JP2014192261A - Reactor and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that is able to ensure insulation properties for a coil and a core by a simple structure, is excellent in coil heat dissipation, and, furthermore, is excellent in durability and reliability, and to provide a manufacturing method therefor.SOLUTION: A reactor 1 comprises: a core 3 having a slot 32 extending through the interior thereof; and a coil 2 extending through the slot 32 and composed of a conducting wire 20 wound around the core 3. The conducting wire 20 of the coil 2 is composed of a plurality of short conducting wire parts 20a and a plurality of long conducting wire parts 20b longer than the short conducting wire parts 20a. In the slot 32 of the core 3, the short conducting wire parts 20 and long conducting wire parts 20b are arranged such that one alternates the other in the axial direction of the coil 2. Outside the slot 32, one end of each long conducting wire part 20b is joined to one end of another short conductive wire part 20a adjacent on one side in the direction of lamination, and the other of it is jointed to the one end of further another short conductive wire part 20a adjacent on the other side in the direction of the lamination.

Description

  The present invention relates to a reactor used in a power converter and the like and a method for manufacturing the reactor.

  Conventionally, a reactor used for a power conversion device mounted on a hybrid vehicle, an electric vehicle, or the like is known. As the reactor, for example, there is a reactor including a cylindrical coil formed by winding a conducting wire and a core made of a magnetic powder mixed resin obtained by mixing magnetic powder in an insulating resin, and the coil is embedded in the core.

  Patent Document 1 discloses a reactor in which a coil surrounded by an insulating enclosure is embedded in the core in order to ensure electrical insulation between the coil and the core (hereinafter simply referred to as insulation). Patent Document 2 discloses a reactor in which a coil molded with an insulating resin is embedded in the core in order to ensure the insulation between the coil and the core.

JP 2006-4957 A JP 2007-19402 A

However, the reactors of Patent Documents 1 and 2 have the following problems.
That is, in the manufacturing process of the reactor, before the coil is embedded in the core, it is necessary to enclose the coil in advance with an insulating enclosure or mold it with an insulating resin. Therefore, the man-hour in the manufacturing process is increased. Further, the insulation structure between the coil and the core becomes complicated.

  In the reactor manufacturing process, when the coil is embedded in the core, for example, after the coil is covered with the magnetic powder mixed resin, the magnetic powder mixed resin is cured to form the core. However, when the core is molded, stress is applied from the coil side to the core side due to curing shrinkage of the magnetic powder mixed resin. Therefore, damage such as cracks may occur in the core.

  Further, the coil that generates heat when energized when the reactor is used is embedded in a core made of a magnetic powder mixed resin having a relatively low thermal conductivity. Therefore, it cannot be said that the heat dissipation of the coil is sufficient. Further, when the reactor is used, thermal stress is applied from the coil side to the core side due to the temperature difference between the coil and the core and the difference in coefficient of linear thermal expansion, which may cause damage such as cracks in the core.

  In addition, if the coil is wound around a pre-formed core, there will be no problems such as cracks. However, in such a configuration, the above-described coil can be embedded in the core so that the core can be placed outside the coil. The advantages of the reactor are not obtained.

  The present invention has been made in view of such a background, can ensure insulation between the coil and the core with a simple structure, has excellent heat dissipation of the coil, and further has excellent durability and reliability. And a method of manufacturing the same.

One aspect of the present invention includes a core having a slot penetrating the inside;
A coil composed of a conductive wire wound around the core while penetrating the slot,
The conducting wire of the coil is composed of a plurality of short conducting wire portions and a plurality of long conducting wire portions longer than the short conducting wire portion,
In the slot of the core, the short conductor portion and the long conductor portion are alternately stacked in the axial direction of the coil,
Outside the slot, the long conducting wire portion has one end joined to one end of the short conducting wire portion adjacent to one side in the stacking direction and the other end to one end of the short conducting wire portion adjacent to the other side in the stacking direction. It is in the reactor characterized by being joined (Claim 1).

Another aspect of the present invention is a method for producing the above reactor,
A core production process for producing a core having a slot penetrating the inside;
Conductor part production process for producing the plurality of short conductor parts and the plurality of long conductor parts,
A plurality of the short conductor portions and a plurality of the long conductor portions, and alternately laminating each other, a portion of each conductor portion being disposed through the slot;
The long conducting wire portion is bent, one end of the long conducting wire portion is joined to one end of the short conducting wire portion adjacent to one side in the stacking direction, and the other end of the long conducting wire portion is adjacent to the other side in the stacking direction. And a coil forming step of forming the coil wound around the core by joining to one end of the short conducting wire portion. (Claim 6)

  In the reactor, the core is provided with a slot penetrating the core. And the conducting wire which comprises a coil is wound by the core, penetrating the slot of a core. That is, the coil is not embedded in the core as in the prior art, but is configured by winding a lead wire around a slot of the core prepared in advance.

