the above-mentioned metal side adhesive layer), compared to the case where both adhesive layers have the same thickness and are thick A reactor having a short distance between the coil and the metal member can be manufactured. In particular, by curing the adhesive constituting the adhesive layer in a state where the combination of the coil and the magnetic core is placed on the above-described specific double-sided adhesive sheet, the thickness of both adhesive layers is increased by this curing. Can be thin. Here, when the multilayer adhesive layer is formed by performing the curing for each layer, the outermost layer in contact with the combined body among the multilayer adhesive layers is arranged in an uncured state, and then Cured. For this reason, the thickness of the outermost layer after curing tends to be thinner than that before curing by being pressed by the combination. However, since the adhesive layer below the outermost layer is already cured, the thickness of the lower adhesive layer does not substantially change after the outermost layer is cured. In other words, it does not become thin. Therefore, the method for manufacturing the reactor of the present invention using the double-sided adhesive sheet having a specific relationship in the thickness of the adhesive layer is compared with the case where a multilayer adhesive layer is constructed by curing each layer. A reactor having a shorter distance between the metal member and the metal member can be manufactured. Also from this point, the manufacturing method of the reactor of this invention can manufacture the reactor excellent in heat dissipation. Moreover, the manufacturing method of the reactor of this invention can manufacture a small reactor because the distance between a coil and a metal member is short.

  The reactor of the present invention can be suitably used as a component part of a converter. The converter of the present invention includes the reactor of the present invention.

  The converter of this invention is excellent in heat dissipation, insulation, and productivity by providing the reactor of this invention excellent in heat dissipation, insulation, and productivity.

  The converter of the present invention can be suitably used as a component part of a power converter. The power converter of the present invention includes the converter of the present invention.

  The power converter of the present invention is excellent in heat dissipation, insulation, and productivity by including the converter of the present invention including the reactor of the present invention that is excellent in heat dissipation, insulation, and productivity.

  The reactor of this invention is excellent in heat dissipation and insulation, and is also excellent in productivity. The reactor manufacturing method of the present invention can manufacture a reactor excellent in heat dissipation and insulation with high productivity.

1 is a schematic perspective view showing a reactor of Embodiment 1. FIG. 1 is an exploded perspective view showing an outline of a reactor of Embodiment 1. FIG. FIG. 3 is an exploded perspective view schematically showing a combination of a coil and a magnetic core provided in the reactor of the first embodiment. (A) is a partial cross-sectional view showing the (IV)-(IV) cross section in the reactor shown in FIG. 1, (B) is an enlarged cross-sectional view in the broken line region in FIG. 4 (A), (C) is a double-sided adhesive tape It is sectional drawing. 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 in detail with reference to the drawings. The same reference numerals in the figure indicate the same names.

[Embodiment 1]
The reactor according to the first embodiment will be described with reference to FIGS.

(Overall reactor structure)
As shown in FIG. 1, the reactor 1 includes a coil 2 formed by spirally winding a winding 2w and a magnetic core 3 on which the coil 2 is disposed. Furthermore, the reactor 1 of this example also includes a case 4 that houses an assembly 10 of the coil 2 and the magnetic core 3. The case 4 includes a bottom plate portion 40 (FIG. 2) on which the combined body 10 is placed and a side wall portion 41 standing from the bottom plate portion 40. The bottom plate part 40 is a metal member made of a metal material. The coil 2 is fixed to the bottom plate portion 40 by a bonding layer 42 (FIG. 2) interposed between the coil 2 and the bottom plate portion 40. The feature of the present invention is that the bonding layer 42 is composed of a double-sided adhesive sheet having a specific three-layer structure. Hereinafter, the outline of the coil 2 and the magnetic core 3 that are the main components of the reactor 1, the outline of the case 4 that accommodates these, the bonding layer 42 (double-sided adhesive sheet 420) that is a characteristic point, the method for manufacturing the reactor 1, and The main effects based on the feature points will be described first, and then each configuration will be described in detail.

(Outline of coil and magnetic core)
Both the coil 2 and the magnetic core 3 can be of a known shape and material. Here, as shown in FIGS. 2 and 3, the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a winding 2w, and a connecting portion 2r that connects both the coil elements 2a and 2b. With 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. Here, the winding 2w is a covered rectangular wire including a conductor made of a copper rectangular wire and an insulating coating covering the surface of the conductor. Each of the coil elements 2a and 2b is an edgewise coil in which the covered rectangular wire is wound edgewise.

  Here, the magnetic core 3 includes a pair of columnar inner core portions 31 and a pair of columnar outer core portions 32 as shown in FIG. Each inner core portion 31 is inserted and arranged in the coil elements 2a and 2b arranged side by side, and is used as a coil arrangement portion. The outer core portion 32 is a portion that is exposed from the coil 2 and is not substantially disposed. The outer core portions 32 are arranged so as to connect the inner core portions 31 arranged side by side to form an annular magnetic core 3.

(Outline of the case)
As shown in FIG. 2, the case 4 is a member in which the bottom plate portion 40 constituting the bottom portion of the case 4 and the side wall portion 41 constituting the wall portion of the case 4 are independent in the manufacturing process of the reactor 1. In the completed state of the reactor 1, as shown in FIG. 1, the bottom plate portion 40 and the side wall portion 41 are assembled by a fixing member (not shown) to form a box shape.

