JP2015012145A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor of high productivity which can be arranged stably even in a place exposed directly to a liquid refrigerant, and can enhance heat dissipation.SOLUTION: A reactor including a combination body of a coil formed by winding a wire, and a magnetic core arranged in and out of the coil to form a closed magnetic path is further provided with a heatsink mounting the combination body and arranged, together with the combination body, in a place where liquid refrigerant is supplied, an adhesive layer interposed between the combination body and heatsink, and constituting a conjugate by bonding the combination body and heatsink, and an annular member surrounding the conjugate so as to come into contact with both the surface in the conjugate on the combination body side and the surface on the heatsink side.

Description

  The present invention relates to a reactor used for a component part of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that is highly productive and that can be stably disposed even in a portion that is directly exposed to a liquid refrigerant, thereby improving heat dissipation.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. The reactor is used in a converter mounted on a vehicle such as a hybrid vehicle. As the reactor, for example, there is one shown in Patent Document 1.

  The reactor of Patent Document 1 is configured such that an assembly of a coil molded body obtained by integrally molding a coil and a part of an annular core with an inner resin portion and the remaining portion of the core is covered with an outer resin portion. When the reactor is viewed in plan, the outer resin portion includes a flange portion that protrudes outward from the contour of the combined body. The flange portion is formed with a through hole through which a bolt for fixing the reactor to the installation target is inserted. The reactor is housed in a housing portion through which liquid refrigerant is circulated, and is fixed in the housing portion by inserting a bolt through the through hole of the flange portion. And a reactor is cooled by distribute | circulating a liquid refrigerant in this accommodating part, and making a reactor into an immersion state.

JP 2011-049494 A

  The reactor described above has a problem that it has many manufacturing processes (manufacturing time is long) and productivity is not good. In particular, in recent years, with the rapid development of hybrid vehicles and electric vehicles, the demand for reactors is steadily expanding, and improvement in reactor productivity is desired.

  For example, productivity can be improved by omitting the outer resin portion. In that case, although productivity can be improved, the structure which replaces a flange part is calculated | required as a means for fixing a reactor to installation object. Therefore, the outer resin part is omitted, and the assembly of the coil and magnetic core is fixed to the heat sink with an adhesive, thereby improving productivity and installing the reactor with bolts through the heat sink. We considered stable fixation to the subject. However, although productivity can be improved, when the assembly is fixed to the heat dissipation plate via an adhesive, when the reactor is immersed in the liquid refrigerant as in the above-described Patent Document 1, the liquid refrigerant is dissipated from the combination and heat dissipation. Adhesion with the board is adversely affected, and this adhesion may be insufficient. In that case, the assembly cannot be stably fixed to the installation target, and of course, the heat of the coil cannot be efficiently transmitted to the installation target via the heat radiating plate, resulting in a decrease in heat dissipation.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor that is highly productive and that can be stably placed even at locations directly exposed to a liquid refrigerant to improve heat dissipation. There is to do.

  The reactor of the present application includes a combination of a coil formed by winding a winding and a magnetic core that is disposed inside and outside the coil to form a closed magnetic circuit. The reactor includes a heat radiating plate, an adhesive layer, and an annular member. The heat radiating plate is disposed at a place where the combination is placed and the liquid refrigerant is supplied together with the combination. The adhesive layer is interposed between the combined body and the heat sink, and forms a joined body by bonding the combined body and the heat sink. The annular member surrounds the outer periphery of the joined body so as to be in contact with both the combination-side surface and the heat sink-side surface of the joined body.

  The reactor has high productivity, and can be stably disposed even in a place where it is directly exposed to the liquid refrigerant, thereby improving heat dissipation.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a front view of the reactor shown in FIG. It is a disassembled perspective view which shows the outline of the union body with which the reactor of Embodiment 1 is equipped. It is the elements on larger scale which show the space enclosed with the coil of the reactor of Embodiment 1, and a heat sink. It is a schematic explanatory drawing which shows the use condition of the reactor of Embodiment 1. It is a schematic perspective view which shows the reactor of the modification 1-1. It is (VII)-(VII) sectional drawing of the reactor shown in FIG. It is a principal part expansion perspective view which shows the coil side surface vicinity of the reactor of the modification 1-2. It is a principal part expansion perspective view which shows the coil side surface vicinity of the reactor of the modification 1-3. It is a principal part expansion perspective view which shows the coil side surface vicinity of the reactor of the modification 1-4. It is a schematic perspective view which shows the reactor of Embodiment 2. It is a principal part enlarged view which shows the coil | winding edge part vicinity of the reactor of the modification 2-1. It is a principal part enlarged view which shows the coil | winding end part vicinity of the reactor of the modification 2-2. 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 a power converter device provided with a converter.

<< Description of Embodiments of the Present Invention >>
First, embodiments of the present invention will be listed and described.

  (1) A reactor according to the embodiment includes a combination of a coil formed by winding a winding and a magnetic core that is disposed inside and outside the coil to form a closed magnetic path. The reactor further includes a heat sink, an adhesive layer, and an annular member. The heat radiating plate is disposed at a place where the combination is placed and the liquid refrigerant is supplied together with the combination. The adhesive layer is interposed between the combined body and the heat sink, and forms a joined body by bonding the combined body and the heat sink. The annular member surrounds the outer periphery of the joined body so as to be in contact with both the combination-side surface and the heat sink-side surface of the joined body.

  According to said structure, the state which integrated the assembly and the heat sink can be maintained by providing an annular member irrespective of a time-dependent deterioration of a contact bonding layer. That is, even if the bonding between the combined body and the heat sink by the adhesive layer becomes insufficient, the combined state of the combined body and the heat sink can be maintained. Therefore, even if the reactor is disposed at a location that is directly exposed to the supplied liquid refrigerant, the combined body can be stably fixed to the heat radiating plate, and the state can be maintained, so that the heat dissipation of the reactor can be improved.

  Moreover, since the said reactor can shorten manufacturing time (a manufacturing process is simplified) rather than the conventional reactor, it is excellent in productivity. Since the heat sink is used to fix the reactor to the installation target, the reactor can be manufactured by placing and fixing the assembly on the heat sink with an adhesive layer and passing over the annular member. This is because it is not necessary to mold the outer resin part having the above.

  (2) As one form of the said reactor, an annular member is provided with the horizontal annular member currently spanned in the direction orthogonal to the axial direction of a coil.

  According to said structure, integration with an assembly and a heat sink can be maintained, without damaging a magnetic core. By providing a horizontal annular member that hangs in a direction orthogonal to the axial direction of the coil, the contact portion of the horizontal annular member with the joined body can be a coil and a heat sink, and the magnetic core can be in non-contact. Because it can.

  (3) As one form of the said reactor, it is mentioned that an annular member is provided with the vertical annular member currently spanned by the axial direction of a coil.

  According to said structure, in addition to maintenance of integration with an assembly and a heat sink, the vibration and noise at the time of operation | movement of a reactor can be suppressed. Since the vibration during the operation of the reactor tends to work mainly in the axial direction of the coil due to the expansion due to the magnetostriction of the magnetic core and the contraction due to the magnetic attraction force, it is possible to reduce the vibration and noise by providing a vertical annular member that spans the axial direction of the coil. It is effective for suppression.

  (4) As one form of the said reactor, it is mentioned that a heat sink has a positioning part for positioning an annular member with respect to a heat sink.

  According to said structure, it is easy to maintain the state which integrated the assembly and the heat sink. This is because the positioning of the annular member can prevent the annular member from being displaced.

  (5) As one form of the reactor, it is possible to include a case in which a joined body is housed and a liquid refrigerant is supplied and discharged.

  According to said structure, since a coil and a magnetic core can be made to contact a liquid refrigerant directly and can be cooled, the heat dissipation of a reactor can be improved.

  (6) As one form of the reactor, when the case is included, the case may include an attachment surface facing the heat sink and a space forming portion formed on the attachment surface. A space formation part forms the space which distribute | circulates a liquid refrigerant between a heat sink and an attachment surface, when a conjugate | zygote is accommodated in a case.

  According to said structure, the heat dissipation of a reactor can be improved more. This is because the space forming portion can form a space through which the liquid refrigerant is circulated on the installation side of the heat radiating plate, and the liquid refrigerant can also be brought into direct contact with the installation side surface of the heat radiating plate. Moreover, even if the annular member protrudes from the installation side surface of the heat sink, the annular member does not interfere with the mounting surface of the case. This is because the space can be formed on the installation side of the heat sink by the space forming portion as described above.

  (7) As one form of the said reactor, providing the sensor which measures the physical quantity at the time of operation | movement of a reactor is mentioned. In this case, the coil includes a pair of coil elements that are connected to each other and arranged in parallel so that the axes are parallel to each other. And the sensor is being fixed by the contact bonding layer in the space enclosed by a pair of said coil element and a heat sink.

  According to said structure, compared with the case where a sensor is provided in the said opposing side between a pair of coil elements by providing a sensor in the space enclosed by a pair of coil element and a heat sink, the physical quantity at the time of operation | movement of a reactor. It is easy to measure accurately. If the sensor is placed at the location facing the outside of the assembly and in contact with the liquid refrigerant, the sensor may be affected by the physical quantity of the liquid refrigerant, particularly the temperature of the liquid refrigerant, and it may be difficult to measure the physical quantity accurately. Because there is.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings. In addition, this invention is not limited to these illustrations, is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included.