  Therefore, at least a part of the coil (at least a part of the conductive wire of the coil) is always exposed to the outside of the core. Thereby, at the time of use of a reactor, the heat which generate | occur | produced in the coil by electricity supply can be radiated easily, and the heat dissipation of a coil can be improved. In addition, since at least a part of the coil is always exposed to the outside of the core, the thermal stress generated by the temperature difference between the coil and the core and the difference in linear thermal expansion coefficient is suppressed and dispersed when the reactor is used. Can do. Thereby, it is possible to prevent the core from being damaged such as cracks, and it is possible to improve the durability and reliability of the reactor.

  The reactor is wound with a coil lead wire while passing through a core slot that has been formed in a predetermined shape in advance. That is, the core can be formed into a predetermined shape in advance separately from the coil. Therefore, the problem that occurred in the case of the conventional structure in which the coil is embedded in the core, specifically, the stress from the coil side to the core side due to the hardening shrinkage of the magnetic powder mixed resin covering the coil at the time of molding the core. There is no longer a possibility that a problem such as cracking or the like occurs in the core due to the addition of.

  Further, as described above, the conductive wire of the coil is wound while penetrating the slot of the core. Therefore, for example, an insulating member such as insulating paper is disposed in advance at a portion where the coil conductor and the core are in contact with each other (a portion where the coil conductor is wound around the core), and the coil conductor is passed through the core slot. If it winds, an insulating member can be easily interposed between a coil and a core. Thereby, it is possible to sufficiently ensure the insulation between the coil and the core with a simple structure.

  However, a coil formed of a conductive wire wound around a core while penetrating through a slot has a very poor workability and is not practical from the viewpoint of productivity if it is formed by a single conductive wire. On the other hand, in the reactor, the coil conductor is composed of a plurality of short conductor portions and a plurality of long conductor portions. That is, the conducting wire constituting the coil is composed of a plurality of conducting wire portions (a plurality of short conducting wire portions and a plurality of long conducting wire portions). Therefore, by inserting each short conducting wire portion and each long conducting wire portion individually into the slot of the core, the conducting wire of the coil can be easily set in the core.

  Further, in the slot of the core, the short conducting wire portions and the long conducting wire portions are alternately stacked in the axial direction of the coil. The long conducting wire portion has one end joined to one end of the short conducting wire portion adjacent to one side in the laminating direction and the other end joined to one end of the short conducting wire portion adjacent to the other side in the laminating direction. A spiral coil can be easily formed by such a laminated arrangement and a joining relationship between the short conductor portion and the long conductor portion. That is, a coil formed of a conductive wire wound around a core while penetrating the slot can be obtained with high productivity by the laminated arrangement and the joining relationship of the short conductive wire portion and the long conductive wire portion as described above.

  In the method of manufacturing the reactor, in the conductor portion arranging step, a plurality of short conductor portions and a plurality of long conductor portions are alternately stacked, and a part of each is inserted and disposed in the slot. Thereby, the conducting wire of a coil can be easily set to a core. And in the said coil formation process, a some short conducting wire part and a some long conducting wire part can be joined easily and reliably, and a coil can be formed. As a result, as described above, the insulation between the coil and the core can be ensured with a simple structure, and a reactor excellent in heat dissipation of the coil and excellent in durability and reliability can be obtained with high productivity. it can.

  As described above, it is possible to provide a reactor having a simple structure and ensuring insulation between the coil and the core, excellent in heat dissipation of the coil, and excellent in durability and reliability, and a method for manufacturing the same.

The perspective view which shows the reactor (especially 1st side surface side of a core) in Example 1. FIG. The perspective view which shows the reactor (especially 3rd side surface side of a core) in Example 1. FIG. Explanatory drawing which looked at the reactor in Example 1 from the 1st end surface side of the core. Explanatory drawing which looked at the reactor in Example 1 from the 1st side surface side of the core. The VV arrow directional cross-sectional view of FIG. 3 in Example 1. FIG. FIG. 3 is a perspective view showing a core in the first embodiment. Explanatory drawing which shows the cross section orthogonal to the X direction of a reactor in Example 1. FIG. Explanatory drawing which shows the cross section orthogonal to the Z direction of a reactor in Example 1. FIG. Explanatory drawing which shows the short conducting wire part and the long conducting wire part in Example 1. FIG. The perspective view which shows the state which has arrange | positioned the short conducting wire part and the long conducting wire part in the slot of the core in Example 1. FIG. The perspective view which shows the reactor of another example in Example 1. FIG. Explanatory drawing which shows the reactor in Example 2. FIG.