  The bottom plate portion 40 on which the combined body 10 is placed is a metal member as described above, and functions as a heat radiating member that transfers the heat of the coil 2 to the outside. In the completed state of the reactor 1, the bonding layer 42 is interposed between the area facing the bottom plate 40 in the coil 2 (the lower surface in FIGS. 2 and 4A) and the inner surface 40i of the bottom plate 40, and the coil 2 And the bottom plate portion 40 are joined by the joining layer 42 (FIG. 4A). In FIG. 4 (A), only the vicinity of the bottom plate portion 40 is shown for easy understanding. In FIGS. 4A and 4B, the coil 2 is not hatched for easy understanding. FIG. 4B shows an enlarged view of a region surrounded by a dotted line in FIG.

(Junction layer)
As shown in FIG. 4B, the bonding layer 42 has a three-layer structure including an insulating sheet 422 made of an insulating material and adhesive layers 425 and 427 formed on the front and back surfaces of the insulating sheet 422, respectively.

  The insulating sheet 422 is a flat plate-like member for improving electrical insulation between the coil 2 and the metal member (here, the bottom plate portion 40). Therefore, the insulating sheet 422 has a predetermined withstand voltage characteristic. For example, an in-vehicle reactor that has 10 kV / mm or more is preferable. Further, when the insulating sheet 422 is made of a material having high thermal conductivity, it is preferable because heat dissipation is improved. For example, an insulating sheet having a thermal conductivity of 0.1 W / m · K or more, 0.15 W / m · K or more, 0.5 W / m · K or more, 1 W / m · K or more, or 2.0 W / m · K or more 422 can improve heat dissipation.

Specific materials for the insulating sheet 422 include polyimide resin, amideimide resin, polyester resin, and epoxy resin. A polyimide resin is excellent in heat resistance and insulation. Amidoimide resins have very high heat resistance. Epoxy resin is excellent in insulation. Although depending on the thickness, these resins can have a withstand voltage characteristic of about 5 kV to 7 kV, for example, when the thickness is 50 μm. Examples of other materials include ceramics such as silicon nitride (Si ₃ N ₄ ), alumina (Al ₂ O ₃ ), aluminum nitride (AlN), boron nitride (BN), and silicon carbide (SiC). The thing containing the filler which consists of is mentioned. The insulating sheet 422 made of a resin containing a filler made of the ceramic can further improve heat dissipation and insulation.

The thickness t _i of the insulating sheet 422 can be appropriately selected as long as the desired withstand voltage characteristics are satisfied as described above. The thickness t _i of the insulating sheet 422 depends on the material, but if it is 10 μm or more and 100 μm or less, the insulation layer 42 is excellent and the bonding layer 42 can be made thin. Since the bonding layer 42 is thin, the distance between the coil 2 and the metal member (here, the bottom plate portion 40) can be shortened, and the reactor 1 is excellent in heat dissipation. In particular, when the insulating sheet 422 is made of a material having excellent insulating properties (for example, when the withstand voltage characteristic satisfies 7 kV or more), even if the insulating sheet 422 is thin (for example, 10 μm or more and 50 μm or less, further 30 μm or less), Excellent insulation. Further, since the insulating sheet 422 is thin as described above, the bonding layer 42 is thinned, and as a result, the distance between the coil 2 and the metal member (here, the bottom plate portion 40) can be shortened, and the heat dissipation is further improved. When the insulating sheet 422 is made of a material having excellent thermal conductivity (for example, when the thermal conductivity satisfies 0.5 W / m · K or more), the heat dissipation is excellent even if the insulating sheet 422 is made thick within the above range.

  Adhesive layers 425 and 427 provided on the front and back surfaces of the flat insulating sheet 422 are used for bonding between the coil 2 and the insulating sheet 422, and bonding between the insulating sheet 422 and the metal member (here, the bottom plate portion 40), respectively. Is done. The former adhesive layer = coil side adhesive layer 425 and the latter adhesive layer = metal side adhesive layer 427 can be joined as described above, and have heat resistance against the temperature reached when the reactor 1 is used. Things are available. Specific examples of the material include thermosetting resins such as epoxy resins, silicone resins, and unsaturated polyesters, and thermoplastic resins such as acrylic resins, polyphenylene sulfide (PPS) resins, and liquid crystal polymers (LCP). The material of both layers 425 and 427 can be the same or different.

  By applying the above-mentioned resin to the front and back surfaces of the insulating sheet 422 and then curing to some extent, a double-sided adhesive sheet 420 having a three-layer structure in which the insulating sheet 422 is held between the two adhesive layers 425 and 427 can be manufactured ( FIG. 4 (C)). The bonding layer 42 is formed by completely curing the double-sided adhesive sheet 420 having a three-layer structure.

In the bonding layer 42, the thickness t _c of the coil side adhesive layer 425 and the thickness t _m of the metal side adhesive layer 427 are different. Specifically, the thickness t _c of the coil side adhesive layer 425 is thicker than the thickness t _m of the metal side adhesive layer 427. Note that the thickness t _c of the coil side adhesive layer 425 and the thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 are the thicknesses of the adhesive layers 425 and 427 completely cured.