Embodiment 1
[Overall structure of the reactor]
With reference to FIGS. 1-5, the reactor 1A of Embodiment 1 is demonstrated. The reactor 1A will be described in detail in the state of use of the reactor 1A, which will be described later. However, the reactor 1A is arranged at a location that is directly exposed to the liquid refrigerant. 1 A of reactors are provided with the combination 10 of the coil 2 and the magnetic core 3 which is arrange | positioned inside and outside this coil 2, and forms a closed magnetic circuit. The combined body 10 is placed and fixed on the heat sink 5 by the adhesive layer 6. The assembly 10, the heat radiating plate 5, and the adhesive layer 6 constitute a joined body 100. The main feature of reactor 1A is that it includes an annular member 7 that surrounds the outer periphery of joined body 100 so as to be in contact with both the assembly 10 side surface and the heat sink 5 side surface of joined body 100. Hereinafter, the characteristic part of reactor 1A, the structure of related parts, and main effects will be described in order, and then each structure will be described in detail. Here, let the heat sink 5 side of the joined body 100 be an installation side (lower side), and let the opposite side (combined body 10 side) be an opposing side (upper side). The same reference numerals in the figure indicate the same names.

[Composition of main features and related parts]
[Union]
(coil)
As shown in FIGS. 1 and 3, the coil 2 connects a pair of coil elements 2 a and 2 b formed by spirally winding a single continuous winding 2 w without a joint, and both coil elements 2 a and 2 b. Connecting portion 2r. Each coil element 2a, 2b is a hollow cylindrical body having the same number of turns, and is arranged in parallel (side by side) so that the respective axial directions are parallel. The connecting portion 2r is configured such that a part of the winding is bent in a U shape on one end side of the coil 2 (the right side in FIG. 1 and FIG. 3). The upper surface of the connecting portion 2r is substantially flush with the upper surface of the turn forming portion of the coil 2. Both ends 2e of the winding 2w forming each coil element 2a, 2b are extended from the turn forming portion. Both end portions 2e are connected to a terminal member (not shown), and an external device (not shown) such as a power source for supplying power is connected to the coil 2 through this terminal member.

(Magnetic core)
As shown in FIG. 3, the magnetic core 3 includes a pair of inner core portions 31 disposed inside the coil elements 2 a and 2 b, and a pair of outer cores exposed from the coil 2 without the coil 2 being disposed. Part 32. The magnetic core 3 has an outer core portion 32 disposed so as to sandwich the inner core portion 31 that is spaced apart, and the end surface 31e of each inner core portion 31 and the inner end surface 32e of the outer core portion 32 are brought into contact with each other. Formed. The inner core portion 31 and the outer core portion 32 can be joined by an adhesive, an adhesive tape, or the like. The inner core portion 31 and the outer core portion 32 form a closed magnetic circuit when the coil 2 is excited.

[Heatsink]
The heat sink 5 is as shown in FIG. It is a plate-like member that supports the combined body 10 and is disposed at a location where the liquid refrigerant 8L is supplied together with the combined body 10 (FIG. 5). Specifically, the upper surface side of the heat radiating plate 5 (the upper side in FIG. 1 and FIG. 2) is a mounting surface on which the coil 2 is placed, and the lower surface side of the heat radiating plate 5 (the lower side in FIG. 8 (FIG. 5).

  The size of the heat sink 5 is larger than the lower surface of the combined body 10. Then, since the outer core part 32 can also be supported with the heat sink 5, it functions also as a heat dissipation path of the outer core part 32, and can further improve heat dissipation. The size of the lower surface of the combined body 10 is regarded as the size of the contour shape of the combined body 10 when the combined body 10 is viewed in plan. What is necessary is just to select the shape of the heat sink 5 according to the said outline shape of the union body 10 suitably. Here, the shape of the heat sink 5 is rectangular. The length of the heat radiating plate 5 along the width direction of the coil 2 is substantially equal to the width of the coil 2. The thickness of the heat sink 5 can be appropriately selected depending on the material of the heat sink 5. For example, when the heat radiating plate 5 is made of a nonmagnetic metal such as aluminum, if the thickness of the heat radiating plate 5 is about 1 mm or more and 5 mm or less, in addition to the heat radiating property, it may have sufficient strength and magnetic flux shielding properties. it can.

  Insertion holes 51 are provided at the four corners of the radiator plate 5 outside the region corresponding to the contour shape of the combined body 10. Reactor 1A is formed by inserting a fixing member such as a bolt 51b (FIG. 5) into this insertion hole 51 and screwing the fixing member to an installation target (space forming portion 82 (described later with reference to FIG. 5)). Can be fixed to the installation target. Since the heat sink 5 is made of metal as will be described later, it has high rigidity and exhibits high resistance to the clamping force of the fixing member. Therefore, reactor 1A can be fixed very firmly to the installation target. In addition, after fixing, even if the reactor 1A is operated to vibrate the reactor 1A, it is difficult for the reactor 1A to fall off the installation target.

[Adhesive layer]
The adhesive layer 6 forms the joined body 100 by bonding the combined body 10 and the heat sink 5. The region where the adhesive layer 6 is formed is preferably a region extending over substantially the entire lower surface of the combined body 10. If it does so, the whole union body 10 can be pasted up to heat sink 5, and union body 10 and heat sink 5 can fully be pasted up. The constituent material of the adhesive layer 6 will be described later.

[Annular members]
The annular member 7 surrounds the outer periphery of the joined body 100 so as to be in contact with both the upper surface of the assembly 10 (coil 2) of the joined body 100 and the lower surface of the heat sink 5. Thereby, the combined body 10 and the heat sink 5 can be maintained in an integrated state regardless of the deterioration of the adhesive layer 6 over time. In other words, even if the bonding between the combined body 10 and the heat sink 5 by the adhesive layer 6 becomes insufficient, the combined state of the combined body 10 and the heat sink 5 can be maintained.

  The annular member 7 is spanned in a horizontal manner in which the annular member 7 is stretched in a direction orthogonal to the axial direction of the coil 2 (a parallel direction of the coil elements 2a and 2b) and in a vertical manner in which the annular member 7 is stretched in the axial direction of the coil 2. It is assumed that at least one of the molds (details will be described in a second embodiment described later). That is, the annular member 7 has at least one of a horizontal annular member 7S that extends in a direction orthogonal to the axial direction of the coil 2 and a vertical annular member 7L (described later with reference to FIG. 11) that extends in the axial direction of the coil 2. Preparation. Here, it is set as the form provided with the horizontal annular member 7S which is the former horizontal type. In addition, the form provided with the vertical annular member 7L which is the latter vertical hanging type is demonstrated in Embodiment 2 mentioned later. Although description is abbreviate | omitted, the annular member 7 can also be set as the form provided with both the horizontal annular member 7S and the vertical annular member 7L. That is, the horizontal annular member 7 </ b> S and the vertical annular member 7 </ b> L can be spanned so as to cross each other on the outer periphery of the joined body 100.

  The lateral annular member 7S includes a band portion 71 disposed on the outer periphery of the magnetic core 3, and a binding unit including a lock portion 72 that is attached to one end of the band portion 71 and fixes a loop formed by the band portion 71 to a predetermined length. It is mentioned to use as a material. A plurality of thin protrusions (not shown) arranged in parallel in the width direction are provided in a certain region in the longitudinal direction from the other end of the belt portion 71. The lock portion 72 has an insertion hole (not shown) through which the other end side of the band portion 71 provided with the protrusion is inserted, and a tooth portion (not shown) provided in the insertion hole to bite the protrusion. ). The protrusions of the belt part 71 and the tooth parts of the lock part 72 are, for example, the protrusions can get over the tooth parts in the traveling direction (tightening direction) of the belt part 71, but in the backward direction A mechanism (ratchet mechanism) in which the ridge is hooked on the tooth portion and cannot be moved backward is configured. A commercially available binding material can also be used as the binding material. For example, tie wrap (registered trademark of Thomas and Bets International Inc.) and peak tie (bonding band manufactured by Heraman Tighton Co., Ltd.) can be used.

  The length, width, and thickness of the band portion 71 can be appropriately selected in consideration of the size of the coil 2 and the thickness for one turn. Here, the length in the longitudinal direction of the band portion 71 is simply the length, and the length in the axial direction of the annular member 7 in a state of being stretched over the joined body 100 is the width, the direction orthogonal to both the longitudinal direction and the width direction. The length is the thickness. The length of the band portion 71 is preferably set to a length that substantially surrounds the outer periphery of the joined body 100. Then, since it is easy to maintain the integration of the combined body 10 and the heat radiating plate 5, even if the bonding between the combined body 10 and the heat radiating plate 5 becomes insufficient, the combination 10 and the heat radiating plate 5 An integrated state can be maintained. The width of the band portion 71 is preferably longer than the thickness of one turn of the coil 2. Then, it is easy to enclose the outer peripheral surface of the coil 2. The thickness of the belt portion 71 may be appropriately selected so as to be easy to handle. However, the thinner, the easier it is to improve the heat dissipating property of the portion in contact with the coil 2, and the protrusion from the lower surface of the heat radiating plate 5 can be reduced. The length, width, and thickness are the same for the vertical annular member 7L described later.

  The number of the horizontal annular members 7S may be single or plural. In the case where the number of the horizontal annular members 7S is singular, it is possible to provide the horizontal annular members 7S at substantially the center of the joined body 100 (substantially the center in the axial direction of the coil 2), and the number of the lateral annular members 7S is plural. In this case, the lateral annular member 7 </ b> S may be provided to be spaced from each other in the axial direction of the coil 2.

  The contact portions of the lateral annular member 7S (band portion 71) with the joined body 100 are the lower surface and both side surfaces of the heat sink 5, the upper surfaces of the coil elements 2a and 2b, the width direction outer surfaces (hereinafter simply referred to as outer surfaces), And it is the connection surface of the corner | angular part which connects the said upper surface and the said outer surface (FIG. 2). By contacting these surfaces, it is easy to maintain the integration of the combined body 10 and the heat sink 5, and even if the bond between the combined body 10 and the heat sink 5 becomes insufficient, the combined body 10 and The integrated state of the heat sink 5 can be maintained. In particular, since the horizontal annular member 7S and the magnetic core 3 do not come into contact with each other, damage due to contact of the magnetic core 3 with the horizontal annular member 7S can be prevented.

