JP2015188019A - Gap member, magnetic core and reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a gap member which allows connection between core pieces without using an adhesive.SOLUTION: A gap member 4 is interposed between a core piece 31m and another core piece 31m. The gap member 4 comprises: a gap plate 4g which has both of the core pieces 31m arranged on both sides, and which is interposed between end surfaces facing each other; a protrusion 4e which protrudes, from the peripheral surface of the gap plate 4g, further outward than the end surfaces of both of the core pieces 31m; a wall 4f which extends from both sides of the protrusion 4e in the thickness direction of the gap plate 4g so as to surround the peripheral surface of the end of each core piece 31m; and a protrusion 4p which protrudes inward from the inner peripheral surface of the wall 4f so as to press the peripheral surface of each core piece 31m.

Description

  The present invention is interposed between a core piece and a core piece constituting a magnetic core in a reactor used for a component such as an in-vehicle DC-DC converter or a power conversion device mounted on a vehicle such as a hybrid vehicle. The present invention relates to a gap member. It is related with the gap member which can connect core pieces especially, without using an adhesive agent.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. For example, in Patent Document 1, as a reactor provided in a boost converter disposed in a vehicle such as a hybrid vehicle, a core divided into a plurality of partial cores, a plurality of gap spacers interposed between the plurality of partial cores, A reactor having a partial core and an annular coil provided around a gap spacer is disclosed. Patent Document 1 describes that the gap spacer has a protruding portion that protrudes outward from the partial core, and the coil is supported by the protruding portion.

JP 2008-28287 A

  Generally, a magnetic core constituting a reactor is configured by connecting a plurality of core pieces, and a gap plate is interposed between the core pieces in order to adjust inductance. In general, a conventional magnetic core has a structure in which a core piece and a gap plate are joined with an adhesive, and a plurality of core pieces are connected via a gap plate.

  However, in the configuration in which the core piece and the gap plate are joined with an adhesive, it takes time to assemble the magnetic core (reactor) because an adhesive work is required to apply the adhesive or harden the adhesive. . In addition, if heat is applied after the magnetic core is assembled, the adhesive may deteriorate, such as internal strain in the adhesive, and using the adhesive may cause problems such as peeling of the adhesive. . Therefore, a technique for fixing the core piece to the gap plate without using an adhesive is desired from the viewpoint of improving the assembling workability of the magnetic core (reactor) and eliminating problems caused by the use of the adhesive.

  Then, one of the objectives of this invention is providing the gap member which can connect core pieces, without using an adhesive agent. Another object of the present invention is to provide a magnetic core having the gap member and a reactor including the magnetic core.

  The gap member of the present invention is a gap member interposed between the core pieces. In the gap member of the present invention, both the core pieces are disposed on both sides, the gap plate portion is interposed between the opposing end surfaces of the both core pieces, and the end surfaces of the both core pieces from the peripheral surface of the gap plate portion A projecting portion projecting outward, a wall portion extending from both sides of the projecting portion in the thickness direction of the gap plate portion, surrounding a peripheral surface of an end portion of each core piece, and an inner circumference of the wall portion And a protrusion that protrudes inward from the surface and presses the peripheral surface of each core piece.

  The magnetic core of the present invention is a magnetic core formed by connecting a plurality of core pieces. In the magnetic core of the present invention, at least two of the core pieces are connected via a gap member, and the gap member is the gap member of the present invention.

  The reactor of this invention is a reactor provided with the coil formed by winding a coil | winding, and the magnetic core in which the said coil is arrange | positioned and forms a closed magnetic circuit. In the reactor of the present invention, the magnetic core is the magnetic core of the present invention.

  The gap member of this invention can connect core pieces, without using an adhesive agent. The magnetic core and the reactor of the present invention are excellent in assembling workability by using the gap material of the present invention.

1 is a schematic perspective view showing a reactor according to Embodiment 1. FIG. It is a schematic perspective view which shows the magnetic core with which the reactor shown in FIG. 1 is equipped. 3 is a schematic exploded perspective view of the magnetic core shown in FIG. 2. It is a schematic front view which shows the middle gap member which has in the magnetic core shown in FIG. It is a schematic sectional drawing of the middle gap member cut | disconnected by the VV line shown in FIG. It is a schematic front view which shows the side gap member which has in the magnetic core shown in FIG. It is a schematic back view which shows the side gap member which has in the magnetic core shown in FIG. It is a schematic front view which shows an example of the gap member of the modification 1. 12 is a schematic front view showing an example of a gap member of Modification 2. FIG. 10 is a schematic cross-sectional view showing an example of a gap member of Modification 3. FIG. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of 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) The gap member which concerns on embodiment is a gap member interposed between a core piece and a core piece. The gap member has both core pieces disposed on both sides, and a gap plate portion interposed between the opposite end surfaces of the both core pieces, and the outer surface of the gap plate portion protrudes outward from the end surfaces of both core pieces. And a protrusion. The gap member extends from both sides of the protruding portion in the thickness direction of the gap plate portion, and surrounds the peripheral surface of the end portion of each core piece, and protrudes inward from the inner peripheral surface of the wall portion. And a protruding portion that presses the peripheral surface.