The relatively large thickness t _c of the coil-side adhesive layer 425 that joins the coil 2 and the insulating sheet 422 increases the contact area with the coil 2, absorbs the variation in the outer shape of the turn in the coil 2, and provides insulation. Can be improved. Since the thickness t _m of the metal-side adhesive layer 427 that joins the insulating sheet 422 and the metal member (here, the bottom plate portion 40) is relatively thin, the joining layer 42 becomes thin, and consequently the reactor 1 is reduced in size. be able to. Such a bonding layer 42 is formed by using a double-sided adhesive sheet 420 in which the thickness t _cs of the coil side adhesive layer 425 is thicker than the thickness t _ms of the metal side adhesive layer 427 as shown in FIG. can do. The thickness t _cs of the coil side adhesive layer 425 and the thickness t _ms of the metal side adhesive layer 427 in the double-sided adhesive sheet 420 are the thicknesses before the adhesive layers 425 and 427 are completely cured (typically, The thickness when the coil 2 and the metal member are not arranged and are in an independent state.

A specific thickness t _c of the coil side adhesive layer 425 in the bonding layer 42 is, for example, more than 30 μm and 350 μm or less. When the thickness t _c of the coil-side adhesive layer 425 is 350 μm (0.35 mm) or less, the bonding layer 42 is sufficiently thin, and heat dissipation can be improved and the size can be reduced. Since the thickness t _c of the coil side adhesive layer 425 is more than 30 μm, the thickness t _cs of the double-sided adhesive sheet 420 before being completely cured also has a sufficient thickness, and the contact area described above Increase, variation absorption, and insulation can be improved. When the thickness t _c of the coil side adhesive layer 425 is 300 μm or less, 200 μm or less, and further less than 100 μm, the bonding layer 42 is further thinned, and when the thickness t _c is 50 μm or more and further 100 μm or more, the insulating property is improved. Further enhanced. Accordingly, it is considered that the thickness t _c of the coil side adhesive layer 425 is preferably about 70 μm or more and 120 μm or less. Here, the thickness t _c of the coil-side adhesive layer 425 in the bonding layer 42 is the average thickness between the surface of the coil 2 facing the bottom plate portion 40 and one surface of the insulating sheet 422 (FIG. 4B). .

The thickness t _cs for the double-sided adhesive sheet 420 may be adjusted so that the thickness t _c of the coil-side adhesive layer 425 in the bonding layer 42 becomes a desired thickness. For example, the thickness t _cs of the coil side adhesive layer 425 provided in the double-sided adhesive sheet 420 may be 50 μm or more and 500 μm or less.

A specific thickness t _m of the metal side adhesive layer 427 in the bonding layer 42 is, for example, 5 μm or more and 50 μm or less (where t _c > t _m ). When the thickness t _m of the metal-side adhesive layer 427 satisfies the above range, the insulating sheet 422 and the metal member (here, the bottom plate portion 40) can be sufficiently bonded, and the bonding layer 42 is thin, so that heat dissipation is achieved. Improvement and downsizing can be achieved. The thickness t _m of the metal side adhesive layer 427 can be set to 20 μm or more.

The thickness t _ms for the double-sided adhesive sheet 420 may be adjusted so that the thickness t _m of the metal-side adhesive layer 427 in the bonding layer 42 becomes a desired thickness. For example, the thickness t _ms of the metal side adhesive layer 427 provided in the double-sided adhesive sheet 420 may be more than 5 μm and not more than 100 μm.

In the state where the combined body 10 is placed, both the adhesive layers 425 and 427 of the double-sided adhesive sheet 420 are simultaneously cured to bond the combined body 10 and the metal member (here, the bottom plate portion 40), thereby mounting the combined body 10. The thickness t _c and t _m for the reactor 1 are usually thinner than the thickness t _cs and t _ms for the double-sided adhesive sheet 420 before placement due to the pressing of the union 10 by its own weight. (t _c <t _cs , t _m <t _ms ). However, the above-described thickness relationship (the thickness of the coil-side adhesive layer 425 is greater than the thickness of the metal-side adhesive layer 427) is maintained even after the curing. In addition, the thickness t _is of the insulating sheet 422 when only the double-sided adhesive sheet 420 _{is used} may become thin due to pressing by the weight of the combined body 10 (t _i ≦ t _is ).

The ratio of the thickness t _c of the coil side adhesive layer 425 to the thickness t _m of the metal side adhesive layer 427 in the bonding layer 42: t _c / t _m can be selected as appropriate. Can be mentioned. The ratio of the thickness t _cs of the coil-side adhesive layer 425 to the thickness t _ms of the metal-side adhesive layer 427 in the double-sided adhesive tape 420 so that the above-mentioned thickness ratio is obtained: t _cs / t _ms , curing conditions, etc. Adjust it. If the thickness ratio of the double-sided adhesive tape 420: t _cs / t _ms is too large, the coil side adhesive layer 425 will be too thick, leading to thickening of the bonding layer 42, or the coil side adhesive layer 425 and the metal side adhesive. Since there is a risk of warping based on the difference in thermal expansion and contraction with the layer 427, it is considered that the range of 2 to 5 is preferable. The ratio of the thickness t _c in the bonding layer 42: t _c / t _m may substantially maintain the ratio of the thickness t _cs in the double-sided adhesive tape 420: t _cs / t _ms, as will be described later. When the adhesive constituting the metal-side adhesive layer 425 is interposed between turns, the thickness t _c in the bonding layer 42 is small, and therefore t _c / t _m ≠ t _cs / t _ms may be satisfied.