  The contact portion of the horizontal annular member 7S with the joined body 100 can be adjusted by adjusting the size of the loop formed by the band portion 71 of the horizontal annular member 7S. To make this loop a desired size, the other end side of the band portion 71 is inserted into the insertion hole of the lock portion 72 to form a loop, and the loop is further reduced by pulling the other end side. The above-mentioned ridge of the band portion 71 is appropriately bitten into the above-mentioned tooth portion of the lock portion 72 with a short loop length. And a loop can be fixed to a desired magnitude | size by selecting suitably the position of the said protrusion to make this bite.

  The constituent material of the annular member 7 (transverse annular member 7S) may be a material having heat resistance to such an extent that it does not soften with respect to the maximum temperature achieved when the reactor 1A is used. In particular, it is preferable to use a material that is excellent in insulation and heat dissipation in addition to heat resistance. Examples of such constituent materials include resins such as polyamide, polypropylene, fluororesin, polyether ether ketone (PEEK), rubbers such as chloroprene rubber, nitrile rubber, fluororubber, stainless steel, copper / copper alloy, aluminum / aluminum Non-magnetic metals such as alloys can be mentioned. If the annular member 7 is a nonmagnetic material, the reactor 1A is not affected electromagnetically. When a resin is used for the annular member 7, it is easy to obtain an appropriate strength with little deterioration over time, and thus it is easy to maintain the joined state between the assembly 10 and the heat sink 5. When rubber is used for the annular member 7, it is difficult to damage the combined body 10, and the combined body 10 and the radiator plate 5 can be easily pressed. When a metal material is used for the annular member 7, the strength is strong and it is easy to maintain the combined body 10 and the heat sink 10 in a sufficiently joined state. In particular, in the case of a metal material, a material whose surface is resin-coated is preferable. This is because it is easy to prevent damage to the objects to be bound and to ensure insulation from the combined body 10.

  In addition, although the horizontal annular member 7S is formed of a binding material provided with the band portion 71 and the lock portion 72 here, an endless rubber band having elasticity can also be used. Since the rubber band can surround the outer periphery of the joined body 100 simply by expanding the diameter and fitting it into the outer periphery of the joined body 100, the manufacturing operation is easy and the manufacturing time can be shortened.

[Reactor usage status]
The use state of the reactor 1A will be described with reference to FIG.

[Case]
The reactor 1 </ b> A can further include a case 8 that houses and fixes the joined body 100 (FIG. 5). The case 8 is a box-shaped member into which the liquid refrigerant 8L is supplied and discharged. The supply port 80i for supplying the liquid refrigerant 8L into the case 8 and the liquid refrigerant 8L in the case 8 are discharged out of the case 8. And a discharge port 80o. The liquid refrigerant 8L is supplied into the case 8 from the supply port 80i, and the liquid refrigerant 8L in the case 8 is discharged out of the case 8 through the discharge port 80o. Then, the discharged liquid refrigerant 8L is cooled to a predetermined temperature by a cooler (not shown) or the like, and is supplied again from the supply port 80i into the case 8. In this way, the liquid refrigerant 8L is circulated and supplied into the case 8.

The arrangement location and the diameter of the supply port 80i and the discharge port 80o can be selected as appropriate. By appropriately adjusting these, a part of the joined body 100 is immersed in the liquid refrigerant 8L, or the upper surface of the coil 2 is below the liquid surface of the liquid refrigerant 8L as shown in FIG. 5 (the end 2e of the winding 2w is The entire joined body 100 can be constantly immersed in the liquid refrigerant 8L so as to be positioned on the liquid surface. Here, the supply port 80i is provided above the joined body 100, and the discharge port 80o is provided at a position substantially the same as the height of the space forming portion 82 described later. The diameter φ _o of the discharge port 80 _o is made smaller than the diameter φ _i of the supply port 80 _i . Thereby, as shown in FIG. 5, the whole joined body 100 is always immersed in the liquid refrigerant 8L.

  The case 8 is formed on the mounting surface 81 facing the heat radiating plate 5 and the mounting surface 81, and when the joined body 100 is stored in the case 8, the liquid refrigerant 8L is circulated between the heat radiating plate 5 and the mounting surface 81. A space forming part 82 for forming a space. The space forming part 82 is configured by a protrusion protruding from the mounting surface 81. As the shape of the space forming portion 82, a block shape, a column shape, a pipe shape, or the like can be suitably used. In FIG. 5, the columnar space forming portion 82 is used. The height of the space forming part 82 is set to such an extent that the liquid refrigerant can sufficiently flow below the heat radiating plate 5. If it does so, the heat dissipation of reactor 1A can be improved more. This is because the space forming portion 82 can form a space for allowing the liquid refrigerant 8L to flow between the heat radiating plate 5 and the mounting surface 81, and the liquid refrigerant 8L can also be brought into direct contact with the lower surface of the heat radiating plate 5. Further, since the space forming portion 82 can form a space between the heat sink 5 and the mounting surface 81, the horizontal annular member 7 </ b> S protrudes from the lower surface of the heat sink 5, but the horizontal annular member 7 </ b> S is attached to the case 8. There is no interference with the surface 81.

  The number of the space forming portions 82 can be equal to or more than the number of the insertion holes 51 of the heat radiating plate 5, and the location of the space forming portions 82 is, for example, a location corresponding to the insertion holes 51 of the heat radiating plate 5. Can be mentioned. An insertion hole through which a bolt 51b for fixing the heat radiating plate 5 is inserted is formed in a contact surface of the space forming portion 82 with the heat radiating plate 5. The insertion hole is internally threaded, and the heat sink 5 (joined body 100) can be fixed to the case 8 by screwing a bolt 51b into the insertion hole.

  Examples of the material of the case 8 include metals such as aluminum and alloys thereof, magnesium and alloys thereof, copper and alloys thereof, silver and alloys thereof, iron, and austenitic stainless steel. In particular, aluminum, magnesium, and alloys thereof are lightweight and can be expected to have a shielding function. Aluminum and its alloys are also excellent in heat dissipation. In addition, examples of the material of the case 8 include insulating resins such as polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, and acrylonitrile-butadiene-styrene (ABS) resin. These insulating resins may contain ceramic fillers such as silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide.

[Liquid refrigerant]
As the liquid refrigerant 8L, a liquid refrigerant whose form does not change depending on the maximum temperature achieved when the reactor 1A is used (for example, liquid that does not vaporize in liquid) can be suitably used. Specifically, fluorinated inert liquids such as ATF (Automatic Transmission Fluid) and Fluorinert (registered trademark) which are lubricating oils for automatic transmissions, chlorofluorocarbon refrigerants such as HCFC-123 and HFC-134a, methanol and alcohol, etc. Examples thereof include alcohol-based refrigerants and ketone-based refrigerants such as acetone. When the reactor 1A is used for an automobile or the like, if the ATF is used, the liquid refrigerant 8L does not need to be prepared separately, and if a circulation supply mechanism is constructed, a heat dissipation structure in the reactor 1A using the liquid refrigerant 8L can be easily formed. it can.

[Effects of the main features of the reactor]
According to the reactor 1A, the combined body 10 and the heat radiating plate 5 can be formed without damaging the outer core portion 32 by surrounding the outer periphery of the joined body 100 with the lateral annular member 7S extending in the direction orthogonal to the axial direction of the coil 2. Is easy to maintain. This is because the contact portion of the lateral annular member 7S with the joined body 100 can be the coil 2 and the heat radiating plate 5, and the outer core portion 32 can be in non-contact. In other words, even if the bonding between the combined body 10 and the heat sink 5 by the adhesive layer 6 becomes insufficient, the combined state of the combined body 10 and the heat sink 5 can be maintained. Therefore, even if it is disposed at a location that is directly immersed in the supplied liquid refrigerant 8L, the combined body 10 can be stably fixed to the heat radiating plate 5 and the state can be maintained, so that the heat dissipation of the reactor 1A can be improved. .

[Description of each configuration including other features]
[coil]
As the winding 2w constituting the coil 2, a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, or an alloy thereof can be suitably used. . In the present embodiment, the conductor is made of a copper rectangular wire, and the insulation coating is a coated rectangular wire made of enamel (typically polyamideimide), and each of the coil elements 2a and 2b uses the coated rectangular wire as edgewise. This is a wound edgewise coil (FIG. 3). Moreover, although the end surface shape of each coil element 2a, 2b is made into the shape which rounded the rectangular corner | angular part, end surface shape can be changed suitably, such as circular shape. The coil may include a pair of coil elements formed by spirally winding two independent windings, and a connecting member that connects both coil elements with members independent of both coil elements. Good.

[Magnetic core]
(Size / shape)
The inner core part 31 is arrange | positioned inside coil element 2a, 2b (coil 2) as mentioned above. The “inner core portion disposed inside the coil” means an inner core portion at least partially disposed inside the coil. For example, the case where the central portion of the inner core portion is disposed inside the coil and the vicinity of the end portion of the inner core portion is located outside the coil is also included in the “inner core portion disposed inside the coil”. That is, the axial length of the inner core portion 31 may be longer than the axial length of the coil elements 2a and 2b, and the end surface of the inner core portion 31 and the vicinity thereof protrude from the end surfaces of the coil elements 2a and 2b. May be exposed.