  The said gap member has a wall part surrounding the peripheral surface of the edge part of each core piece on the both sides, and can position and arrange | position both core pieces with respect to a gap member. In addition, since the gap member has the protrusion on the inner peripheral surface of the wall portion, both the core pieces can be mechanically fixed by pressing the peripheral surface of each core piece surrounded by the wall portion with the protrusion. Therefore, the said gap member can connect core pieces, without using an adhesive agent.

  In addition, the gap member has a gap plate portion interposed between the opposing end surfaces of both core pieces, so that the gap distance between the core pieces can be secured by the thickness of the gap plate portion. In particular, the gap distance between the core pieces can be defined and maintained by the gap plate portion coming into contact with the opposing end surfaces of the two core pieces. Further, since the gap member is formed with a wall portion so as to surround the peripheral surface of the end portion of the core piece from the protruding portion protruding outward from the end surface of the core piece, at least one of the core pieces is disposed inside the coil. When arrange | positioning, a contact with a core piece and a coil can be prevented with a protrusion part and a wall part, and the electrical insulation between a core piece and a coil can be ensured. Therefore, conventionally, a cylindrical bobbin disposed between the core piece and the coil in order to prevent the contact between the core piece and the coil can be eliminated, and the manufacturing cost can be reduced.

  (2) As one form of the gap member, at least the shape of the end face of the core piece is rectangular, and the protrusions are provided at positions facing the four sides of the peripheral face of the core piece. .

  According to the said form, the core piece can be hold | gripped by pressing the four sides of the surrounding surface of a core piece with a projection part, respectively, and a core piece can be fixed stably.

  (3) Of the core pieces arranged on both sides of the gap member, one core piece is a pair of middle core pieces arranged in parallel inside the coil, and the other core piece is a coil. In the case of a side core piece having an inner end face opposed to each end face of the middle core piece, as one form of the gap member, two walls surrounding the peripheral surface of each end part of the middle core piece on one side And one wall portion surrounding the peripheral surface of the end portion of the side core piece on the other side.

  According to the said form, a pair of middle core piece and one side core piece can be connected with one gap member, a number of parts can be reduced and manufacturing cost can be reduced.

  (4) The magnetic core according to the embodiment is a magnetic core formed by connecting a plurality of core pieces. And at least 2 core piece is connected via the gap member, The gap member is a gap member of embodiment described in any one of (1)-(3) mentioned above.

  Since the core pieces are connected to each other by the gap member, the magnetic core does not require an adhesive and has excellent assembly workability. Moreover, since it is not necessary to use an adhesive for joining the core piece and the gap member as in the prior art, problems due to the use of the adhesive such as peeling of the adhesive can be prevented.

  (5) The reactor which concerns on embodiment is a reactor provided with the coil formed by winding a coil | winding, and the magnetic core in which a coil is arrange | positioned and forms a closed magnetic circuit. The magnetic core is the magnetic core according to the embodiment described in (4) above.

  Since the core pieces constituting the magnetic core are connected by the gap member, the reactor does not require an adhesive and is excellent in assembling workability. Moreover, since it is not necessary to use an adhesive for joining the core piece and the gap member as in the prior art, problems due to the use of the adhesive such as peeling of the adhesive can be prevented.

<< Details of Embodiment of the Present Invention >>
Specific examples of the gap member, the magnetic core, and the reactor according to the embodiment of the present invention will be described below with reference to the drawings. The same reference numerals in the figure indicate the same names. Below, the coil and magnetic core which are the basic structures of a reactor are demonstrated first, and then the gap member interposed between the core pieces which comprise a magnetic core is demonstrated. In addition, this invention is not limited to these illustrations, is shown by the claim, and is intended that all the changes within the meaning and range equivalent to the claim are included.