From the above, the thickness t (= t _i + t _c + t _m ) of the bonding layer 42 is more than 45 μm and about 500 μm or less, preferably about 200 μm or less, and the thickness t _s (= t _is + t _cs ) of the double-sided adhesive sheet 420. + T _ms ) is about 65 μm or more and 700 μm or less, preferably about 500 μm or less.

  The bonding layer 42 and the double-sided adhesive sheet 420 have an area where at least a surface facing the metal member (here, the bottom plate portion 40) of the coil 2 (here, a virtual surface formed by a plurality of turns) can be sufficiently contacted. If it is, shape and size are not particularly limited. Here, as shown in FIG. 2, the bonding layer 42 and the double-sided adhesive sheet 420 are surfaces facing the metal member in the assembly 10 (here, the virtual surface of the coil 2 and the metal member side of the outer core portion 32). The shape is in line with the contour created by the surface. Therefore, both the coil 2 and the outer core portion 32 can sufficiently contact the bonding layer 42, and heat of both can be transmitted to the outside through the metal member, so that heat dissipation can be further improved.

Here, the bonding layer 42 and the insulating sheet 422 of the double-sided adhesive sheet 420 are made of polyimide, and the adhesive layers 425 and 427 are made of epoxy resin. In addition, here, a double-sided adhesive sheet 420 in which the thickness t _is of the insulating sheet 422 is 25 μm, the thickness t _cs of the coil side adhesive layer 425 is 300 μm, and the thickness t _ms of the metal side adhesive layer 427 is 30 μm is used. The thickness t _i of the insulating sheet 422 in the layer 42 is 25 μm, the thickness t _c of the coil side adhesive layer 425 is 100 μm, and the thickness t _m of the metal side adhesive layer 427 is 10 μm (t _c / t _m = 10). is there.

(Reactor manufacturing method)
The reactor 1 can be manufactured through the following steps (1) to (4), for example.

(1) Preparation step: A double-sided adhesive sheet 420 is prepared.
In this step, the above-mentioned specific three-layer structure double-sided adhesive sheet 420 is prepared. As described above, the adhesive layers 425 and 427 are formed on the front and back surfaces of the insulating sheet 422 so that the thickness t _cs of the coil side adhesive layer 425 is larger than the thickness t _ms of the metal side adhesive layer 427. Further, the double-sided adhesive sheet 420 is cut into a desired shape.

(2) Sheet placement step: The double-sided adhesive sheet 420 is placed on a metal member.
In this step, the prepared double-sided adhesive sheet 420 is placed on a metal member (here, the bottom plate portion 40). Here, since the bottom plate portion 40 and the side wall portion 41 are independent as described above, the double-sided adhesive sheet 420 can be disposed on the bottom plate portion 40 with the side wall portion 41 removed, and the workability is excellent.

(3) Combined body mounting step: The combined body 10 is mounted on the double-sided adhesive sheet 420.
In this step, the combined body 10 is prepared in advance, and this combined body 10 is placed on the double-sided adhesive sheet 420. Here, as shown in FIG. 3, the combined body 10 is formed by laminating a plurality of core pieces 31m and a gap material 31g to form two inner core portions 31, and the inner core portions 31 are respectively connected to the coil elements 2a and 2b. After being disposed inside, it can be manufactured by assembling so that the end surfaces 31e of both inner core portions 31 and the inner end surfaces 32 of the outer core portions 32 are in contact with each other. The higher the mounting step, since the adhesive layer 425, 427 made somewhat thinned by imposition of its own weight or below of the combined product 10, the thickness t _s of the double-sided adhesive sheet 420 is somewhat thinner.

(4) Joining process: The adhesive layers 425 and 427 provided on the double-sided adhesive sheet 420 are cured, and the coil 2 and the metal member are joined by the double-sided adhesive sheet 420.
In this process, by making the double-sided adhesive sheet 420 at a predetermined temperature, both the adhesive layers 425 and 427 are softened to some extent, the coil 2 and the insulating sheet 422 are joined by the coil-side adhesive layer 425, and the metal-side adhesive layer 427 is used. The insulating sheet 422 and the metal member (here, the bottom plate portion 40) can be joined, and then cured to fix the joined state. As a result, the coil 2 and the metal member are joined by the double-sided adhesive sheet 420.

  The step (4) includes the coil 2, the magnetic core 3, and the metal member (here, the bottom plate portion 40), and the coil 2 and the metal member are configured by curing the double-sided adhesive sheet 420. The reactor 1 bonded through the bonding layer 42 is obtained.

Furthermore, the reactor 1 can be configured such that an adhesive constituting the coil-side adhesive layer 425 is interposed between adjacent turns in the coil 2 as shown in FIG. 4 (B). This form is a contact between the coil 2 and the adhesive as compared with the case where the adhesive is mainly in contact with the surface facing the metal member (here, the bottom plate portion 40) in the coil 2 (the virtual surface described above). The area increases. Therefore, in this embodiment, the heat of the coil 2 can be easily transmitted by the metal member, the heat dissipation is excellent, and the coil 2 is firmly fixed by the metal member. Further, the adhesive constituting the coil side adhesive layer 425 provided in the double-sided adhesive sheet 420 is cured in a state of being interposed between the turns, so that the thickness t _c of the coil side adhesive layer 425 in the bonding layer 42 is further increased. Can be thinned efficiently. Also from this point, this form is excellent in heat dissipation. In particular, when an edgewise coil is used as in this example, stronger anchoring can be realized by an anchor effect due to the presence of an adhesive as compared to a flatwise coil or a coil using a round wire.