The reactor is used as a component part of a power conversion device such as an inverter mounted on a hybrid vehicle, an electric vehicle or the like.
The coil generates magnetic flux when energized. On the other hand, the core serves as a magnetic path for magnetic flux generated by energizing the coil.
The core may be constituted by a single core member or may be constituted by a plurality of core members. However, the slot that penetrates the inside of the core is not formed between the plurality of core members, but is in a state of penetrating at least one member. That is, penetrating the inside of the core does not mean that it is formed between a plurality of core members, but means that it penetrates at least one core member.

In addition, as what a core is comprised with a single core member, there exists what was integrally molded by the magnetic powder mixed resin mentioned later, for example. Moreover, as what a core is comprised with a several core member, there exists what is comprised by laminating | stacking a some laminated steel plate, for example. In this case, the slot can penetrate the laminated steel sheet in the thickness direction.
The joining of the short conducting wire portion and the long conducting wire portion can be performed by, for example, welding, soldering, caulking, or the like.

The core is provided with at least one slot. That is, there may be one slot or a plurality of slots.
The core may include at least a pair of the slots, and the short conducting wire portion and the long conducting wire portion may both penetrate both the pair of slots (claim 2).
In this case, since the portion around the pair of slots in the core can be used effectively as a magnetic path, it is easy to improve the magnetic characteristics of the reactor. Moreover, since the short conducting wire portion and the long conducting wire portion respectively penetrate both the pair of slots, it is easy to stably set the short conducting wire portion and the long conducting wire portion on the core, and the productivity can be improved. .

Moreover, it is preferable that the junction part of the said long conducting wire part and the said short conducting wire part is located in a line with the axial direction of the said coil (Claim 3).
In this case, a plurality of joints can be formed efficiently. That is, when the joint portions are arranged in parallel in the axial direction, it is easy to sequentially join a plurality of joint portions (end portions of the short conductor portion and the long conductor portion) along the direction. Therefore, a reactor with higher productivity can be obtained.
Further, by aligning the joint portion in the vicinity of the opening of the slot, for example, the short conductor portion and the long conductor portion can be joined more efficiently.

Moreover, the said core shall be comprised by the one member in which the external shape has a rectangular parallelepiped shape (Claim 4).
In this case, it is easy to stably arrange the coil with respect to the core.

The core may be integrally formed of a magnetic powder mixed resin obtained by mixing a magnetic powder with an insulating resin (claim 5).
In this case, a reactor having excellent magnetic characteristics can be obtained easily and reliably. In addition, when the core is composed of a magnetic powder mixed resin, it is necessary to pay attention to the occurrence of cracks in the core, but as described above, by adopting a structure that does not easily generate cracks, it has excellent durability and reliability. A reactor can be easily obtained.

Next, in the manufacturing method of the reactor, in the core manufacturing step, the core having at least a pair of the slots is manufactured, and in the conductor portion arranging step, the short conductor portion and the long conductor portion are respectively It can be inserted and arranged in both of the pair of slots.
In this case, a reactor having excellent magnetic characteristics can be easily obtained. Further, by arranging the short conducting wire portion and the long conducting wire portion through both of the pair of slots, it is easy to stably set the short conducting wire portion and the long conducting wire portion on the core, and the productivity can be improved.

Further, in the coil manufacturing step, the joining of the long conducting wire portion and the short conducting wire portion is performed in a state where the joining portions of the long conducting wire portion and the short conducting wire portion are arranged in parallel with the axial direction of the coil. (Claim 8).
In this case, a plurality of joints can be formed efficiently.

In the core manufacturing step, the core can be integrally formed with a magnetic powder mixed resin obtained by mixing a magnetic powder with an insulating resin (claim 9).
In this case, a reactor having excellent magnetic characteristics can be obtained easily and reliably.

The reactor may further include a case that accommodates the coil and the core, and the coil may be in contact with at least a part of a portion exposed to the outside of the core.
In this case, when the reactor is used, the heat generated in the coil by energization can be efficiently radiated from the portion of the coil exposed to the outside of the core (hereinafter, simply referred to as an exposed portion) through the case. Thereby, the heat dissipation of a coil can be improved further.

Further, at least a part of the core may be in contact with the case.
That is, when the reactor is used, the coil generates heat when energized, but the core around which the coil is wound also generates heat. Therefore, with the above configuration, the heat generated in the core can be efficiently radiated through the case. Thereby, the heat dissipation of a core can be improved.

The case containing the coil and the core may be filled with an insulating resin for filling.
In this case, the vibration resistance of the reactor can be improved by filling the gap in the case with the filling insulating resin. Moreover, the insulation between the coil and the core can be further enhanced by filling the gap in the slot of the core with the filling insulating resin. Also, if the case is filled with a filling insulating resin having a high thermal conductivity, the heat dissipation of the coil and the core can be further enhanced.
As the filling insulating resin filled in the case, for example, an epoxy resin containing an inorganic filler having a high thermal conductivity such as alumina, or a silicone resin can be used.