[Embodiment 1]
<Basic structure of the reactor>
With reference to FIGS. 1-7, the reactor 1 which concerns on Embodiment 1 is demonstrated. The reactor 1 includes a coil 2 formed by winding a winding 2w, and a magnetic core 3 in which the coil 2 is disposed to form a closed magnetic circuit. In the following, for convenience of explanation, when the reactor is installed on an installation target such as a cooling base or a bottom plate of the case, the installation target side is described as the lower side, and the opposite side is described as the upper side.

(coil)
As shown in FIG. 1, the coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a winding 2w, and a connecting portion 2r for connecting both the coil elements 2a and 2b. Both coil elements 2a and 2b are formed in a hollow cylindrical shape in the same winding direction, and are arranged in parallel (side by side) so that the axial directions of the coil elements 2a and 2b are parallel to each other. In this example, the coil elements 2a and 2b are formed in a rectangular tube shape, and the end faces in the axial direction of the coil elements 2a and 2b are rectangular rings with rounded corners. The winding 2w is a covered rectangular wire having an insulating coating such as a polyamide-imide resin on the conductor surface of a rectangular wire made of copper, aluminum, or an alloy thereof. The coil 2 (coil elements 2a and 2b) is an edgewise coil obtained by edgewise winding a covered rectangular wire. In this example, a rectangular wire is used as the conductor of the winding 2w, but various shapes such as a round wire can be used.

  The winding end 2e of the coil 2 is drawn out from the turn forming portion of the coil 2 in an appropriate direction. In this example, both winding ends 2e of the coil 2 are drawn upward from the turn forming surface (coil upper surface). The ends of the two winding ends 2e of the coil 2 are stripped of the insulation coating to expose the conductor, and the conductor exposed portion is connected to a terminal fitting (not shown) for connection to an external device (not shown) such as a power source. (Not shown) is attached.

  The coil 2 illustrated in FIG. 1 is formed by a single continuous winding 2w. Specifically, after one coil element 2a is formed from one end side to the other end side, the winding 2w drawn from the other end side is bent into a U shape to form a connecting portion 2r. The other coil element 2b is formed from the other end side toward the one end side. In addition, in the coil 2, the coil elements 2a and 2b are formed by separate windings, and the coil ends on the other end side of the coil elements 2a and 2b are directly joined by welding, soldering, pressure welding, or the like. It is also possible to manufacture by joining via a connecting member (for example, a plate material) made of a conductive material prepared separately. In this example, the end surfaces in the axial direction of the coil elements 2a and 2b have a rectangular shape, but can be appropriately changed to a circular shape or the like.

(Magnetic core)
As shown in FIGS. 1 to 3, the magnetic core 3 includes a pair of columnar middle core portions 31 disposed inside the coil 2 (coil elements 2 a and 2 b) and the outside of the coil 2 (coil elements 2 a and 2 b). It has a pair of block side core parts 32 arranged and connected to the middle core part 31. The middle core portion 31 is a portion where the coil 2 is disposed inside the coil elements 2a and 2b arranged in parallel. In this example, the middle core portion 31 is configured by connecting three middle core pieces 31m. On the other hand, the side core portion 32 is located outside the coil elements 2a and 2b and is a portion where the coil 2 is not substantially disposed (that is, protrudes from the coil 2). It is composed of one side core piece 32m. In the magnetic core 3, a pair of side core portions 32 is disposed so as to sandwich a pair of middle core portions 31 disposed in parallel from both ends, and an end surface 31e of the middle core portion 31 (middle core pieces 31m at both ends) is a side core portion 32 (side core piece). 32m) are respectively connected to the inner end face 32e to form an annular shape, and form a closed magnetic circuit when the coil 2 is excited.

(Core piece: Middle core piece, side core piece)
As shown in FIGS. 2 and 3, in the middle core portion 31, the middle core pieces 31 m and the gap members 4 (middle gap members 41) are alternately arranged, and the middle core pieces 31 m are connected to each other via the middle gap members 41. . In this example, the shape of the end surface 31e of the middle core piece 31m is rectangular, and the middle core portion 31 is formed in a quadrangular prism shape in accordance with the inner peripheral shape of each of the coil elements 2a and 2b. On the other hand, the side core part 32 (side core piece 32m) has an inner end face 32e facing each end face 31e of a pair of middle core parts 31 (middle core pieces 31m) arranged in parallel. And a pair of middle core piece 31m and the side core piece 32m are connected via the gap member 4 (side gap member 42). In this example, the side core piece 32m has an inner end surface 32e formed of one plane, the inner end surface 32e has a rectangular shape, and the upper surface and the lower surface are substantially trapezoidal (the cross-sectional area is outward from the inner end surface 32e). It is formed in a block shape of a small deformed trapezoid. The shapes of the middle core piece 31m and the side core piece 32m can be changed as appropriate. For example, the shape of the middle core portion 31m may be changed to a circular shape by changing the end surface shape of the middle core piece 31m to a circular shape.