In the above configuration, when the distance between adjacent turns is narrowed, specifically, when it is 0.3 mm or less, and further 0.2 mm or less, the axial length of the coil 2 does not become too long, and the coil 2 and the metal member (here Then, the adhesive constituting the coil-side adhesive layer 425 can be sufficiently interposed between the bottom plate portion 40) and this is preferable. The coil 2 is formed so that a desired interval is provided between adjacent turns. Further, by narrowing the distance between adjacent turns as described above, the adhesive before curing can penetrate to some extent by capillary action, although it depends on the viscosity of the adhesive before curing. Further, by pressing the combination 10 against the double-sided adhesive sheet 420 side with a jig or the like when the above-mentioned curing is performed, the penetration depth of the adhesive before the curing can be further increased, and the adjacent turn It is possible to uniformly penetrate between them. As a result, it is possible to penetrate the height h _i is larger reactor adhesive interposed between adjacent turns.

The penetration height h _i can be selected as appropriate. For example, when the coil 2 is an edgewise coil, the intrusion height h _i is about 1/4 to 1/2 (about 0.25 × W to 0.5 × W) of the width W of the winding 2w (flat wire). In this case, the above contact area is sufficiently large, and the thickness t _c of the coil side adhesive layer 425 can be sufficiently secured. It is preferable to adjust the interval between turns and the pressing force so that the penetration height h _i becomes a desired height.

The manufacture of the reactor 1 shown in FIG. 1 further includes a step of assembling the case 4 by assembling the bottom plate portion 40 and the side wall portion 41.
Here, the side wall 41 is disposed on the bottom plate portion 40 so as to cover the outer peripheral surface of the combination 10 fixed by the bonding layer 42 from above the combination 10. Then, the bottom plate portion 40 and the side wall portion 41 are integrated by a fixing member (a connecting bolt not shown here). By this step, the reactor 1 in which the combined body 10 is stored in the case 4 is obtained.

(Main effects)
Reactor 1 is excellent in heat dissipation from the following points.
(1) Since the coil 2 and the metal member (here, the bottom plate part 40) are joined by the joining layer 42, even if the coil generates heat during use, this heat is efficiently transferred to the outside (such as the installation target of the reactor 1). ).
(2) Since the bonding layer 42 includes the insulating sheet 422 and is excellent in insulation, the bonding layer 42 can be thinned, and the distance between the coil 2 and the metal member can be shortened.
(3) Since the coil-side adhesive layer 425 in the bonding layer 42 is thick, the coil 2 can sufficiently contact.

(4) By using the specific double-sided adhesive sheet 420, both the adhesive layers 425 and 427 in the bonding layer 42 can be thinned, and the distance between the coil 2 and the metal member can be further shortened.
For example, formation of the first adhesive layer on the metal member (here, the bottom plate portion 40) → placement of the insulating sheet → curing of the first adhesive layer → formation of the second adhesive layer on the insulating sheet → combination Consider the case where the second adhesive layer is cured in this order. In this case, the second adhesive layer can be made thinner than before curing by the weight of the assembly or pressing. However, since the assembly is placed after the first adhesive layer is cured, the first adhesive layer is unlikely to be thin. On the other hand, in the reactor 1, since both the adhesive layers 425 and 427 can be made thinner than before curing by the weight of the combined body 10 or pressing, the coil 2 and the metal member are made more than in the case of performing the above two curings. The distance between them can be shortened.

  In addition, the reactor 1 is also excellent in insulation because the bonding layer 42 includes the insulating sheet 422. In addition, the reactor 1 includes the specific double-sided adhesive sheet 420 as the bonding layer 42, so that the curing process and the curing time can be reduced, and the productivity is excellent. Furthermore, the reactor 1 can absorb variations in the shape of the coil 2 because the coil-side adhesive layer 425 in the bonding layer 42 is thick, and is excellent in shape accuracy and dimensional accuracy.

Hereinafter, details of each component of the reactor 1 will be described.
(coil)
As shown in FIGS. 2 and 3, the coil 2 is formed by a single continuous winding 2w. More specifically, a part of the winding 2w extending from the end of one coil element 2a is bent in a U shape to form a connecting part 2r, and subsequently the other coil element 2b is connected to the connecting part 2r. Is formed. 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, the end face shape of the coil elements 2a and 2b is a rectangular shape with rounded corners, but may be appropriately changed such as an annular shape.

  Each coil element is manufactured with separate windings, and one end of each coil element winding is directly joined by welding, soldering, crimping, etc., or through a separately prepared connecting member (for example, plate material). It can also be a coil joined.

  As the winding 2w, a coated wire having an insulating coating made of an insulating material (typically polyamideimide) can be suitably used on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof. The conductor is typically a round wire or a rectangular wire. As in this example, when using a rectangular wire for the winding 2w as an edgewise coil, (1) it is easier to form a coil with a higher space factor than when using a round wire, so it is compact. (2) Since at least a part of the outer peripheral surface (virtual surface) formed by a plurality of turns can be flat, it is possible to secure a wide contact area with the bonding layer 42 and improve heat dissipation, (3) winding There is an advantage that a large contact area can be secured between the wire 2w and a connection object such as a terminal fitting 8 (described later).

