JP2016076587A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor that can be manufactured with good productivity, and each component of which is coupled firmly.SOLUTION: A reactor includes a coil 2 having windings 2A, 2B, and a magnetic core 3 having an inner core arranged in the windings and an outer core 32 arranged on the outside of the windings. The reactor includes an inner integral components 3A, 3B having an inner core, and an inner resin part covering at least a part of the inner core, and an outer resin part covering at least a part of the outer core 32, and integrating the outer core 32 with the inner integral components 3A, 3B. The inner resin part includes a joint rib 53 projecting toward the outer core 32 and embedded in the outer resin part.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a reactor that is used in a vehicle-mounted DC-DC converter or a component of a power conversion device mounted on an electric vehicle such as a hybrid vehicle.

  Magnetic parts including a coil having a winding portion formed by winding a winding, such as a reactor and a motor, and a magnetic core partially inserted into the winding portion are used in various fields. . As such a magnetic component, for example, Patent Document 1 discloses a reactor used for a circuit component of a converter mounted on an electric vehicle such as a hybrid vehicle.

  FIG. 1 of Patent Document 1 discloses a mold type reactor in which respective members constituting the reactor are integrated by covering most of the outer periphery of the reactor with resin. FIG. 9 of Patent Document 1 discloses a case storage type reactor in which a reactor is stored inside a bottomed container-like case and a resin is filled in the case.

JP 2011-199238 A

  Reactors used for hybrid vehicles and electric vehicles are used under severe vibration. In addition, the reactor itself used with high-frequency power vibrates violently. Therefore, it is necessary that the members constituting the reactor are firmly connected to each other. In the mold type reactor and the case storage type reactor described in Patent Document 1, the resin that covers the outer periphery of the combined body in which a plurality of members are combined has a function of firmly connecting the constituent members. However, both the mold type reactor and the case storage type reactor have a problem that their productivity is not good. This is because both the mold type reactor and the case storage type reactor use a large amount of resin, so it takes time to prepare and store the resin, and it also takes time and labor to cure the resin. In particular, in the case of the case storage type, there is a trouble of preparing the case and a trouble of storing the case in a complete state, so that the productivity of the reactor is not good.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor that can be manufactured with high productivity and each member constituting the reactor is firmly connected to each other. is there.

  A reactor according to an aspect of the present invention includes a coil having a winding portion, an inner core portion disposed inside the winding portion, and a magnetic core having an outer core portion disposed outside the winding portion. , A reactor comprising The reactor includes an inner integral part having an inner resin part that covers at least a part of the inner core part and the inner core part, and at least a part of the outer core part, and the outer core part is covered with the inner integral part. An outer resin portion integrated with the outer resin portion, and the inner resin portion includes a joining rib that protrudes toward the outer core portion and is embedded in the outer resin portion.

  Although the said reactor is a reactor in which each member which comprises a reactor was mutually connected firmly, it is excellent in productivity.

It is a schematic perspective view of the reactor of Embodiment 1. It is a schematic perspective view of the assembly and outer core part with which the reactor of Embodiment 1 is equipped. FIG. 2 is a schematic exploded perspective view of a braid included in the reactor according to the first embodiment. FIG. 3 is a schematic perspective view of an inner integrated part that is one of the constituent members of the assembly provided in the reactor according to the first embodiment. It is the elements on larger scale of the joint rib which provided the securing part. It is the elements on larger scale of a joining rib provided with the securing part of a form different from FIG.

-Description of embodiment of this invention First, the embodiment of this invention is listed and demonstrated.

The reactor of the <1> embodiment includes a coil having a winding part, a magnetic core having an inner core part arranged inside the winding part and an outer core part arranged outside the winding part, It is a reactor provided with. The reactor includes an inner integral part having an inner resin part that covers at least a part of the inner core part and the inner core part, and at least a part of the outer core part, and the outer core part is covered with the inner integral part. An outer resin portion integrated with the outer resin portion, and the inner resin portion includes a joining rib that protrudes toward the outer core portion and is embedded in the outer resin portion.