  In the assembled state of the magnetic core 3, the upper surface of the middle core piece 31m and the upper surface of the side core piece 32m are substantially flush. On the other hand, the lower surface of the side core piece 32m protrudes from the lower surface of the middle core piece 31m. When the coil 2 is disposed on the magnetic core 3, the lower surface of the side core piece 32m and the lower surface of the coil 2 (coil elements 2a and 2b) Is approximately the same.

  The middle core piece 31m and the side core piece 32m contain a soft magnetic material as a main component. Examples of the soft magnetic material include iron, iron alloy, and ferrite. The middle core piece 31m and the side core piece 32m are formed of a laminate in which a plurality of compacts using soft magnetic powder and magnetic thin plates having an insulating coating (for example, electromagnetic steel plates represented by silicon steel plates) are stacked. Examples of the molded body include a powder molded body (a powder magnetic core), a sintered body, and a composite material obtained by molding a mixture containing soft magnetic powder and a resin. As the resin serving as the binder in the composite material, a thermosetting resin such as an epoxy resin or a thermoplastic resin such as a polyphenylene sulfide (PPS) resin can be used. The composite material may be mixed with a ceramic filler such as alumina or silica. In this example, the middle core piece 31m and the side core piece 32m are formed of a green compact.

(Gap member: Middle gap member, Side gap member)
2 and 3, the middle gap member 41 is a gap member interposed between the middle core pieces 31m, and the middle core pieces 31m are arranged on both sides. The middle gap member 41 has a function of securing a gap distance between the middle core pieces 31m and a function of connecting the middle core pieces 31m.

  4 and 5, the middle gap member 41 has a gap plate portion 4g interposed between the opposed end surfaces of the middle core pieces 31m arranged on both sides thereof. Therefore, since the middle gap member 41 has the gap plate portion 4g, the gap distance between the middle core pieces 31m can be secured by the thickness of the gap plate portion 4g. In this example, in the middle gap member 41, the gap plate portion 4g is in contact with the mutually opposing end surfaces of the middle core pieces 31m, and the gap distance between the middle core pieces 31m can be defined and maintained by the thickness of the gap plate portion 4g. . In addition, the gap plate portion 4g is formed in a rectangular flat plate shape in accordance with the end surface shape of the middle core piece 31m, and the thickness of the gap plate portion 4g (from one end surface facing the end surface of one middle core piece 31m in the gap plate portion 4g to the other The distance to the other end surface facing the end surface of the middle core piece 31m is uniform. The thickness of the gap plate portion 4g may be appropriately set so as to prevent magnetic saturation of the magnetic core 3 and to obtain a predetermined inductance.

  The middle gap member 41 includes a protruding portion 4e that protrudes outward from the peripheral surface of the gap plate portion 4g beyond the end surface of the middle core piece 31m, and extends from both sides of the protruding portion 4e in the thickness direction of the gap plate portion 4g. It has the wall part 4f surrounding the peripheral surface of the edge part of the piece 31m, and the projection part 4p which protrudes inward from the internal peripheral surface of the wall part 4f. Therefore, the middle gap member 41 has the wall portions 4 f on both sides, so that the middle core pieces 31 m can be positioned and arranged with respect to the middle gap member 41. In addition, the middle gap member 41 has the protrusion 4p on the inner peripheral surface of the wall portion 4f, thereby pressing the peripheral surface of each middle core piece 31m surrounded by the wall portion 4f to mechanically connect the middle core pieces 31m to each other. Can be fixed and connected. The thickness direction of the gap plate portion 4g basically matches the direction of the lines of magnetic force (magnetic flux) when the magnetic core 3 forms a closed magnetic path.

  In this example, the protruding portion 4e is formed over the entire circumference of the gap plate portion 4g, and the wall portion 4f is formed in a rectangular frame shape so as to surround the entire peripheral surface of the end portion of each middle core piece 31m (FIG. 4). The wall 4f is formed perpendicular to each end surface of the gap plate 4g. The protrusions 4p are respectively provided at positions facing the four sides of the peripheral surface of the middle core piece 31m, and one is provided at each intermediate position of the sides forming the wall 4f. Each protrusion 4p has a triangular cross-sectional shape when viewed from the opening side of the wall 4f, and the corners of the apex that come into contact with the peripheral surface of the middle core piece 31m are rounded. Each protrusion 4p has a uniform height from the opening side of the wall 4f toward the gap plate 4g (see FIG. 5). What is necessary is just to set suitably the height (distance from the inner peripheral surface of the wall part 4f to the vertex) of the protrusion part 4p so that the peripheral surface of the middle core piece 31m may be pressed and the middle core piece 31m may be hold | gripped.