  At both ends of the winding 2w forming the coil 2, the terminal fitting 8 is typically 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. In some cases, it is directly connected to a connection point of an external device without going through the terminal fitting 8. The winding 2w and the terminal fitting 8 may be joined at an appropriate time. In this example, it may be performed after the case 4 is assembled.

(Magnetic core)
As shown in FIG. 3, the inner core portion 31 of the magnetic core 3 has 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 pieces 31m. It is an arranged laminate. When the core piece 31m and the gap material 31g are integrated with an adhesive, it is easy to handle and it is expected that noise can be reduced by firmly fixing the core piece 31m and the gap material 31g. In addition, when the core piece 31m and the gap material 31g are integrated with an adhesive tape or the like, it is easy to handle. The outer core portion 32 is a core piece made of a soft magnetic material.

  Here, the inner core portion 31 has a rectangular parallelepiped shape, and the outer core portion 32 has a columnar shape in which the upper surface and the lower surface in FIG. 3 have a dome shape (a deformed trapezoidal shape whose cross-sectional area decreases outward from the inner end surface 32e). The shape of the inner core portion 31 (core piece 31m / gap material 31g) and the shape of the outer core portion 32 can be appropriately selected. Further, here, the facing surface (the lower surface in FIG. 3) of the outer core portion 32 with the metal member (here, the bottom plate portion 40 (FIG. 2)) is the facing surface of the coil 2 with the metal member (the lower surface in FIG. 3). The size of the outer core portion 32 is adjusted so as to be flush with each other. That is, when the magnetic core 3 is assembled in an annular shape, the outer peripheral surface (particularly the lower surface) of the outer core portion 32 protrudes from the outer peripheral surface of the inner core portion 31. By doing so, the facing surface of the combined body 10 with the metal member is mainly composed of the lower surface of the two outer core portions 32 and the lower surface of the coil 2, and not only the coil 2 but also the outer core portion 32 includes the bonding layer 42. To touch.

  The core pieces constituting the inner core portion 31 and the outer core portion 32 have a molded body using a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, an oxide containing iron, or an insulating coating. A laminated plate body in which a plurality of magnetic thin plates (for example, an electromagnetic steel plate typified by a silicon steel plate) is laminated may be mentioned. The above-mentioned molded body is a compact material (typically using a coating powder having an insulating coating), a sintered body, a composite material obtained by injection molding or cast molding a mixture containing soft magnetic powder and resin. Etc. Here, each core piece is a powder compact of soft magnetic metal powder containing iron such as iron or steel.

  A known material can be used as the gap material 31g. The specific material of the gap material 31g is a mixture containing a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as polyphenylene sulfide (PPS) resin, and magnetic powder (for example, soft magnetic powder such as iron powder). Etc.

  Here, each core piece constituting the magnetic core 3 has the same specification (compact compact) made of a uniform material, but the inner core portion 31 and the outer core portion 32 are magnetic. Characteristics and specifications can be varied. For example, it is possible to adopt a form in which a green compact and a composite material are combined, or a form in which composite materials having different materials and mixed amounts of soft magnetic powder are combined.

  Furthermore, the reactor 1 also includes an insulator 5 interposed between the coil 2 and the magnetic core 3, and is excellent in insulation between the coil 2 and the magnetic core 3. As shown in FIG. 3, the insulator 5 shown in this example includes a pair of peripheral wall portions 51 that are interposed between the coil element 2a or the coil element 2b and the inner core portion 31 to insulate them, and the coil elements 2a and 2b. And a pair of frame plate portions 52 that are interposed between the inner end surface 32e and the inner end surface 32e of the outer core portion 32 to insulate them. The shape of the insulator 5 shown in FIG. 3 is an example, and can be changed as appropriate.

  Here, the peripheral wall 51 is composed of divided members 512 and 514 having a bowl-shaped cross section. The shape of the dividing members 512 and 514 can be selected as appropriate. Here, the dividing members 512 and 514 are formed so as to partially cover the outer periphery of the inner core portion 31. For this reason, in the form including the sealing resin described later, it is easy to deaerate at the time of filling the sealing resin, and it is excellent in manufacturability, and the contact area between the inner core portion 31 and the sealing resin can be increased, and noise is suppressed. It is expected to be possible. By configuring the peripheral wall portion 51 with the plurality of divided members 512 and 514, it is easy to arrange the peripheral wall portion 51 on the outer periphery of the inner core portion 31, and the assembly workability is excellent.

  The frame plate portion 52 is a B-shaped flat plate member having a pair of openings (through holes) into which the two inner core portions 31 can be inserted. Here, when the frame plate 52 is assembled to the coil 2, the partition 52b disposed so as to be interposed between the two coil elements 2a, 2b, the connecting portion 2r of the coil 2, and one outer core portion 32. And a flat plate-like pedestal 52p. The partition part 52b protrudes from the one surface of the frame plate part 52 toward the coil side, and the pedestal 52p protrudes from the other surface of the frame plate part 52 toward the outer core part 32 side. The partition part 52b and the pedestal 52p may be omitted.

  As a constituent material of the insulator 5, an insulating material such as PPS resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, liquid crystal polymer, or the like can be used.