In addition, a coolant channel for circulating the coolant may be provided inside the case.
In this case, the heat radiation of the coil and the core through the case can be performed more efficiently. Thereby, the heat dissipation of a coil or a core can be improved further.

Further, the reactor may include a plurality of the coils. That is, a plurality of coils may be wound around one core.
In this case, if it is set as the structure which connects a some coil in series, the inductance performance of a reactor can be improved. Further, since the magnetic flux generated by each coil passes through the common core, the magnetic flux can be effectively used. This also makes it possible to reduce the size of the reactor.

Example 1
The Example which concerns on the said reactor is described using figures.
As shown in FIG. 1 to FIG. 8, the reactor 1 of this example includes a core 3 having a slot 32 penetrating the inside, and a coil 2 constituted by a conducting wire 20 wound around the core 3 while penetrating the slot 32. And.

The conducting wire 20 of the coil 2 includes a plurality of short conducting wire portions 20a and a plurality of long conducting wire portions 20b longer than the short conducting wire portion 20a.
In the slots 32 of the core 3, the short conductor portions 20 a and the long conductor portions 20 b are arranged alternately stacked in the axial direction of the coil 2.
Outside the slot 32, the long conducting wire portion 20b is joined to one end of the short conducting wire portion 20a adjacent to one side in the stacking direction, and the other end 202b is connected to the other side in the stacking direction of the short conducting wire portion 20a. It is joined to one end.
This will be described in detail below.

As shown in FIGS. 1-5, the reactor 1 is used as components, such as power converters, such as an inverter mounted in a hybrid vehicle, an electric vehicle, etc., for example.
The reactor 1 includes a coil 2 that generates a magnetic flux when energized, a core 3 that is a magnetic path of the magnetic flux generated when the coil 2 is energized, and an insulating member 4 that is interposed between the coil 2 and the core 3. ing. In addition, illustration of the insulating member 4 is abbreviate | omitted in FIGS. 1-4.

As shown in FIG. 6, the core 3 is made of a magnetic powder mixed resin in which magnetic powder is mixed and dispersed in an insulating resin. The core 3 is integrally formed of a magnetic powder mixed resin and has a rectangular parallelepiped shape.
As the insulating resin in the magnetic powder mixed resin, for example, a thermosetting resin such as an epoxy resin, a thermoplastic resin, or the like can be used. Moreover, as a magnetic powder, a ferrite powder, iron powder, silicon alloy iron powder etc. can be used, for example.

As shown in the figure, the core 3 has four side surfaces that connect a pair of end surfaces (first end surface 301, second end surface 302) facing each other and the pair of end surfaces (first end surface 301, second end surface 302). (First side surface 311, second side surface 312, third side surface 313, fourth side surface 314). The first side surface 311 and the third side surface 313 are opposed to each other, and the second side surface 312 and the fourth side surface 314 are opposed to each other.
In this example, the direction in which the first end surface 301 and the second end surface 302 face each other is in the X direction, the direction in which the second side surface 312 and the fourth side surface 314 face each other in the Y direction, and the first side surface 311 and the third side surface. The direction in which 313 faces is the Z direction.

As shown in the figure, the core 3 is provided with two slots 32 (a first slot 32a and a second slot 32b) penetrating the core 3 thereof. The first slot 32a and the second slot 32b are formed in the Z direction so as to penetrate between the first side surface 311 and the third side surface 313 facing each other. The first slot 32a is formed on the second side surface 312 side, and the second slot 32b is formed on the fourth side surface 314 side. Moreover, the cross-sectional shape orthogonal to the Z direction in the first slot 32a and the second slot 32b is a substantially rectangular shape having a large width in the X direction and a small width in the Y direction.
The first slot 32a and the second slot 32b are formed in parallel to each other. These are formed in parallel to the second side surface 312 and the fourth side surface 314.

  As shown in FIGS. 7 and 8, between the coil 2 and the core 3, three insulating members 4 (first insulating member 4a, second insulating member 4b, and third insulating member 4c) made of insulating paper are arranged. It is installed. The insulating member 4 is disposed at a portion where the conducting wire 20 of the coil 2 and the core 3 are in contact, that is, a portion where the conducting wire 20 of the coil 2 is wound around the core 3. 7 and 8, the illustration of the coil 2 is omitted.

  Specifically, the first insulating member 4a includes, in the core 3, a wall surface 321a inside the first slot 32a, a space between the first slot 32a and the second slot 32b on the first side surface 311, and an inside of the second slot 32b. The wall surface 321b and the third side surface 313 are disposed so as to cover the space between the first slot 32a and the second slot 32b. Further, the second insulating member 4 b is disposed so as to cover a wall surface other than the inner wall surface 321 a in the first slot 32 a of the core 3. Further, the third insulating member 4 c is arranged so as to cover the wall surface other than the inner wall surface 321 b in the second slot 32 b of the core 3.