  In addition, since the wall 4f of the middle gap member 41 is disposed between the outer peripheral surface of the middle core piece 31m and the inner peripheral surface of the coil 2 (coil elements 2a and 2b), the middle core piece 31m and the coil 2 are in contact with each other. And electrical insulation between the middle core piece 31m and the coil 2 can be secured.

  As shown in FIGS. 2 and 3, the side gap member 42 is a gap member interposed between the middle core piece 31m and the side core piece 32m. The pair of middle core pieces 31m is disposed on one side, and the side core is disposed on the other side. A piece 32m is arranged. The side gap member 42 has a function of securing a gap distance between the middle core piece 31m and the side core piece 32m, and a function of connecting the middle core piece 31m and the side core piece 32m.

  The side gap member 42 has the same basic configuration as the middle gap member 41 in that the side gap member 42 includes a gap plate portion, a protruding portion, a wall portion, and a protruding portion. 6 and 7, the side gap member 42 has two gap plate portions 4g interposed between the opposed end surfaces of the pair of middle core pieces 31m and the side core pieces 32m disposed on both sides thereof. . Therefore, the side gap member 42 has the gap plate portion 4g, so that the gap distance between each middle core piece 31m and the side core piece 32m can be secured by the thickness of the gap plate portion 4g. In this example, the side gap member 42 is such that the gap plate portion 4g is in contact with the mutually facing end surfaces of the middle core piece 31m and the side core piece 32m, and the middle core piece 31m and the side core piece 32m are separated by the thickness of the gap plate portion 4g. It is possible to define and maintain a gap distance between them. Further, the gap plate portion 4g is formed in a rectangular flat plate shape in accordance with the end surface shape of the middle core piece 31m, and the thickness of the gap plate portion 4g (from one end surface facing the end surface of the middle core piece 31m in the gap plate portion 4g to the side core piece 32m). The distance to the other end face opposite to the end face is uniform. The thickness of the gap plate portion 4g may be appropriately set so as to prevent magnetic saturation of the magnetic core 3 and to obtain a predetermined inductance.

  The side gap member 42 has a protruding portion 4e that protrudes outward from the peripheral surface of the gap plate portion 4g to the end surface of the middle core piece 31m. Then, on one side of the side gap member 42 (middle core piece 31m side (see FIG. 3)), the peripheral surface of each end portion of the pair of middle core pieces 31m is extended from the protruding portion 4e in the thickness direction of the gap plate portion 4g. Two surrounding wall portions 4fm and the other side (side core piece 32m side (see FIG. 3)) extend from the protruding portion 4e in the thickness direction of the gap plate portion 4g to surround the peripheral surface of the end portion of the side core piece 32m. And four wall portions 4fs. Furthermore, the side gap member 42 has a protruding portion 4p that protrudes inward from the inner peripheral surfaces of the wall portions 4fm, 4fs. Accordingly, the side gap member 42 has the two wall portions 4fm on one side and the wall portion 4fs on the other side, thereby positioning the pair of middle core pieces 31m and the side core pieces 32m with respect to the side gap member 42. Can be arranged. In addition, the side gap member 42 has the protrusions 4p on the inner peripheral surfaces of the wall portions 4fm and 4fs, thereby pressing the peripheral surfaces of the middle core pieces 31m and the side core pieces 32m surrounded by the wall portions 4fm and 4fs. Each middle core piece 31m and side core piece 32m can be mechanically fixed and connected.

  In this example, the wall portion 4fm is formed in a rectangular frame shape so as to surround the entire end surface of the middle core piece 31m, and the wall portion 4fs is formed in a rectangular frame shape so as to surround the entire end surface of the side core piece 32m. (See FIGS. 6 and 7). The wall portions 4fm and 4fs are formed perpendicular to the end surfaces of the gap plate portion 4g. Further, the protrusions 4p of the wall 4fm are provided at positions facing the four sides of the peripheral surface of the middle core piece 31m, respectively, and are provided one at each intermediate position of the sides forming the wall 4fm. On the other hand, the protrusions 4p of the wall 4fs are respectively provided at positions facing the four sides of the peripheral surface of the side core piece 32m, and two of each of the sides forming the wall 4fs are at intermediate positions between the upper side and the lower side. One is provided at each intermediate position on both sides. As with the middle gap member 41, each protrusion 4p has a triangular cross-section when viewed from the opening side of the walls 4fm, 4fs, and the corners of the apexes that contact the peripheral surfaces of the core pieces 31m, 32m are rounded. And is uniformly formed from the opening side of the wall portions 4fm and 4fs toward the gap plate portion 4g. The height of the protrusion 4p (the distance from the inner peripheral surface of the wall 4f to the apex) may be set as appropriate so that the peripheral surfaces of the core pieces 31m and 32m can be pressed and the core pieces 31m and 32m can be gripped. . The two gap plate portions 4g are connected by a wall portion 4fs, and a penetrating rectangular hole is formed between the gap plate portions 4g (see FIGS. 2, 6, and 7).