  In addition, a core component in which one or both of the inner core portion 31, the peripheral wall portion 51, and the one frame plate portion 52 of the magnetic core 3 are integrally formed with a resin can be obtained. As this resin, thermoplastic resins such as PPS resin, PTFE resin, LCP, nylon 6, nylon 66, and PBT resin can be used.

(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 upper side that faces the bottom plate portion 40 is open. Yes (Figure 1).

  The bottom plate portion 40 is typically a plate material fixed in contact with the installation target when the reactor 1 is installed on the installation target. Since the bottom plate portion 40 is used for the heat dissipation path of the coil 2, it is generally made of a metal that is a material having high thermal conductivity. Specific 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 or more and 5 mm or less in consideration of strength, shielding properties, heat dissipation, noise characteristics, and the like. Here, the bottom plate portion 40 is made of an aluminum alloy, and the thermal conductivity of the bottom plate portion 40 is sufficiently higher than the thermal conductivity of the side wall portion 41 described later.

  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. 2, 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 assembling the bottom plate portion 40 and the side wall portion 41, the attachment portion 400 of the bottom plate portion 40 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. If the bolt hole 411h of the side wall portion 41 is made of a metal tube, the strength is excellent even if the side wall portion 41 is made of resin as will be described later.

  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 side wall part 41 is a frame-like body (here, rectangular shape), and the whole is made of an insulating resin. Therefore, even when the coil 2 and the side wall 41 are arranged close to each other as shown in FIG. 1 (for example, the distance between the outer peripheral surface of the coil 2 and the inner surface of the side wall 41 is about 0 mm or more and 1.0 mm or less) Excellent in properties. Moreover, the reactor 1 can be reduced in size by reducing the said space | interval. Examples of the insulating resin include PBT resin, urethane resin, PPS resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like.

  If at least a part of the side wall portion 41 is made of metal (particularly nonmagnetic metal such as aluminum or magnesium), an improvement in heat dissipation and a shielding function can be expected. If all of the side wall 41 is made of an insulating resin as in this example, (1) excellent insulation between the coil 2 and the case 4 will be obtained. (2) Even complicated shapes will be easily manufactured by injection molding. It has the advantage that (3) weight reduction can be achieved.

  Here, the side wall portion 41 includes two flange portions 410 formed of a flat plate that covers a part of the opening of the case 4 (FIG. 2). By providing the collar 410, (1) improved vibration resistance, (2) improved rigidity of the case 4 (especially the side wall 41), (3) external environment of the magnetic core 3 (especially the outer core 32) Various effects such as protection from mechanical and mechanical protection, and (4) prevention of the union 10 from falling off are obtained. Here, one flange portion 410 (left side in FIG. 2) is used as a terminal block to which the terminal fitting 8 is fixed. Further, the terminal 410 is provided with a terminal groove so that the terminal fitting 8 can be positioned. Further, here, after the terminal metal fitting 8 is arranged on the flange portion 410, the upper portion thereof is covered with a flat terminal fixing member 9, and the terminal fixing member 9 is fixed to the flange portion 410 with a bolt 91 to form a terminal block. doing. The terminal fixing member 9 is preferably formed of the above-described insulating resin. It is also possible to insert-mold the terminal fitting 8 into the side wall portion 41 to form a side wall portion including the terminal fitting 8.

  Here, the bottom plate portion 40 and the side wall portion 41 are integrated by the connecting bolt as described above, but an adhesive may be used together with the connecting bolt. Or you may connect the baseplate part 40 and the side wall part 41 only using an adhesive agent. When the adhesive is used, for example, the double-sided adhesive sheet 420 has the same size as the bottom plate part 40, and the large double-sided adhesive sheet 420 allows the bonding layer 42 and the adhesive layer to join the bottom plate part 40 and the side wall part 41 to each other. Both of them can be formed. That is, the bonding layer 42 can be constituted by a part of the double-sided adhesive sheet 420 and the adhesive layer for integrating the case 4 can be constituted by the other part. In this embodiment, the curing step of the bonding layer 42 and the curing step of the adhesive layer that bonds the bottom plate portion 40 and the side wall portion 41 can be performed simultaneously, and the curing step can be reduced. Therefore, this form can improve productivity.

(Other components: sealing resin)
The case 4 may be filled with a sealing resin (not shown). The sealing resin fixes the position of the assembly 10 stored in the case 4, mechanical protection of the assembly 10 and protection from the external environment (improved corrosion resistance), improved heat dissipation depending on the material, insulation Can be improved. In this embodiment, for example, when the end of the winding 2w is exposed from the sealing resin, the end of the winding 2w and the terminal fitting 8 are easily joined. After joining the end portion of the winding 2w and the terminal fitting 8, it is also possible to have a form in which the joining portion is embedded in the sealing resin.

  Examples of the sealing resin include insulating resins such as an epoxy resin, a urethane resin, and a silicone resin. When the resin contains the filler made of ceramics described in the section of the material of the insulating sheet 422 described above, heat dissipation and insulation can be improved.

  In the form including the sealing resin, if a packing (not shown) is provided between the bottom plate portion 40 and the side wall portion 41, the 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.

(Other components: lid)
The reactor 1 can be configured to include a lid (not shown) that covers the opening of the case 4. Examples of the constituent material of the lid include the insulating resin described in the material section of the side wall portion 41. In the form having a lid, noise reduction, mechanical protection of the assembly 10 and protection from the external environment (improvement of corrosion resistance), avoidance of contact with external components, insulation, etc. can be achieved.