  As shown in FIGS. 1 to 3, the coil 2 is formed in a cylindrical shape by winding the conductor 20 spirally around the core 3 while passing the conducting wire 20 through the slot 32 (the first slot 32 a and the second slot 32 b). Has been. Specifically, the conductive wire 20 of the coil 2 passes through the first slot 32a and the second slot 32b of the core 3 alternately (in the first slot 32a, on the first side surface 311, in the second slot 32b, It is wound so as to pass in the order on the third side surface 313). A part of the conductive wire 20 of the coil 2 is exposed to the outside of the core 3 (on the first side surface 311 and on the third side surface 313).

The conducting wire 20 of the coil 2 is a rectangular conducting wire having a substantially rectangular cross section, and the surface thereof is covered with an insulating coating made of enamel.
As shown in FIGS. 4 and 5, the conducting wire 20 of the coil 2 has a plurality of short conducting wire portions 20 a and a plurality of long conducting wire portions 20 b longer than the short conducting wire portion 20 a, and these are connected. It is configured. In the first slot 32a and the second slot 32b of the core 3, the short conductor portions 20a and the long conductor portions 20b are alternately stacked. The short conducting wire portion 20a and the long conducting wire portion 20b each penetrate both the pair of slots 32. 4 and 5, the short conductor portion 20a and the long conductor portion 20b are illustrated in a simplified manner.

  As shown in FIGS. 1 and 4, one end 201 b of each long conducting wire portion 20 b is located on one side in the stacking direction (X direction) in the vicinity of the opening 322 b on the first side surface 311 side of the second slot 32 b in the core 3 ( It is joined by welding to one end of the short conductor portion 20a adjacent to the first end face 301 side). Further, the other end 202b of each long conducting wire portion 20b is on the other side (second end surface 302 side) in the stacking direction (X direction) in the vicinity of the opening 322a on the first side surface 311 side of the first slot 32a in the core 3. It joins to the end of the adjacent short conducting wire part 20a by welding. The joint portion (welded portion P) between the long conducting wire portion 20b and the short conducting wire portion 20a is arranged in parallel with the axial direction of the coil 3. FIG. 4 shows a welding point P between the short conductor portion 20a and the long conductor portion 20b.

Next, the manufacturing method of the reactor 1 of this example is demonstrated.
The manufacturing method of the reactor of this example is provided with the following core preparation processes, a conducting wire part manufacturing process, a conducting wire part arrangement process, and a coil formation process.
In the core manufacturing process, as shown in FIG. 6, the core 3 having the slots 32 penetrating the inside is manufactured. In the conductor portion manufacturing step, a plurality of short conductor portions 20a and a plurality of long conductor portions 20b are respectively prepared as shown in FIG. In the conducting wire portion arranging step, as shown in FIG. 10, a plurality of short conducting wire portions 20 a and a plurality of long conducting wire portions 20 b are alternately stacked, and a part of each is inserted and arranged in the slot 32. In the coil forming step, as shown in FIG. 1, the long conductor portion 20b is bent, and one end 201b of the long conductor portion 20b is joined to one end of the short conductor portion 20a adjacent to one side in the stacking direction, The other end 202b of the long conducting wire portion 20b is joined to one end of the short conducting wire portion 20a adjacent to the other side in the stacking direction to form the coil 2 wound around the core 3.

More specifically, as shown in FIG. 9, a plurality of short conductor portions 20a and a plurality of long conductor portions 20b processed into a U-shape are prepared. The surfaces of the short conducting wire portion 20a and the long conducting wire portion 20b are covered with an insulating film, but both end portions are exposed from the insulating coating. Further, the core 3 having a predetermined shape having the first slot 32a and the second slot 32b is integrally formed using a magnetic powder mixed resin (see FIG. 6).
Subsequently, the insulating member 4 (4a-4c) is arrange | positioned in the predetermined place of the core 3, specifically the part in which the conducting wire 20 of the coil 2 is wound in the core 3 (refer FIG. 7, FIG. 8).

  Next, as shown in FIG. 10, the short conducting wire portions 20 a and the long conducting wire portions 20 b are alternately stacked in the first slot 31 a and the second slot 32 b of the core 3. The short conducting wire portion 20 a and the long conducting wire portion 20 b are inserted and arranged in both the pair of slots 32. Further, the long conducting wire portions 20b are arranged at both ends in the stacking direction. At this time, both ends of the short conductor portion 20a and both ends of the long conductor portion 20b are arranged so as to protrude from the opening portion 322a of the first slot 32a and the opening portion 322b of the second slot 32b in the core 3. The short conducting wire portion 20a and the long conducting wire portion 20b protrude from both ends in the same direction.

  Next, after bending one end of the long conductor 20b protruding from the opening 322a of the first slot 32a in the core 3 to the second slot 32b side, in the vicinity of the opening 322b of the second slot 32b, the stacking direction (X direction) Are welded to one end of the short conductor portion 20b adjacent to one side (the first end face 301 side) (see FIGS. 1 and 4).