  In addition, the wall portion 4fm of the side gap member 42 is disposed between the outer peripheral surface of the middle core piece 31m and the inner peripheral surface of the coil 2 (coil elements 2a and 2b), similarly to the wall portion 4f of the middle gap member 41. The Therefore, contact between the middle core piece 31m and the coil 2 can be prevented, and electrical insulation between the middle core piece 31m and the coil 2 can be secured. Further, on one side of the side gap member 42 where the wall portion 4fm is provided, the surface of the protruding portion 4e faces the end surface of the coil 2 (coil elements 2a and 2b) (see FIG. 6). That is, since this protrusion 4e is disposed between the inner end face 32e of the side core piece 32m and the end face of the coil 2 (coil elements 2a, 2b), the contact between the side core piece 32m and the coil 2 is prevented, Electrical insulation between the side core piece 32m and the coil 2 can be secured.

  The gap member 4 (the middle gap member 41 and the side gap member 42) has an electrical insulating property and is formed of a material having a lower relative permeability than the core pieces 31m and 32m constituting the magnetic core 3. Specific materials for forming the gap member 4 include, for example, ceramics such as resin and alumina. Examples of the resin include PPS resin, epoxy resin, acrylonitrile-butadiene-styrene (ABS) resin, liquid crystal polymer (LCP), polyamide (PA) resin, polytetrafluoroethylene (PTFE) resin, and polybutylene terephthalate (PBT) resin. Or a fiber reinforced resin (FRP) in which fibers are combined with these resins. It is advantageous to form the gap member 4 from resin in terms of formability, workability, cost, and the like. In this example, the gap member 4 is formed of PPS resin, and the gap plate portion, the protruding portion, the wall portion, and the protruding portion are integrally formed.

<Reactor manufacturing method>
Next, an example of a method for manufacturing the reactor 1 will be described with reference mainly to FIG.

  First, the middle core portion 31 is assembled by connecting the three middle core pieces 31 m via the middle gap member 41. Specifically, the middle gap member 31 is disposed between the core pieces of the three middle core pieces 31m. The middle core pieces 31m arranged on both sides are press-fitted into the wall portion 4f of the middle gap member 41, and the end faces 31e of the middle core pieces 31m are in contact with the gap plate portion 4g. The part is fitted into the wall part 4f. And a pair of middle core part 31 is produced.

  One side core piece 32m and a pair of middle core portions 31 are connected via a side gap member 42, and the U-shaped portion formed by one side core piece 32m and the pair of middle core portions 31 of the magnetic core 3 is formed. Assemble the parts. Specifically, the pair of middle core portions 31 and the one side core piece 32m are arranged so that the end surfaces 31e on one end side of the pair of middle core portions 31 (middle core pieces 31m) and the inner end surface 32e of the one side core piece 32m face each other. A side gap member 42 is disposed between them. The middle core piece 31m at one end of each middle core portion 31 is press-fitted into the wall portion 4fm of the side gap member 42, and the side core piece 32m is press-fitted into the wall portion 4fs. And each end part of the middle core piece 31m is fitted in the wall part 4fm so that each end surface 31e of the middle core piece 31m and the inner end face 32e of the side core piece 32m are in contact with the gap plate part 4g. The end is fitted into the wall 4fs.

  Next, the pair of middle core portions 31 are inserted into the coil elements 2 a and 2 b (see FIG. 1) of the coil 2, and the coil 2 is disposed on the middle core portion 31. Thereafter, the other side core piece 32m and the pair of middle core portions 31 are connected via the side gap member 42 to assemble the annular magnetic core 3 (see FIG. 2). Specifically, the pair of middle core portions 31 and the side core pieces 32m are arranged so that the end surface 31e on the other end side of the pair of middle core portions 31 (middle core pieces 31m) and the inner end surface 32e of the other side core piece 32m face each other. A side gap member 42 is disposed between them. The middle core piece 31m at one end of each middle core portion 31 is press-fitted into the wall portion 4fm of the side gap member 42, and the side core piece 32m is press-fitted into the wall portion 4fs. And each end part of the middle core piece 31m is fitted in the wall part 4fm so that each end surface 31e of the middle core piece 31m and the inner end face 32e of the side core piece 32m are in contact with the gap plate part 4g. The end is fitted into the wall 4fs.