  The shape of the inner core portion 31 and the shape of the outer core portion 32 can be appropriately selected. Here, as shown in FIG. 3, the shape of the inner core portion 31 is a rectangular parallelepiped shape, and the shape of the outer core portion 32 is a dome shape on the upper surface and the lower surface (a deformation base whose cross-sectional area decreases from the inner end surface 32e outward. Shape) columnar body. As the shape of the outer core portion 32, for example, a prismatic body can be used.

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

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

  Each core piece is typically made of a soft magnetic material such as iron, an iron alloy, a metal such as an alloy containing a rare earth element, or a non-metal such as ferrite. Examples of iron alloys include Fe-Si alloys, Fe-Al alloys, Fe-N alloys, Fe-Ni alloys, Fe-C alloys, Fe-B alloys, Fe-Co alloys, Fe-P. Alloy, Fe—Ni—Co alloy, Fe—Al—Si alloy and the like. As the core piece, a molded body using the soft magnetic powder made of the soft magnetic material or a laminated body in which a plurality of magnetic thin plates having an insulating coating (for example, an electromagnetic steel plate typified by a silicon steel plate) are stacked can be used. Examples of the molded body include a green compact, a sintered body, and a composite material including soft magnetic powder and a resin. Here, each core piece is a green compact.

  The green compact is typically produced by subjecting a raw material powder to pressure treatment and then appropriate heat treatment. The raw material powder is a soft magnetic powder composed of the above-mentioned soft magnetic material, and a coating powder comprising an insulating coating composed of silicone resin, phosphate, etc. on the surface of the metal particles when the above-mentioned soft magnetic material is a metal, soft magnetic powder In addition, a mixed powder in which a resin such as a thermoplastic resin or an additive such as a higher fatty acid (typically, one that disappears by heat treatment or changes into an insulating material) is appropriately mixed with the coating powder. When the coating powder is used, an insulating material is interposed between the metal particles, and an insulating property is excellent, and a compacted product with low loss can be obtained. Moreover, if a compact iron compact uses pure iron powder (preferably coating powder) as raw material powder, it will be excellent in moldability and it will be easy to manufacture a core piece.

  The average particle diameter of the soft magnetic powder is preferably 1 μm or more and 1000 μm or less, particularly preferably 10 μm or more and 500 μm or less. The soft magnetic powder may be a mixture of a plurality of types of powders having different particle sizes. When a soft magnetic powder obtained by mixing a fine powder and a coarse powder is used as a material for a green compact, a saturated magnetic flux density is high and a low-loss reactor is easily obtained. Note that the size of the soft magnetic powder in the green compact and the powder used for the material are substantially the same (maintained).

  The content of the soft magnetic powder in the green compact is preferably 75% by volume or more and more preferably 80% by volume or more when the green compact is 100%. The adjustment of the content of the soft magnetic powder in the green compact is, for example, the thickness of the insulating coating formed on the surface of the soft magnetic particles, or the resin or additive added to the soft magnetic powder during the production of the green compact. Can be adjusted by quantity. Examples of the magnetic properties of the green compact include a saturation magnetic flux density of 1.0 T or more, further 1.6 T or more, 1.8 T or more, 2 T or more, and a relative magnetic permeability of 50 or more and 500 or less.

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

  The magnetic core 3 may have a form having uniform magnetic characteristics as a whole, or a form in which the magnetic characteristics are partially different, that is, the inner core part 31 and the outer core part 32 have different magnetic characteristics. You can also In the latter case, for example, a compacted body made of a different material may be used for the core piece 31m of the inner core portion 31 and the outer core portion 32. If the saturation magnetic flux density of the core piece 31m of the inner core portion 31 is greater than the saturation magnetic flux density of the outer core portion 32, the area of the inner core portion 31 through which the magnetic flux passes can be easily reduced, and the reactor can be downsized. . If the relative permeability of the core piece 31m of the inner core portion 31 is smaller than the relative permeability of the outer core portion 32, the leakage flux in the outer core portion 32 is reduced because the relative permeability of the outer core portion 32 is relatively high. Easy to do.

(Coating layer)
It is preferable that a coating layer (not shown) is provided at a location where the magnetic core 3 is in contact with the liquid refrigerant 8L (FIG. 5). If it does so, while being able to improve the rust prevention property of the magnetic core 3, the insulation with the coil 2 can be improved. In particular, when the magnetic core 3 has a core piece formed of a compacted body, and further when the core piece constitutes the outer core portion 32 exposed from the coil 2, a coating layer is formed on the outer periphery of the core piece. In addition to rust prevention and insulation, it is also effective in preventing the soft magnetic powder from falling off due to liquid refrigerant. Here, as described above, it is preferable that the entire magnetic core 3 is formed of a compacted body, and at least the surface of the outer core portion 32 is provided with a coating layer. Since the outer core portion 32 is exposed from the coil 2, the liquid refrigerant 8L supplied into the case 8 is likely to be directly applied from the supply port 80i (FIG. 5). Therefore, by providing a coating layer on the surface of the outer core portion 32, in addition to improving rust prevention and insulation, it is particularly effective in preventing the soft magnetic powder of the outer core portion 32 from falling off due to the application of the liquid refrigerant 8L. It is. Of course, if a coating layer is provided on the surface of the inner core portion 31 in addition to the outer core portion 32, the rust prevention property of the inner core portion 31 is improved, the insulation with the coil 2 is improved, and the softness by the liquid refrigerant 8L is increased. Magnetic powder can be prevented from falling off. The coating layer covering the magnetic core 3 may cover the coil 2 together with the magnetic core 3. In that case, the rust prevention property of the coil 2 can also be improved.

  The thickness of the coating layer is 0.1 mm or more and 3 mm or less. By setting the thickness of the coating layer to 0.1 mm or more, rusting of the magnetic core 3 due to the liquid refrigerant can be prevented. Further, the insulation with the coil 2 can be improved. On the other hand, when the thickness of the coating layer is 3 mm or less, the coating layer does not become too thick.

  The constituent material of the coating layer is preferably a material excellent in rust prevention, and particularly preferably a material excellent in insulation and thermal conductivity in addition to rust prevention. Examples of such materials include epoxy resins, urethane resins, polyimide resins, amideimide resins, polyamideimide resins, silicone resins, and phenol resins. The coating layer can be formed by dipping in a constituent resin, or by applying with a brush or spray.

[Insulator]
The reactor 1 </ b> A can include an insulator 4 between the coil 2 and the magnetic core 3 for enhancing the insulation properties and positioning reliability (FIG. 3). The insulator 4 is formed by combining each of the coil elements 2a and 2b with a pair of divided pieces 40a and 40b having the same shape that can be divided in the axial direction of the coil elements 2a and 2b. Each of the divided pieces 40a and 40b is a frame interposed between the peripheral wall portion 41 that covers at least a part of the outer periphery of the inner core portion 31, and both end surfaces of the coil elements 2a and 2b and the inner end surface 32e of the outer core portion 32. A plate portion 42. The frame plate part 42 and the peripheral wall part 41 are integrally connected.

(Peripheral wall and frame plate)
The peripheral wall portion 41 is composed of four plate-like bodies interposed between the inner peripheral surfaces of the respective corner portions of the coil elements 2a and 2b and the respective corner portions of the inner core portion 31, and the coil elements 2a and 2b and the inner sides thereof. Insulates from the core portion 31. Each frame plate portion 42 is configured by a B-shaped flat plate member having a pair of openings (through holes) into which the respective inner core portions 31 can be inserted. The side surface of the coil 2 of each frame plate portion 42 is in contact with the end surfaces (both end surfaces and the lower end surface) excluding the upper end surfaces of the coil elements 2a and 2b (FIG. 2). That is, the frame plate portion 42 does not contact the upper end surface of the coil 2, and the upper end surface of the coil 2 is exposed from the frame plate portion 42.

(Partition)
The split pieces 40a and 40b include a partition portion 43 that ensures insulation between the coil elements 2a and 2b. The partition portion 43 is provided between the peripheral wall portions 41 of the frame plate portion 42 so as to be interposed between the coil elements 2a and 2b.

(Core positioning part)
As shown in FIG. 2, the split pieces 40 a and 40 b include two projecting pieces 44 for positioning the outer core portion 32 with respect to each other. The two projecting pieces 44 are formed at locations where the outer core portion 32 is sandwiched from both sides in the width direction below the side surface of the outer core portion 32. The outer core portion 32 is positioned by arranging the outer core portion 32 between the two projecting pieces 44.

(Material)
Examples of the constituent resin of the insulator 4 include thermoplastic resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6, nylon 66, and polybutylene terephthalate (PBT) resin. Here, PPS resin is used.

[Heatsink]
The constituent material of the heat sink 5 includes a nonmagnetic metal from the viewpoint of thermal conductivity and electromagnetic. As a specific metal, aluminum (thermal conductivity: 237 W / m · K) or an alloy thereof is preferable. In addition, magnesium (156 W / m · K) or an alloy thereof, copper (398 W / m · K) or an alloy thereof. Silver (427 W / m · K) or an alloy thereof, iron, or austenitic stainless steel (for example, SUS304: 16.7 W / m · K) may be used. When these materials are used, the magnetic flux shielding property is also excellent. In particular, if aluminum, magnesium, or an alloy thereof is used, the reactor 1A can be reduced in weight. In particular, aluminum and its alloys are excellent in corrosion resistance, and magnesium and magnesium alloys are excellent in vibration damping properties. The heat sink 5 made of these metal materials can be formed by plastic working such as press working as well as casting such as die casting.