  Further, after bending the other end of the long conductor portion 20b protruding from the opening 322b of the second slot 32b in the core 3 to the first slot 32a side, in the vicinity of the opening 322a of the first slot 32a, the stacking direction (X direction) ) Is welded to one end of the short conductor portion 20a adjacent to the other side (second end surface 302 side) (see FIGS. 1 and 4).

In addition, let the junction part of the long conducting wire part 20b and the short conducting wire part 20a be the state arranged in parallel with the axial direction of the coil 3. FIG. In this state, the long conducting wire portion 20b and the short conducting wire portion 20a are joined (welded).
Further, in this example, in the vicinity of the opening 322a of the first slot 32a and the opening 322b of the second slot 32b in the core 3, the short conducting wire portion 20a and the long conducting wire portion 20b are continuously arc-welded in a single step. (See FIGS. 1 and 4).
The reactor 1 (refer FIGS. 1-5) of this example is obtained by the above.

Next, the function and effect of this example will be described.
In the reactor 1 of this example, the core 3 integrally formed of the magnetic powder mixed resin is provided with slots 32 (first slot 32a and second slot 32b) penetrating through the core 3 thereof. And the conducting wire 20 which comprises the coil 2 is wound with respect to the slot 32 (1st slot 32a, 2nd slot 32b) of the core 3. As shown in FIG. That is, the coil 2 is not embedded in the core 3 as in the prior art, but the lead wire 20 is passed through the slots 32 (the first slot 32a and the second slot 32b) of the core 3 that are integrally formed in advance. It is configured by winding.

  Therefore, a part of the coil 2 (a part of the conducting wire 20 of the coil 2) is always exposed to the outside of the core 3. Thereby, at the time of use of the reactor 1, the heat | fever of the coil which generate | occur | produced by electricity supply can be radiated easily, and the heat dissipation of the coil 2 can be improved. In addition, since a part of the coil 2 is always exposed to the outside of the core 3, the thermal stress generated by the temperature difference between the coil 2 and the core 3 and the difference in linear thermal expansion coefficient is suppressed when the reactor 1 is used.・ Can be distributed. Thereby, it is possible to prevent the core 3 from being damaged such as cracks, and to improve the durability and reliability of the reactor 1.

  Further, the reactor 1 is wound with the conducting wire 20 of the coil 2 in a state of passing through the slot 32 (first slot 32a, second slot 32b) of the core 3 that has been formed in a predetermined shape in advance. That is, the core 3 is formed in advance in a predetermined shape separately from the coil 2. Therefore, the problem that occurred in the case of the conventional structure in which the coil is embedded in the core, specifically, the stress from the coil side to the core side due to the curing shrinkage of the magnetic powder mixed resin covering the coil when the core is molded. There is no longer a possibility that a problem such as cracking or the like occurs in the core due to the addition of.

  Further, as described above, the conducting wire 20 of the coil 2 is wound while passing through the slot 32 (the first slot 32a and the second slot 32b) of the core 3. Therefore, for example, after the insulating member 4 (4a to 4c) is arranged in advance on a portion where the conductive wire 20 of the coil 2 and the core 3 are in contact (portion where the conductive wire 20 of the coil 2 is wound around the core 3), If the conductor 20 is wound while being inserted into the slot 32 (first slot 32a, second slot 32b) of the core 3, the insulating member 4 (4a to 4c) is easily interposed between the coil 2 and the core 32. be able to. Thereby, the insulation between the coil 2 and the core 3 can be sufficiently secured with a simple structure.

  However, the coil 2 constituted by the conducting wire 20 wound around the core 3 while penetrating the slot 32 is extremely poor in workability when it is formed by a single conducting wire, from the viewpoint of productivity. Not realistic. On the other hand, in the reactor 1, the conducting wire 20 of the coil 2 is composed of a plurality of short conducting wire portions 20a and a plurality of long conducting wire portions 20b. That is, the conducting wire 20 constituting the coil 2 includes a plurality of conducting wire portions (a plurality of short conducting wire portions 20a and a plurality of long conducting wire portions 20b). Therefore, the conductor 20 of the coil 2 can be easily set on the core 3 by inserting each short conductor 20a and each long conductor 20b into the slot 32 of the core 3 individually.

  Further, in the slots 32 (first slot 32 a and second slot 32 b) of the core 3, the short conducting wire portions 20 a and the long conducting wire portions 20 b are alternately stacked in the axial direction of the coil 2. The long conducting wire portion 20b has one end joined to one end of the short conducting wire portion 20a adjacent to one side in the stacking direction and the other end joined to one end of the short conducting wire portion 20a adjacent to the other side in the stacking direction. . The spiral coil 2 can be easily formed by such a stacking arrangement and a joining relationship between the short conductor portion 20a and the long conductor portion 20b. That is, the coil 2 constituted by the conducting wire 20 wound around the core 3 while penetrating the slot 32 is obtained with high productivity by the laminated arrangement and the joining relationship of the short conducting wire portion 20a and the long conducting wire portion 20b as described above. be able to.