(Use)
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.

[Embodiment 2]
In the above-described first embodiment, the configuration in which the bottom plate portion 40 and the side wall portion 41 are independent members has been described. In addition, it can be set as the form which provides the case which consists of a box body in which the baseplate part and the side wall part were shape | molded integrally. In this form, when the whole case is comprised with metals, such as the above-mentioned aluminum, the whole case can be utilized for a thermal radiation path | route and heat dissipation is improved. In this case, the above-mentioned double-sided adhesive tape 420 is also disposed between the coil and the side wall portion of the case and cured at the same time, so that an insulating sheet is interposed between the coil and the side wall portion of the case. . In this case, even if the coil is disposed close to the side wall, that is, even if the distance between the coil and the side wall of the case is shortened (for example, 0.5 mm or less), the insulation between the coil and the case can be improved. .

[Embodiment 3]
In Embodiments 1 and 2 described above, the embodiment including a case has been described. In addition, it can be set as the form which does not have a case. In this case, instead of the bottom plate portion 40, a metal member interposed between the coil 2 and the installation target of the reactor 1 is provided. When the metal member is flat or has a flat surface like the above-described bottom plate portion 40, the double-sided adhesive tape 420 and the combination 10 of the coil 2 and the magnetic core 3 can be stably disposed and assembled. Excellent workability. Examples of the constituent material of the metal member include metals having excellent heat dissipation properties such as aluminum and alloys thereof described in the section of the bottom plate portion 40. Further, when the metal member has an attachment portion to the installation object as in the case of the bottom plate portion 40, the installation operation of the reactor can be easily performed. Further, in this embodiment, when the outer resin portion covering the outer periphery of the combined body 10 is provided or the outer resin portion covering both the combined body 10 and the metal member is provided, mechanical protection of the combined body 10 is achieved. And protection from the external environment. In the latter form, the outer resin portion can also contribute to the integration of the combined body 10 and the metal member. When the outer resin portion is made of the above-described insulating resin, the insulation between the coil 2 and the like and the outside can be enhanced.

[Embodiment 4]
The reactor of Embodiments 1 to 3 can be used, for example, as a component part of a converter placed 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 vehicle or an electric vehicle 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. 5, although an inlet is shown as a charging location 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. 6, 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 tends to prevent the change of the current to flow through the circuit. As this reactor L, the reactor of the said Embodiment 1-3 is provided. In addition to excellent heat dissipation and insulation, the power converter 1100 and the converter 1110 are also excellent in heat dissipation, insulation, and productivity by including the reactor 1 that is excellent in productivity.

  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 reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as the reactors of the first to third embodiments, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactors of the first to third embodiments can be used for a converter that converts input power, that is, a converter that only performs 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.

  The reactor of the present invention includes various converters such as an in-vehicle converter (typically a DC-DC converter) and an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can be suitably used as a component part of a power converter. The manufacturing method of the reactor of this invention can be utilized suitably for manufacture of the reactor utilized for the component of a converter and a power converter device.

1 Reactor 10 Union
2 coils
2a, 2b Coil element 2r Connecting 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 40i Inner surface 41 Side wall 42 Bonding layer
400,411 Mounting part 400h, 411h Bolt hole 410 庇
420 Double-sided adhesive sheet 422 Insulating sheet 425 Coil side adhesive layer
427 Metal side adhesive layer
5 Insulator
51 Peripheral wall 512,514 Dividing member 52 Frame plate 52b Partition plate 52p Pedestal
8 Terminal bracket 9 Terminal fixing member 91 Bolt
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 reactor comprising a coil formed by spirally winding a winding and a magnetic core on which the coil is disposed,
A metal member on which the coil is placed;
Comprising a bonding layer interposed between the coil and the metal member to fix the coil to the metal member;
The bonding layer includes both an insulating sheet made of an insulating material, a coil-side adhesive layer that contacts the coil, and a metal-side adhesive layer that contacts the metal member. Composed of adhesive sheet,
A reactor in which the coil side adhesive layer is thicker than the metal side adhesive layer.   2. The reactor according to claim 1, wherein a thickness of the coil side adhesive layer is more than 30 μm and not more than 350 μm.   3. The reactor according to claim 1, wherein an adhesive constituting the coil side adhesive layer is interposed between adjacent turns in the coil. The winding comprises a conductor composed of a flat wire,
The reactor according to any one of claims 1 to 3, wherein the coil is an edgewise coil.   A converter comprising the reactor according to any one of claims 1 to 4.   6. A power conversion device comprising the converter according to claim 5. A reactor manufacturing method for manufacturing a reactor by assembling a coil formed by spirally winding a winding and a magnetic core on which the coil is disposed,
Preparing a double-sided adhesive sheet comprising an insulating sheet composed of an insulating material and an adhesive layer formed on each of the front and back surfaces of the insulating sheet;
Placing the double-sided adhesive sheet on a metal member on which a combination of the coil and the magnetic core is placed;
Placing the combination on the double-sided adhesive sheet;
Curing the adhesive layer provided on the double-sided adhesive sheet, and joining the coil and the metal member via the double-sided adhesive sheet;
The double-sided adhesive sheet is a method for manufacturing a reactor in which the thickness of one adhesive layer in contact with the coil is thicker than the thickness of the other adhesive layer in contact with the metal member.

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