[Adhesive layer]
The constituent material of the adhesive layer 6 may be an insulating resin having a heat resistance to such an extent that it does not soften with respect to the maximum temperature achieved when the reactor 1A is used. For example, a thermosetting resin such as an epoxy resin, a silicone resin, or an unsaturated polyester, or a thermoplastic insulating resin such as a PPS resin or LCP can be suitably used for the adhesive layer 6. This insulating resin may contain at least one ceramic filler selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide. If it does so, the heat dissipation of the contact bonding layer 6 can be improved. The thermal conductivity of the adhesive layer 6 is preferably 0.1 W / m · K or more, more preferably 0.15 W / m · K or more, still more preferably 0.5 W / m · K or more, particularly preferably. 1 W / m · K or more, most preferably 2.0 W / m · K or more. Here, the adhesive layer 6 is formed of an epoxy adhesive containing a filler made of alumina (thermal conductivity: 3 W / m · K or more). The adhesive layer 6 can be easily formed by coating or screen printing.

[Sensor]
Reactor 1A preferably includes a sensor 6S for measuring physical quantities (for example, temperature, current value, voltage value, acceleration, etc.) during operation of reactor 1A (FIG. 4). The operation of the reactor 1 can be stabilized based on the measurement result.

  An arrangement location of the sensor 6S may be a space (trapezoidal space) surrounded by the pair of coil elements 2a and 2b and the heat radiating plate 5. Since this reactor 1A is disposed at a location immersed in the liquid refrigerant 8L, providing the sensor 6S in the trapezoidal space makes it easy to accurately measure the physical quantity during the operation of the reactor 1A. For example, it is considered that it is less susceptible to the physical quantity of the liquid refrigerant 8L, particularly the temperature of the liquid refrigerant 8L, compared to the case where it is provided on the opposite side between the two coil elements 2a and 2b. Further, the space in which the sensor 6S is provided is a place where the temperature tends to be high during the operation of the reactor 1A (combination body 10). Therefore, by measuring the temperature of this location using a temperature sensor including a thermosensitive element such as a thermistor as the sensor 6S, and adjusting the flow rate and temperature of the liquid refrigerant 8L to manage the temperature of the reactor 1A (union 10), The operation of the reactor 1A can be stabilized.

  The sensor 6S may be fixed by the adhesive layer 6 in the space. More specifically, the sensor 6S is embedded in the adhesive layer 6. By adopting such a configuration, the position of the sensor 6S in the space is not displaced due to vibration when the reactor 1A is operated. Therefore, the measurement result by the sensor 6S is less likely to vary, and the measurement result by the sensor 6S. Reliability can be improved. When the reliability of the measurement result is high, the reactor 1A can be operated more stably.

[Manufacture of reactors]
Reactor 1A typically prepares assembly 10 and heat sink 5 ⇒ produces assembly 100 of assembly 10 and heat sink 5 ⇒ arrangement of lateral annular member 7S on the outer periphery of joint 100 ⇒ case 8 It can be manufactured by the process of storing and fixing to the.

[Preparation of union and heat sink]
The coil 2, the magnetic core 3, the insulator 4, and the heat sink 5 are prepared. Here, the coil 2 and the magnetic core 3 having the above-described coating layer may be prepared, or the coil 2 and the magnetic core 3 having no coating layer may be prepared. In the former case, the coil 2 and the magnetic core 3 are individually immersed in the above-described constituent resin in advance, and the outer circumferences of the coil 2 and the magnetic core 3 are covered with the constituent resin. Thereafter, the constituent resin is cured to form a coating layer. Alternatively, the coating layer may be formed by individually coating the coil 2 and the magnetic core 3 by spraying or the like. In the case of the latter, you may form by the coating layer formation process mentioned later. Here, the coil 2 and the magnetic core 3 without the latter coating layer were prepared.

  First, the split piece 40 a (40 b) is fitted to one end side of the inner core portion 31. Subsequently, the inner core portion 31 fitted with the divided piece 40 a is inserted into the coil 2, and the other divided piece 40 b (40 a) is fitted to the other end side of the inner core portion 31. Thereby, the integrated object with which the coil 2, the inner core part 31, and the insulator 4 (divided piece 40a, 40b) were united is produced. And the assembled body 10 is produced by sandwiching the inner core portion 31 between the pair of outer core portions 32. At that time, the outer core portion 32 is positioned by the core positioning portions (projecting pieces 44) of the split pieces 40a and 40b.

[Preparation of joined body]
The combined body 10 and the heat radiating plate 5 are bonded by the adhesive layer 6 to produce the bonded body 100. On the upper surface (mounting surface) of the heat sink 5, the adhesive layer 6 having the same size as the lower surface of the combined body 10 is formed. The combined body 10 is placed on the adhesive layer 6, the adhesive layer 6 is cured, and the combined body 10 and the heat sink 5 are joined.

[Formation of coating layer]
When the coil 2 and the magnetic core 3 not provided with the coating layer are prepared in the preparation process as in this example, the coating layer is formed on the outer peripheral surface of the combined body 10 after the joined body 100 is formed and before the horizontal annular member 7S is provided. To do. For example, in a state where the combined body 10 of the bonded body 100 is directed downward, the bonded body 100 is immersed in the container filled with the constituent resin of the coating layer up to the boundary between the combined body 10 of the bonded body 100 and the heat sink 5. Then, the outer periphery of the combined body 10 is covered with the above-described constituent resin. And the coating layer is formed by hardening the said structural resin which covers the outer periphery of the assembly 10.

[Arrangement of annular members]
A lateral annular member 7 </ b> S is disposed on the outer periphery of the joined body 100. Here, as shown in FIG. 1, the transverse annular member 7 </ b> S is spanned in a direction orthogonal to the axial direction of the coil 2. For example, first, the heat sink 5 of the joined body 100 is disposed on the band portion 71. Subsequently, a loop is formed so as to surround the outer periphery of the joined body 100 by inserting the other end side of the band portion 71 into the insertion hole of the lock portion 72 as described above. Then, the loop is further reduced in diameter by pulling the other end side, and the protrusions of the band portion 71 are appropriately bitten into the tooth portions of the lock portion 72. The loop is reduced in diameter until the lateral annular member 7 comes into contact with the lower surface and both side surfaces of the heat sink 5 and the upper surfaces of the coil elements 2a and 2b, the outer surface, and the connecting surface. Thereby, the outer periphery of the joined body 100 can be enclosed by the lateral annular member 7S.

[Storing and fixing to the case]
Subsequently, the joined body 100 surrounded by the lateral annular member 7 </ b> S is stored and fixed in the case 8. The heat radiating plate 5 is arranged in the space forming portion 82 so that the insertion hole 51 of the heat radiating plate 5 is aligned with the insertion hole of the space forming portion 82 of the case 8. Then, the bolt 51b is inserted into the insertion hole 51 and screwed into the insertion hole. Thus, the heat sink 5 (joined body 100) is fixed to the space forming portion 82. In this state, the liquid refrigerant 8L is supplied into the case 8 from the supply port 80i of the case 8, and the liquid refrigerant 8L is circulated and supplied into the case 8 by discharging the liquid refrigerant out of the case 8 through the discharge port 80o. Reactor 1A is cooled.

  According to the manufacturing method described above, the manufacturing time and process of the reactor 1A can be shortened and simplified as compared with the conventional reactor, and therefore the reactor 1A is excellent in productivity. Since the heat sink 5 is used for fixing the reactor 1A to the installation target, the reactor 1A is manufactured by placing and fixing the combined body 10 on the heat sink 5 with the adhesive layer 6 and passing the horizontal annular member 7S. This is because it is not necessary to mold the outer resin portion having the flange portion as in the prior art. And as for the enclosure to the outer periphery of the joined body 100 of the horizontal annular member 7S, while inserting the other end side of the belt | band | zone part 71 through the said insertion hole of the lock | rock part 72 as above-mentioned, the said protrusion of the belt | band | zone part 71 is said. Can be easily performed by causing the tooth portion of the lock portion 72 to be appropriately bitten. Therefore, reactor 1A can be easily manufactured.

<< Modification 1-1 >>
As a modified example 1-1 of the first embodiment, as illustrated in FIGS. 6 and 7, a reactor 1 </ b> A including a holder 9 for positioning the lateral annular member 7 </ b> S with respect to the coil 2 can be used. Since the configuration other than the holder 9 is the same as that of the first embodiment, the following description will focus on the differences from the first embodiment.

[holder]
The holder 9 positions the horizontal annular member 7 </ b> S with respect to the coil 2, thereby suppressing the lateral annular member 7 </ b> S from shifting in the width direction. As shown in FIG. 6, the holder 9 is disposed between the coil elements 2a and 2b, and is positioned between the coil elements 2a and 2b by engaging both of the divided pieces 40a and 40b. Specifically, as shown in FIG. 7, a main body portion 91 that is supported by both partition portions 43 across the partition portions 43 of the split pieces 40 a and 40 b between the coil elements 2 a and 2 b, and the main body portion. At both ends of 91, an engaging portion 92 that engages with the partition portion 43 is provided.

  The main body 91 is configured by a flat plate-like body in which both side surfaces on the distal end side in the direction in which the holder 9 is inserted between the coil elements 2a and 2b are tapered so that the width decreases toward the distal end. The engaging portion 92 is formed of a thin plate-like body that is formed integrally with the main body portion 91, and has a hook 92f that protrudes toward the partition portion 43 at the end of the thin plate-like body on the distal end side. The shape of the hook 92f is tapered so as to become thinner toward the tip.

  When the holder 9 is inserted between the coil elements 2 a and 2 b, the hook 92 f of the engaging portion 92 is engaged with the partition portion 43, and the main body portion 91 is supported by the both partition portions 43. Thereby, the holder 9 can be prevented from falling off, coming off, and moving in the width direction. In this example, when the main body portion 91 is supported by both partition portions 43, there is almost no gap between the hook 92 f and the partition portion 43. Therefore, the vertical movement of the holder 9 can be suppressed.