  Further, as in this example, by setting the welded portion of the short conductor portion 20a and the long conductor portion 20b to the exposed portion of the core 3, the welding of the short conductor portion 20a and the long conductor portion 20b is facilitated. Further, as in this example, the welded portion is aligned with the vicinity of the opening 322a of the first slot 32a and the opening 322b of the second slot 32b of the core 3, thereby welding the short conducting wire portion 20a and the long conducting wire portion 20b. Can be carried out continuously and efficiently.

  The core 3 has a pair of slots 32 (a first slot 32a and a second slot 32b), and the short conducting wire portion 20a and the long conducting wire portion 20b each have a pair of slots 32 (a first slot 32a and a second slot 32b). ) Therefore, since the portion around the pair of slots 32 in the core 3 can be effectively used as a magnetic path, the magnetic characteristics of the reactor 1 can be easily improved. Further, the short conducting wire portion 20a and the long conducting wire portion 20b pass through both of the pair of slots 32 (the first slot 32a and the second slot 32b), thereby stabilizing the short conducting wire portion 20a and the long conducting wire portion 20b. Thus, it is easy to set in the core 3 and the productivity can be improved.

  Further, the joint portion (welded portion P) between the long conducting wire portion 20 b and the short conducting wire portion 20 a is arranged in parallel with the axial direction of the coil 3. Thereby, a some junction part can be formed efficiently. That is, when the joints (welding points P) are arranged in parallel in the axial direction, joining of a plurality of joints (the ends of the short conductor 20a and the long conductor 20b) is sequentially performed along that direction. It can be carried out. Therefore, the reactor 1 with higher productivity can be obtained.

Moreover, since the core 3 is configured by a single member having an outer shape that is a rectangular parallelepiped shape, the coil 2 can be easily and stably disposed with respect to the core 3.
Moreover, since the core 3 is integrally formed of the magnetic powder mixed resin, the reactor 1 having excellent magnetic characteristics can be obtained easily and reliably. In addition, when the core 3 is composed of a magnetic powder mixed resin, it is necessary to pay attention to the generation of cracks in the core 3, but as described above, by adopting a structure in which cracks are unlikely to occur, durability and reliability are improved. An excellent reactor 1 can be easily obtained.

  Thus, the reactor 1 which can ensure the insulation of the coil 2 and the core 3 with a simple structure, is excellent in the heat dissipation of the coil 2, and is excellent in durability and reliability, and its manufacturing method are provided. be able to.

  In the reactor 1 of this example, as shown in FIG. 1, a rectangular parallelepiped core 3 having substantially the same width in the X direction and the width in the Y direction is used. For example, as shown in FIG. A rectangular parallelepiped core 3 having a small width in the X direction and a large width in the Y direction can also be used. At this time, the number of turns of the coil 2 can be increased by increasing the width of the slot 32 (the first slot 32a and the second slot 32b) in the X direction. In this case, it is easy to optimize the magnetic performance and optimize the component arrangement in the power conversion device on which the reactor 1 is mounted.

(Example 2)
This example is an example of a reactor 1 including a case 5 that houses a coil 2 and a core 3 as shown in FIG.
As shown in the figure, the case 5 has a bottom 51 and a side wall 52 erected from the bottom 51, and has a box shape with an opening opposite to the bottom 51. A plurality of refrigerant channels 53 for circulating the refrigerant W are provided inside the bottom 51.

  As shown in the figure, the core 3 in a state where the coil 2 is wound is housed in the case 5 in such an orientation that the third side surface 313 is on the bottom 51 side of the case 5. The first end surface 301, the second end surface 302, the second side surface 312, and the fourth side surface 314 of the core 3 are in contact with the side wall portion 52 of the case 5. A part of the exposed portion of the coil 2 is in contact with the bottom 51 of the case 5.

As shown in the figure, the case 5 containing the coil 2 and the core 3 is filled with an insulating resin 6 for filling made of epoxy resin or silicone resin containing an inorganic filler having high thermal conductivity such as alumina. ing. The filling insulating resin 6 is filled so as to fill a gap formed in the case 5 and further a gap formed in the slot 32 (the first slot 32 a and the second slot 32 b) of the core 3.
Other basic configurations are the same as those in the first embodiment. Moreover, about the structure similar to Example 1, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

Next, the effect in the reactor 1 of this example is demonstrated.
The reactor 1 of this example includes a case 5 that houses a coil 2 and a core 3. A part of the coil 2 exposed to the outside of the core 3 is in contact with the case 5. Therefore, when the reactor 1 is used, heat generated in the coil 2 by energization can be efficiently radiated from the exposed portion of the coil 2 through the case 5. Thereby, the heat dissipation of the coil 2 can be improved further.