  Thus, the reactor 1 shown in FIG. 1 is completed.

(Main effect)
In the middle gap member 41, the adjacent middle core pieces 31m can be positioned and arranged with respect to the middle gap member 41 by the wall portions 4f on both sides, and each middle core piece 31m can be mechanically moved by the protrusion 4p of the wall portion 4f. Can be fixed. The side gap member 42 can position and arrange the pair of middle core pieces 31m with respect to the side gap member 42 by the two wall portions 4fm on one side, and each middle core piece 31m by the protrusion 4p of the wall portion 4fm. Can be fixed mechanically. Further, the side gap member 42 can be positioned by positioning the side core piece 32m with respect to the side gap member 42 by the wall portion 4fs on the other side, and the side core piece 32m can be mechanically arranged by the protrusion portion 4p of the wall portion 4fs. Can be fixed. Therefore, by using the gap members 41 and 42, the core pieces (the middle core pieces 31m, the middle core pieces 31m and the side core pieces 32m) can be connected without using an adhesive, and thus the magnetic core 3 extends. In addition to improving the assembly workability of the reactor 1, it can also prevent problems caused by the use of an adhesive. The gap members 41 and 42 can ensure a gap distance between the core pieces (between the middle core pieces 31m and between the middle core pieces 31m and the side core pieces 32m) by the gap plate portion 4g. Particularly, when the end face of the core piece is brought into contact with the gap plate portion 4g, the gap distance can be defined by the thickness of the gap plate portion 4g, which is preferable.

  The middle gap member 41 and the side gap member 42 can prevent contact between the outer peripheral surface of the middle core piece 31m and the inner peripheral surface of the coil 2 by the wall portion 4f and the wall portion 4fm, thereby ensuring insulation. Further, the side gap member 42 can prevent electrical contact between the side core piece 32m and the coil 2 by preventing the contact between the inner end face 32e of the side core piece 32m and the inner peripheral surface of the coil 2 by the protruding portion 4e. .

[Modification 1]
In Embodiment 1 mentioned above, although the cross-sectional shape of the projection part 4p of the gap member 4 (the middle gap member 41 and the side gap member 42) was a triangle shape (refer FIG. 4), sectional shape of the projection part 4p was demonstrated. However, the present invention is not limited to this, and various shapes such as a semicircular shape, a rectangular shape, and a trapezoidal shape can be adopted. For example, as shown in FIG. 8, when the cross-sectional shape of the protrusion 4p has a trapezoidal shape or the like and has a top surface that is in surface contact with the peripheral surface of the core piece (middle core piece 31m or side core piece 32m), The contact area with the surface increases and the core piece can be fixed more firmly.

[Modification 2]
The number and position of the protrusions 4p of the gap member 4 can be changed as appropriate. In the first embodiment, the middle gap member 41 and the side gap member 42 have been described in which one protrusion 4p is provided on each side forming the wall 4f and the wall 4fm (see FIG. 4). However, you may provide the some protrusion part 4p in each edge | side which forms the wall part 4f and the wall part 4fm. In the first embodiment, the mode in which the protrusions 4p are respectively provided at positions facing the four sides of the peripheral surface of the core piece (see FIG. 4) has been described. For example, as shown in FIG. May be provided respectively at positions facing the four corners of the peripheral surface of the core piece. Each of the protrusions 4p illustrated in FIG. 9 has an arc shape in cross section, and is formed so as to press a corner of the peripheral surface of the core piece. In addition, it is preferable to provide the projection part 4p in the up-down and left-right symmetrical position seeing from the opening side of a wall part.

[Modification 3]
In the first embodiment, the mode in which the height of the protruding portion 4p of the gap member 4 is constant from the opening side of the wall portion 4f toward the gap plate portion 4g (see FIG. 5) has been described. You may incline toward the gap board part 4g from the opening side of a part. For example, as shown in FIG. 10, when the protrusion 4p is formed so that the height increases from the opening side of the wall 4f toward the gap plate 4g, it is easy to press-fit the core piece into the wall.