  The holder 9 includes a concave portion 91 c into which the horizontal annular member 7 </ b> S (band portion 71) is fitted on the upper surface of the main body portion 91. The concave portion 91c positions the lateral annular member 7S (band portion 71). The width of the recess 91c is set such that the width of the horizontal annular member 7S (band portion 71) has an extra width necessary for fitting. If it does so, the belt | band | zone part 71 is fitted in this recessed part 91c, and the shift | offset | difference to the width direction of the horizontal annular member 7S can be suppressed. It is preferable that the depth of the concave portion 91c be set such that the bottom surface of the concave portion 91c is substantially flush with the upper surfaces of the coil elements 2a and 2b. If it does so, it will be easy to make the belt | band | zone part 71 closely_contact | adhere to the upper surface of coil element 2a, 2b.

  The constituent material of the holder 9 can be an insulating resin similar to the constituent material of the insulator 4 described above. Then, even when the holder 9 is disposed in contact with the coil elements 2a and 2b, the insulation between them is excellent.

  In addition, in this example, although the holder 9 demonstrated the form provided with the engaging part 92 which has the hook 92f, the holder 9 does not need to be provided with the engaging part 92. Even if the holder 9 does not include the engaging portion 92, the upward movement of the holder 9 can be suppressed by the downward force of the holder 9 by the lateral annular member 7S (band portion 71). On the other hand, the downward movement of the holder 9 can be suppressed by the main body portion 91 being supported by both partition portions 43. Further, even when the holder 9 does not include the engaging portion 92, the displacement of the lateral annular member 7S can be suppressed. When the holder 9 does not include the engaging portion 92, the holder 9 is more easily inclined in the parallel direction of the coil elements 2a and 2b than when the holder 9 includes the engaging portion 92. However, since the holder 9 is in contact with the coil elements 2a and 2b, the horizontal annular member 7S does not tilt so as to be disengaged from the recess 91c of the holder 9. The movement of the holder 9 in the axial direction of the coil 2 is suppressed between the pair of split pieces 40a and 40b (partition portion 43).

[Heatsink]
The heat sink 5 preferably includes an insertion hole (not shown) for drawing the wiring of the sensor 6S from the trapezoidal space surrounded by the coil elements 2a and 2b and the heat sink 5 to the outside of the joined body 100. The place where the insertion hole is formed may be a place corresponding to the space between the coil elements 2 a and 2 b of the heat radiating plate 5. Since the reactor 1A has a space between the heat sink 5 and the mounting surface 81 of the case 8 as described above, the wiring of the sensor 6S can be easily made from the lower surface of the heat sink 5 through the insertion hole of the heat sink 5. It can be pulled out. In particular, when the holder 9 is provided as in this example, it is difficult to draw the wiring of the sensor 6S upward from between the coil elements 2a and 2b. Therefore, by providing the insertion hole, the wiring of the sensor 6S can be drawn. It is effective.

  According to this configuration, the holder 9 can easily suppress the lateral annular member 7S from shifting in the width direction. In particular, it is easy to suppress the lateral annular member 7S from shifting in the width direction even with respect to vibration during the operation of the reactor 1A. Therefore, it is easy to maintain the integration of the combined body 10 and the heat sink 5.

<< Modification 1-2 >>
As a modified example 1-2, as shown in FIG. 8, the heat sink 5 can be a reactor having a positioning portion for positioning the lateral annular member 7 </ b> S with respect to the heat sink 5. Since the configuration other than the heat radiating plate 5 is the same as that of the first embodiment, the following description will focus on the differences from the first embodiment. This is also the case with Modifications 1-3 and 1-4 described later. FIG. 8 is a perspective view of the reactor when the lower surface of the heat radiating plate 5 is viewed obliquely, and shows the lower surface and side surfaces of the heat radiating plate 5 and the lateral annular member 7S in the vicinity thereof in an enlarged manner.

[Heatsink]
The positioning portion is formed on the lower surface of the heat radiating plate 5 and includes a groove 52 into which the lateral annular member 7S is fitted. The groove 52 is formed over the entire area of contact with the lateral annular member 7 </ b> S on the lower surface of the heat radiating plate 5. The width of the groove 52 is preferably set such that the extra width necessary for fitting is provided in the width of the horizontal annular member 7S. If it does so, the shift | offset | difference to the axial direction of the coil 2 of the horizontal annular member 7S can be suppressed. The depth of the groove 52 may be greater than or equal to the thickness of the lateral annular member 7S. Then, when the horizontal annular member 7S is fitted into the groove 52, the horizontal annular member 7S can be prevented from protruding from the lower surface of the heat sink 5. Therefore, even if the installation target of the heat sink 5 is a flat surface, formation of a gap due to the thickness of the lateral annular member 7S can be suppressed between the heat sink 5 and the heat sink 5 and the installation target can be easily brought into close contact with each other.

<< Modification 1-3 >>
As modification 1-3, as shown in FIG. 9, it can be set as the reactor which has a positioning part different from modification 1-2. FIG. 9 is a perspective view of the reactor when the upper surface of the heat radiating plate 5 is viewed obliquely, and shows the upper surface and side surfaces of the heat radiating plate 5 and the lateral annular member 7S in the vicinity thereof enlarged.

  A positioning part is formed in the both sides | surfaces of the heat sink 5, and is comprised by the recessed part 53 in which the horizontal annular member 7S is engage | inserted. It is preferable that the width of the recess 53 is set to an extent that the extra width necessary for fitting is provided in the width of the horizontal annular member 7S. If it does so, the shift | offset | difference to the axial direction of the coil 2 of the horizontal annular member 7S can be suppressed. It is preferable that the depth of the concave portion 53 is set so that the bottom surface of the concave portion 53 and the outer surface of the coil element 2a (2b) are flush with each other. Here, it is mentioned that the depth of the concave portion 53 is approximately the same as the thickness of the lateral annular member 7S. If it does so, since it is easy to contact the strip | belt part 71 of the horizontal annular member 7S, and the said outer surface of the coil element 2a (2b), it is easy to maintain integration with the assembly 10 and the heat sink 5. FIG. That is, even if the bonding between the combined body 10 and the heat sink 5 becomes insufficient, the combined state of the combined body 10 and the heat sink 5 can be maintained.

<< Modification 1-4 >>
As modification 1-4, as shown in FIG. 10, it can be set as the reactor which has a positioning part different from modification 1-2 and 1-3. FIG. 10 is a perspective view of the reactor as seen from an oblique view of the upper surface of the heat radiating plate 5 as in FIG. 9, and shows the upper surface and side surfaces of the heat radiating plate 5 and the lateral annular member 7S in the vicinity thereof.

  The positioning portion is composed of a pair of projecting pieces 54 projecting from both sides in the width direction of the upper surface of the heat radiating plate 5. The inner side surfaces (surfaces facing each other) of both projecting pieces 54 are in contact with the outer side surfaces of the coil elements 2a and 2b.

  The width of the protruding piece 54 may be equal to or greater than the width of the lateral annular member 7S. In particular, if it is sufficiently wider than the width of the annular member 7, the horizontal annular member 7 </ b> S can be easily routed and the assembly can be easily positioned. Although the width of the projecting piece 54 depends on the width of the horizontal annular member 7S, for example, it is preferable that the width of the projecting piece 54 is not more than half of the length in the axial direction of the coil 2 and more preferably not more than one third. If it does so, the exposure area | region from the protruding piece 54 of the said outer side surface of the coil element 2a (2b) will become wide, and it can be easy to contact | connect the liquid refrigerant 8L (FIG. 5), and can improve heat dissipation. The height of the projecting piece 54 is such that at least the inner surface of the projecting piece 54 is in contact with the outer surface of the coil element 2a (2b). If it does so, in addition to positioning of the horizontal annular member 7S with respect to the heat sink 5, positioning of the combination 10 with respect to the heat sink 5 can also be performed. The height of the protruding piece 54 may be about half of the height of the coil element 2a (2b). If it does so, the said exposure area | region of the said outer side surface of the coil element 2a (2b) will become wide, and it will be easy to contact | connect the liquid refrigerant 8L, and can improve heat dissipation.

[Annular members]
The contact points of the lateral annular member 7S with the joined body 100 include the lower surface, both side surfaces, and the outer surface (opposite side of the inner surface) of the projecting piece 54, the upper surfaces of the coil elements 2a and 2b, and A part of the connecting surface. That is, the lateral annular member 7S does not come into contact with the outer surface of the coil element 2a (2b) and a part of the connecting portion by the protruding piece 54. However, since the horizontal annular member 7S is in contact with the lower surface, both side surfaces of the heat radiating plate 5, and the outer surface of the projecting piece 54, and the upper surfaces of the coil elements 2a and 2b, the combined body 10 and the heat radiating plate. 5 can be sufficiently maintained.

<< Embodiment 2 >>
In Embodiment 1 and Modifications 1-1 to 1-4, the horizontal reactor 1 </ b> A including the horizontal annular member 7 </ b> S in which the annular member 7 is stretched in a direction orthogonal to the axial direction of the coil 2 has been described. In the second embodiment, a vertical reactor 1B including a vertical annular member 7L in which the annular member 7 is stretched in the axial direction of the coil 2 will be described with reference to FIG. Hereinafter, the description will focus on the differences from the first embodiment, and the same configuration and effects will be omitted.