  Part of the core 3 is in contact with the case 5. That is, when the reactor is used, the coil 2 generates heat when energized, but the core 3 around which the coil 2 is wound also generates heat. Therefore, with the above configuration, the heat generated in the core 3 can be efficiently radiated through the case 5. Thereby, the heat dissipation of the core 3 can be improved.

  The case 5 containing the coil 2 and the core 3 is filled with an insulating resin 6 for filling. Therefore, the vibration resistance of the reactor 1 can be improved by filling the gap in the case 5 with the filling insulating resin 6. Further, by filling the gap in the slot 32 (first slot 32a, second slot 32b) of the core 3 with the filling insulating resin 6, the insulation between the coil 2 and the core 3 can be further enhanced. Moreover, if the case 5 is filled with the insulating resin 6 for filling with high thermal conductivity as in this example, the heat dissipation of the coil 2 and the core 3 can be further enhanced.

Further, a coolant channel 53 for circulating the coolant W is provided inside the case 5. Therefore, the heat radiation of the coil 2 and the core 3 through the case 5 can be performed more efficiently. Thereby, the heat dissipation of the coil 2 and the core 3 can be improved further.
Other basic functions and effects are the same as those of the first embodiment.

1 Reactor 2 Coil 20 Conductor 20a Short Conductor Part 20b Long Conductor Part 3 Core 32 Slot

Claims (9)

A core (3) having a slot (32) extending therethrough;
A coil (2) composed of a conducting wire (20) wound around the core (3) while penetrating the slot (32),
The conducting wire (20) of the coil (2) is composed of a plurality of short conducting wire portions (20a) and a plurality of long conducting wire portions (20b) longer than the short conducting wire portions (20a).
In the slot (32) of the core (3), the short conductor portion (20a) and the long conductor portion (20b) are alternately stacked in the axial direction of the coil (2). And
The long conductor portion (20b) has one end (201b) joined to one end of the short conductor portion (20a) adjacent to one side in the stacking direction and the other end (202b) outside the slot (32). A reactor (1) characterized in that the reactor (1) is joined to one end of the short conducting wire (20a) adjacent to the other side in the stacking direction.   The reactor (1) according to claim 1, wherein the core (3) has at least a pair of the slots (32), and the short conductor (20a) and the long conductor (20b) The reactor (1) characterized by penetrating both the pair of slots (32).   The reactor (1) according to claim 1 or 2, wherein a joint (P) between the long conducting wire portion (20b) and the short conducting wire portion (20a) is arranged in parallel with the axial direction of the coil (3). Reactor (1) characterized by   The reactor (1) according to any one of claims 1 to 3, wherein the core (3) is configured by a single member having an outer shape having a rectangular parallelepiped shape.   The reactor (1) according to any one of claims 1 to 4, wherein the core (3) is integrally formed of a magnetic powder mixed resin in which an insulating resin is mixed with a magnetic powder. (1). A method for producing the reactor (1) according to any one of claims 1 to 5,
A core production process for producing a core (3) having a slot (32) extending therethrough;
A conductor part manufacturing step for manufacturing the plurality of short conductor parts (20a) and the plurality of long conductor parts (20b);
A plurality of the short conductor portions (20a) and a plurality of the long conductor portions (20b) alternately stacked on each other, and a portion of each of the conductor portions is inserted into the slot (32).
The long conducting wire portion (20b) is bent, and one end (201b) of the long conducting wire portion (20b) is joined to one end of the short conducting wire portion (20a) adjacent to one side in the stacking direction. A coil forming step of joining the other end (202b) of (20b) to one end of the short conducting wire portion (20a) adjacent to the other side in the laminating direction and forming the coil wound around the core; The manufacturing method of the reactor characterized by including these.   7. The method of manufacturing a reactor according to claim 6, wherein in the core manufacturing step, the core (3) having at least a pair of the slots (32) is manufactured, and in the conductive wire portion arranging step, the short conductive wire portion is formed. (20a) and the long conducting wire portion (20b) are respectively inserted and disposed in both the pair of slots (32).   In the manufacturing method of the reactor of Claim 6 or 7, in the said coil production process, the junction part (P) of the said long conducting wire part (20b) and the said short conducting wire part (20a) is made into the said coil (3). A method of manufacturing a reactor, comprising joining the long conducting wire portion (20b) and the short conducting wire portion (20a) in a state where the long conducting wire portion (20b) is arranged in parallel with the axial direction.   10. The reactor manufacturing method according to claim 6, wherein, in the core manufacturing step, the core (3) is integrally formed of a magnetic powder mixed resin obtained by mixing a magnetic powder with an insulating resin. 10. Production method.

Images