[Modification 4]
In the first embodiment, for example, in the middle gap member 41, the protruding portion 4e is formed over the entire circumference of the gap plate portion 4g, and the wall portion 4f is formed in a frame shape so as to surround the entire circumferential surface of the end portion of the middle core piece 31m. The form (refer FIG. 4) currently described was demonstrated. Instead, the protrusion 4e is formed only on each side or each corner of the gap plate portion 4g, and the wall 4f is formed so as to surround only each side or each corner of the peripheral surface of the middle core piece 31m. Also good. In the first embodiment, the gap plate portion 4g is formed in a rectangular plate shape according to the end surface shape of the middle core piece 31m. However, the shape of the gap plate portion 4g is not limited to this, and is a polygonal shape. It may be an irregular shape different from the end face shape of the core piece 31m, such as a cross plate shape or a disc shape. When the gap plate portion 4g is in contact with the end face of the core piece (middle core piece 31m or side core piece 32m), at least a part of the end face of the core piece may be in contact with the gap plate portion 4g. Or a recess may be formed.

[Embodiment 2]
The reactor according to the embodiment described above is used in applications where the energization conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, operating frequency: about 5 kHz to 100 kHz, typically an electric vehicle, The present invention can be used as a component part of a converter mounted on a vehicle such as a hybrid vehicle or a component part of a power conversion device including this converter.

  As shown in FIG. 11, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210. 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 FIG. 11, although an inlet is shown as a charging location of the vehicle 1200, it can be set as a form provided with a plug.

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

  As shown in FIG. 12, 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). As the switching element 1111, a power device such as a field effect transistor (FET) or an insulated gate bipolar transistor (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 embodiment is provided. In particular, when a case in which a liquid refrigerant circulates in the converter 1110 is provided, the reactor can be effectively cooled by storing the reactor L in the case.

  In addition to converter 1110, vehicle 1200 is connected to power supply device converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting 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. Note that some of the power supply device converters 1150 perform DC-DC conversion. The reactor of the power supply device converter 1150 and the auxiliary power supply converter 1160 has the same configuration as the reactor of the embodiment, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactor of the embodiment can be used for a converter that performs conversion of input power and that performs only boosting or only performs step-down.

  The gap member of the present invention can be used for a magnetic core formed by connecting a plurality of core pieces. The magnetic core of this invention can be utilized for the magnetic core with which a reactor is equipped. The reactor of the present invention includes various on-vehicle converters (typically DC-DC converters) mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles, and converters for air conditioners. It can utilize suitably for the component of a converter and a power converter.

DESCRIPTION OF SYMBOLS 1 Reactor 2 Coil 2a, 2b Coil element 2r Connection part 2w Winding 2e Winding end part 3 Magnetic core 31 Middle core part 31m Middle core piece 31e End face 32 Side core part 32m Side core piece 32e Inner end face 4 Gap member 41 Middle gap member 42 Side gap Member 4g Gap plate part 4e Projection part 4f, 4fm, 4fs Wall part 4p Projection part 1100 Power conversion device 1110 Converter 1111 Switching element 1112 Drive circuit L Reactor 1120 Inverter 1150 Power supply device converter 1160 Auxiliary power supply converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub-battery 1240 Auxiliary machinery 1250 Wheel

Claims (5)

A gap member interposed between the core piece and the core piece,
The both core pieces are disposed on both sides, and a gap plate portion interposed between the opposing end surfaces of the both core pieces;
A protruding portion that protrudes outward from the peripheral surface of the gap plate portion than the end surfaces of the core pieces;
A wall portion extending from both sides of the protruding portion in the thickness direction of the gap plate portion and surrounding a peripheral surface of an end portion of each core piece;
A gap member that protrudes inward from the inner peripheral surface of the wall portion and presses the peripheral surface of each core piece. The shape of the end face of at least one of the core pieces is rectangular,
The gap member according to claim 1, wherein the protrusions are provided at positions facing the four sides of the peripheral surface of the core piece. Of both the core pieces,
One of the core pieces is disposed inside the coil and is a pair of middle core pieces arranged in parallel.
The other core piece is a side core piece that is disposed outside the coil and has an inner end face that faces each end face of the middle core piece,
2. The two wall portions surrounding the peripheral surface of each end portion of the middle core piece on one side and the one wall portion surrounding the peripheral surface of the end portion of the side core piece on the other side. 3. The gap member according to 2. A magnetic core formed by connecting a plurality of core pieces,
At least two of the core pieces are connected via a gap member;
The magnetic core whose said gap member is a gap member of any one of Claims 1-3. A reactor comprising a coil formed by winding a winding, and a magnetic core in which the coil is arranged to form a closed magnetic path,
A reactor, wherein the magnetic core is the magnetic core according to claim 4.

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