[Annular members]
The number of the vertical annular members 7L may be the same as the number of the coil elements 2a and 2b. If it does so, since the vertical annular member 7L can be spanned for every coil element 2a, 2b, it is easy to maintain integration with the heat sink 5. Here, the number of the longitudinal annular members 7L is two. And each vertical annular member 7L is spanned in the axial direction of each coil element 2a, 2b. The contact portions of the vertical annular members 7L are the upper surfaces of the coil elements 2a and 2b, the lower surface and both end surfaces of the heat sink 5, and the outer surfaces of the outer core portions 32.

[Heatsink]
The heat radiating plate 5 is formed on the lower surface of the heat radiating plate 5 in the same manner as in the above-described modified example 1-2 to modified example 1-4. Further, at least one of a concave portion into which each vertical annular member 7L is fitted and a protruding piece protruding from both end sides of the upper surface of the heat radiating plate 5 may be provided. Two grooves and recesses may be provided on each of the lower surface and both end surfaces of the heat sink 5. A total of four protruding pieces may be provided on each of the front edge portion and the rear edge portion of the heat radiating plate 5, or a total of two protruding pieces may be provided. In the latter case, it may be mentioned that the width of the protruding piece is wider than the outer width in the parallel direction of the two vertical annular members 7L. If it does so, it can be made to contact | abut to a pair of vertical annular member 7L with one protrusion.

  According to the reactor 1B, in addition to the effect in the main characteristic part of the reactor of Embodiment 1, the vibration at the time of operation | movement of the reactor 1B can be suppressed. The vibration during the operation of the reactor 1B tends to work mainly in the axial direction of the coil 2 due to the expansion due to the magnetostriction of each core piece of the magnetic core 3 and the contraction due to the magnetic attraction force between the core pieces. This is because the vibration can be effectively suppressed by providing the passing vertical annular member 7L. Therefore, the noise accompanying the vibration of reactor 1B can also be suppressed.

<< Modification 2-1 >>
As a modified example 2-1 of the second embodiment, as shown in FIG. 12, the insulator 4 and the heat radiating plate 5 may be a reactor having a positioning portion for positioning the longitudinal annular member 7 </ b> L with respect to each other. Since the configuration other than the insulator 4 and the heat radiating plate 5 is the same as that of the second embodiment, the following description will focus on the differences from the second embodiment. The same applies to Modification 2-2 described later. In FIG. 12, the vicinity of the split piece 40a on the end 2e side of the coil 2 in the insulator 4 is shown enlarged, and the split piece 40b on the connecting portion 2r side of the coil 2 is omitted, but both splits are shown. Since the pieces 40a and 40b have the same shape, the same applies to the divided pieces 40b.

[Insulator]
The split piece 40a (40b) includes a base plate 45 that protrudes from the upper surface of the frame plate portion 42 toward the outer core portion 32 (on the side opposite to the coil 2). The shape of the base plate 45 is rectangular here, but may be a shape (dome shape) along the contour shape of the outer core portion 32. The magnitude | size of the baseplate 45 can be suitably selected according to the recessed part 45c mentioned later. On the tip edge side of the base plate 45, a recess 45c into which each vertical annular member 7L is fitted is formed. The concave portion 45c constitutes the positioning portion.

  It is preferable that the width of the concave portion 45c is set to an extent that the extra width necessary for fitting is provided in the width of the vertical annular member 7L (band portion 71). If it does so, the shift | offset | difference to the width direction of the strip | belt part 71 can be suppressed. The depth of the recess 45 c is preferably set such that the bottom surface of the recess 45 c is flush with the outer surface of the outer core portion 32. If it does so, it will be easy to make the vertical annular member 7L and the outer surface of the outer core part 32 contact, and it will be easy to suppress vibration at the time of operation of a reactor. Here, the depth of the recess 45c is approximately the same as the thickness of the vertical annular member 7L (band portion 71).

  In addition, although the figure is abbreviate | omitted as mentioned above, the base plate of the division piece by the side of a connection part is interposed between a connection part and an outer core part. Therefore, sufficient insulation between both the connecting portion and the outer core portion can be ensured.

[Heatsink]
The heat radiating plate 5 is formed on both end surfaces of the heat radiating plate 5 and includes recesses 55 into which the respective vertical annular members 7L are fitted. The concave portion 55 constitutes the positioning portion. The location where the recess 55 is formed is a location that communicates with the recess 45c when the reactor is viewed in plan. The width and depth of the recess 55 may be the same as the width and depth of the recess 45c described above, respectively. In other words, the width of the concave portion 55 is set to an extent that gives the extra width necessary for fitting into the width of the vertical annular member 7L, and the depth of the concave portion 55 is the bottom surface of the concave portion 55 and the outer core portion 32 of the coil element 2a (2b). The depth may be such that the outer surface is flush with the outer surface. If it does so, the shift | offset | difference to the width direction of the vertical annular member 7L can be suppressed. Moreover, since it is easy to contact the belt | band | zone part 71 of the vertical annular member 7L and the outer surface of the outer core part 32, it is easy to suppress the vibration at the time of operation | movement of a reactor. Here, it is mentioned that the depth of the recess 55 is approximately the same as the thickness of the vertical annular member 7L.

  In this example, although the form with which both the insulator 4 and the heat sink 5 were provided with the positioning part was demonstrated, one of the insulator 4 and the heat sink 5 may be provided with the positioning part. Even in that case, it is easy to suppress the displacement of the vertical annular member 7L in the width direction to some extent, and it is also easy to suppress the vibration during the operation of the reactor. However, in this example, since both the insulator 4 and the heat radiating plate 5 include the positioning portion of the vertical annular member 7L, the vertical annular member 7L is prevented from shifting in the width direction on both the upper side and the lower side of the joined body 100. it can. Therefore, even if the bonding between the combined body 10 and the heat sink 5 becomes insufficient, the combined state of the combined body 10 and the heat sink 5 can be firmly maintained.

  Since the split piece 40a (40b) includes the recess 45c at the tip edge of the base plate 45, excessive contact of the vertical annular member 7L to the upper corner portion connecting the upper surface and the outer surface of the outer core portion 32 can be suppressed. . Therefore, the integration of the assembly and the heat sink can be maintained while suppressing damage to the upper corner portion of the outer core portion 32. Moreover, since the heat sink 5 is provided with the concave portions 55 on both end surfaces, excessive contact of the vertical annular member 7L to the lower corner portion connecting the lower surface and the outer surface of the outer core portion 32 can be suppressed. Therefore, it is possible to maintain integration of the combined body and the heat sink while suppressing damage to the lower corner portion of the outer core portion 32.

<< Modification 2-2 >>
As modification 2-2, as shown in FIG. 13, it can be set as the reactor which has a positioning part different from modification 2-1. In FIG. 13, as in FIG. 12, the vicinity of the split piece 40 a on the end 2 e side of the coil 2 in the insulator 4 is shown in an enlarged manner, and the split piece 40 b on the connecting part 2 r side of the coil 2 is omitted. In this example, unlike the modified example 2-1, the pair of divided pieces 40a and 40b are not the same shape.

[Insulator]
The split piece 40a on the end 2e side of the coil 2 includes a frame plate portion 42α having a height higher than that of the split piece of the first embodiment. Specifically, the frame plate portion 42α is higher than the height of the coil formation surface of the coil elements 2a and 2b, and covers the entire end surface of one of the coil elements 2a and 2b (on the end 2e side). That is, the frame plate portion 42α covers the upper end surface in addition to the both end surfaces and the lower end surface of each coil element 2a, 2b (FIG. 11).

  The frame plate portion 42α is formed on the upper surface thereof and includes a recess 46c for fitting each vertical annular member 7L. The concave portion 46c constitutes the positioning portion. The width | variety of the recessed part 46c is made into the grade which gave the extra width required for fitting to the width | variety of the vertical annular member 7L (band | belt part 71) similarly to the above-mentioned recessed part 45c. If it does so, the shift | offset | difference to the width direction of the vertical annular member 7L can be suppressed. The depth of the recess 46c may be a depth at which the bottom surface of the recess 46c is higher than the top surfaces of the coil elements 2a and 2b, or a depth that is flush with the top surfaces of the coil elements 2a and 2b. Good. In the former case, the combined state of the combined body 10 and the heat sink 5 can be maintained in a non-contact state between the longitudinal annular member 7L (band portion 71) and the coil elements 2a and 2b. In the latter case, since the band portion 71 of the vertical annular member 7L can be easily brought into contact with the upper surface of the coil 2, the combined state of the combined body 10 and the heat sink 5 can be firmly maintained.

  In addition, the division | segmentation piece 40a can also be provided with the base plate 45 which has the recessed part 45c in the front end edge side demonstrated in the modification 2-1. Accordingly, the vertical annular member 7L (band portion 71) can be fitted into the concave portion 45c of the base plate 45 in addition to the concave portion 46c of the frame plate portion 42α, and can be easily positioned with respect to the joined body 100. The pedestal 45 may be provided on the edge side of the opening (the insertion hole through which the inner core portion 31 can be inserted) in the upper end surface of the frame plate portion 42α.

  On the other hand, as the frame plate portion of the divided piece on the coupling portion side of the coil 2, the same frame plate portion 42 described in the first embodiment may be used, or the divided piece 40 a ( FIG. 10) may be used.

  According to this configuration, by providing the frame plate portion 42α, it is possible to suppress excessive contact of the vertical annular member 7L to the corner portion connecting the upper surfaces and the upper end surfaces of the coil elements 2a and 2b. Therefore, the integration of the combined body and the heat sink 5 can be maintained while suppressing damage to the corners of the coil elements 2a and 2b.

<< Embodiment 3 >>
As the reactor of the third embodiment, in each of the first and second embodiments and the modified examples 1-1 to 1-4 and 2-1 to 2-2, each core piece constituting the magnetic core is a soft magnetic powder. It can also be set as the composite material containing resin. The composite material can be typically manufactured by injection molding, transfer molding, MIM (Metal Injection Molding), cast molding, press molding using magnetic powder and powdered solid resin, or the like. Among the listed production methods, in methods other than press molding, a composite material having a desired three-dimensional shape can be easily obtained by filling a molding die with a mixture of magnetic powder and resin and then curing the resin as appropriate. can get.

  As the magnetic powder, a powder made of the soft magnetic material described above can be used. Only a single material powder or a combination of a plurality of types of powders of different materials may be used. In the composite material, unlike the pressurization for producing the compacted body, it is not necessary to perform the pressurization enough to plastically deform the magnetic powder, so that even a relatively hard powder such as an alloy powder can be used. In addition, the magnetic powder in the composite material is not substantially plastically deformed as described above, and therefore is substantially the same as the magnetic powder used for the raw material. The shape, size, and material of the magnetic powder of the raw material Is substantially maintained. Accordingly, when the average particle size of the magnetic powder is 1 μm or more and 1000 μm or less, particularly about 10 μm or more and 500 μm or less, the fluidity of the mixture is excellent, and the core piece can be easily manufactured using injection molding or the like. When a plurality of kinds of powders (coarse powder and fine powder) having different particle diameters are included, the saturation magnetic flux density is high, and a low-loss core piece and a magnetic core, and thus a low-loss reactor are easily obtained.

  Typical examples of the resin serving as the binder in the composite material include thermosetting resins such as epoxy resins, phenol resins, silicone resins, and urethane resins. In addition, thermoplastic resins such as PPS resin, polyimide resin, fluorine resin, and polyamide resin, room temperature curable resin, or low temperature curable resin can be used.

  Examples of the content of the magnetic powder in the composite material include 20% by volume or more and 75% by volume or less when the composite material is 100%. When the magnetic powder is 20% by volume or more, the ratio of the magnetic component is sufficiently high, so that the saturation magnetic flux density can be easily increased. When the magnetic substance powder is 75% by volume or less, the fluidity of the mixture of the magnetic substance powder and the resin is excellent, and the productivity of the composite material is excellent. The content of the magnetic powder may be 30% by volume or more, and further 40% by volume or more. Further, the content of the magnetic substance powder is 70% by volume or less, further 65% by volume or less, and 60% by volume or less.

  In addition to the magnetic powder and the resin, a composite material containing a powder (filler) made of a nonmagnetic material such as ceramics such as alumina or silica can be obtained. This composite material can improve heat dissipation and suppress uneven distribution (uniform dispersion) of the magnetic powder. When the filler is finer than the magnetic powder, the decrease in the ratio of the magnetic powder due to the inclusion of the filler can be suppressed. When the content of the filler is 0.2% by mass or more and 20% by mass or less when the composite material is 100% by mass, the above effect can be sufficiently obtained.

  The composite material can easily adjust the magnetic properties of the core piece by adjusting the material and content of the magnetic powder, the presence or absence of the filler, and the like. That is, it is easy to manufacture a core piece or a magnetic core having desired magnetic characteristics. Further, since the composite material contains a resin, even when the material of the magnetic powder is the same as the material of the particles constituting the green compact, the saturation magnetic flux density tends to be low and the relative permeability tends to be low. It is in. Examples of the magnetic properties of the composite material include a saturation magnetic flux density of 0.6 T or more, 1.0 T or more, and a relative permeability of 5 to 50, preferably 10 to 35. In this case, since the relative permeability is relatively low, the gap material can be omitted. The relative magnetic permeability of the entire magnetic core (when the gap material is included, the total relative permeability including the gap material) is preferably 5 or more and 50 or less.

  The above-described relative permeability and saturation magnetic flux density are measured as follows. A ring-shaped test piece having an outer diameter of 34 mm, an inner diameter of 20 mm, and a thickness of 5 mm is produced using the same material as each core piece. The test piece is subjected to winding of 300 turns on the primary side and 20 turns on the secondary side, and the BH initial magnetization curve of the test piece is measured in the range of H = 0 (Oe) to 100 (Oe). For the measurement, for example, a BH curve tracer “BHS-40S10K” manufactured by Riken Denshi Co., Ltd. can be used. The maximum value of the gradient (B / H) of the obtained BH initial magnetization curve is obtained, and this maximum value is set as the relative permeability of the core piece. Usually, the gradient (B / H) of the BH initial magnetization curve becomes maximum near H = 0 or near H = 0. The magnetization curve here is a so-called DC magnetization curve. Further, the relative permeability here is a so-called DC permeability, which is different from the AC relative permeability measured in an AC magnetic field. The saturation magnetic flux density of the core piece is defined as the magnetic flux density when a magnetic field of 10,000 (Oe) is applied to the test piece with an electromagnet and sufficiently magnetically saturated.

  Even when the magnetic core is made of a composite material, the entire structure can have a uniform magnetic property, or the magnetic properties can be made different between the inner core portion and the outer core portion. In the latter case, for example, the material and the ratio of the magnetic powder differing between the core piece of the inner core portion and the outer core portion can be mentioned.

  The inner core part (outer core part) is a composite material and the outer core part (inner core part core piece) is a compacted body or laminated plate body. May be different.

<< Embodiment 4 >>
In the reactors of the first to third embodiments and the modified examples 1-1 to 1-4 and 2-1 to 2-2, the energization conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: 100 V to 1000 V Use frequency: about 5 kHz to 100 kHz, typically used as a component part of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or a component part of a power converter provided with this converter be able to.

  As shown in FIG. 14, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is driven by a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and power supplied from the main battery 1210. 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, vehicle 1200 includes an engine in addition to motor 1220. In addition, in FIG. 14, although an inlet is shown as a charge location of the vehicle 1200, it can be set as the form provided with a plug.

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

  As shown in FIG. 15, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. For the switching element 1111, a power device such as FET or IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that prevents the change of the current to flow through the circuit. As this reactor L, the reactor of Embodiments 1-3, the modification 1-1 to 1-4, 2-1 to 2-2 is provided. In particular, when the converter 1110 includes the case 8 that can circulate and supply the liquid refrigerant, by storing the reactor 1 </ b> A or the like in the case 8, a structure with excellent heat dissipation can be easily constructed. By providing the reactor etc. which are excellent in heat dissipation, the power converter device 1100 and the converter 1110 can also expect improvement in heat dissipation.

  Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary machinery 1240, and main battery 1210. Auxiliary power supply converter 1160 for converting high voltage to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply device converters 1150 perform DC-DC conversion. The 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 and second embodiments, and a reactor whose size and shape are appropriately changed can be used. Moreover, the converter which performs conversion of input electric power, Comprising: The converter of Embodiment 1-3, the modification 1-1 to 1-4, 2-1 to 2-2 is applied to the converter which performs only pressure | voltage rise, and the converter which performs only pressure | voltage fall. A reactor can also be used.

  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.

DESCRIPTION OF SYMBOLS 1A, 1B Reactor 10 Combination body 100 Joint body 2 Coil 2a, 2b Coil element 2r Connection part 2w Winding 2e End part 3 Magnetic core 31 Inner core part 31e End surface 31m Core piece 31g Gap material 32 Outer core part 32e Inner end surface 4 Insulator 40a, 40b Dividing piece 41 Peripheral wall portion 42, 42α Frame plate portion 43 Partition portion 44 Protruding piece 45 Base plate 45c, 46c Recessed portion 5 Heat sink 51 Insertion hole 51b Bolt 52 Groove 53 Recessed portion 54 Protruding piece 55 Recessed portion 6 Adhesive layer 6S Sensor 7 Ring member 7S Horizontal ring member 7L Vertical ring member 71 Band portion 72 Lock portion 8 Case 8L Liquid refrigerant 80i Supply port 80o Discharge port 81 Mounting surface 82 Space forming portion 9 Holder 91 Main body portion 91c Recess 92 Engagement portion 92f Hook 1100 Power conversion Device 1110 Converter 1111 Switch 1111 Drive circuit L Reactor 1120 Inverter 1150 Power supply converter 1160 Auxiliary power supply converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery 1240 Auxiliary equipment 1250 Wheel

Claims (7)

A reactor comprising a combination of a coil formed by winding a winding and a magnetic core disposed inside and outside the coil to form a closed magnetic path,
The radiator is placed on the place where the combination is placed and the liquid refrigerant is supplied together with the combination,
An adhesive layer interposed between the combined body and the heat sink, and forming a bonded body by bonding the combined body and the heat sink;
A reactor comprising: an annular member surrounding an outer periphery of the joined body so as to contact both the surface on the combined body side and the surface on the heat sink side of the joined body.   The reactor according to claim 1, wherein the annular member includes a lateral annular member that is stretched in a direction orthogonal to the axial direction of the coil.   The reactor according to claim 1, wherein the annular member includes a longitudinal annular member that is stretched in the axial direction of the coil.   The reactor according to any one of claims 1 to 3, wherein the heat radiating plate includes a positioning portion for positioning the annular member with respect to the heat radiating plate.   The reactor according to any one of claims 1 to 4, further comprising a case in which the joined body is stored and the liquid refrigerant is supplied and discharged. The case is
A mounting surface facing the heat sink;
The space formation part which forms in the said attachment surface and forms the space which distribute | circulates the said liquid refrigerant between the said heat sink and the said attachment surface when the said conjugate | zygote is accommodated in the said case is provided. Reactor. Comprising a sensor for measuring a physical quantity during operation of the reactor;
The coil includes a pair of coil elements that are connected to each other and arranged in parallel so that the axes are parallel,
The reactor according to any one of claims 1 to 6, wherein the sensor is fixed by a bonding layer in a space surrounded by a pair of the coil elements and the heat radiating plate.

Images