  With the above configuration in which the inner resin part (inner integral part) and the outer resin part are integrated via the joining rib provided on the inner resin part of the inner integral part, the inner resin is obtained by mechanical engagement via the joining rib. The portion and the outer resin portion can be firmly connected. As a result, there is no problem in maintaining the connection between the inner core portion covered by the inner resin portion and the outer core portion covered by the outer resin portion, with the degree of vibration when the reactor is used.

  Further, the outer resin portion only needs to be provided to the extent that the bonding rib of the inner resin portion is embedded therein, and does not need to be provided so as to cover almost the entire reactor. Therefore, the amount of resin to be used can be greatly reduced as compared with the mold type reactor and the case storage type reactor disclosed in Patent Document 1. If the amount of the resin can be reduced, the labor for preparing and storing the resin can be reduced, and the labor and time for curing the resin can be reduced, so that the productivity of the reactor can be improved.

As a reactor of <2> embodiment, the said joint rib can mention the form provided with the securing part formed in the shape which suppresses the said outer side resin part separating from the said inner side resin part.

  By providing the retaining portion, the connection between the outer resin portion and the inner resin portion can be further strengthened.

<3> As the reactor according to the embodiment, the coil includes a pair of winding parts arranged in parallel, and the magnetic core includes a pair of the inner integrated parts corresponding to each of the winding parts, and The form which is a cyclic | annular core which has a pair of said outer core part arrange | positioned at each of the both ends in a pair of said inner integral components can be mentioned. In this case, the inner resin portion of each inner integral part covers an end surface on one end side of the inner core portion, and is an end insulating portion interposed between the end surface of the winding portion and the outer core portion. And an inner insulating portion that covers the peripheral surface of the inner core portion, and the joining rib is preferably provided on an end surface of the inner insulating portion on the other end side of the inner core portion.

  By forming the end insulating portion by a part of the inner resin portion, the number of parts of the reactor can be reduced. Moreover, it is also possible to make a pair of inner integral parts which comprise some annular magnetic cores into the same shape inner integral parts (refer Embodiment 1). In this case, since the pair of inner integrated parts have the same shape, they can be produced with a single mold, so that the productivity of the reactor can be improved.

<4> As the reactor according to the embodiment, the end insulating portion provided in one of the inner integrated parts may include an insertion hole through which a portion where the joining rib is provided in the other inner integrated part is inserted.

  According to the above configuration, since the pair of inner integrated parts can be mechanically engaged, the relative positions of the pair of inner integrated parts can be determined with high accuracy.

<5> As the reactor according to the embodiment, the end insulating portion protrudes to the side where the outer core portion is disposed in the end insulating portion, and includes a drop-off suppressing portion embedded in the outer resin portion. be able to.

  By forming the drop-off suppressing portion in the end insulating portion, it is possible to firmly connect the outer resin portion and the end insulating portion (inner resin portion) provided in the inner integrated part. As a result, the connection between the inner resin portion and the outer resin portion by the joining rib can be further strengthened.

-Details of embodiment of this invention Hereinafter, embodiment of the reactor of this invention is described based on drawing. The same reference numerals in the figure indicate the same names.

<Embodiment 1>
≪Overall structure≫
With reference to FIGS. 1-6, the reactor 1 (alpha) of Embodiment 1 is demonstrated. FIG. 1 is a schematic perspective view of the reactor 1α, FIG. 2 is a schematic perspective view of the assembly 1 and the outer core portion 32 provided in the reactor 1α, and FIG. 3 is a schematic exploded perspective view of the assembly 1. 4 is a schematic perspective view of the inner integrated parts 3A and 3B, which are one of the constituent members of the assembly 1, and FIGS. In FIG. 1, the outer resin portions 6A and 6B, which are one of the constituent members of the reactor 1α, are shown by cross hatching.

  A reactor 1α of the present embodiment shown in the schematic perspective view of FIG. 1 includes a coil 2 and a magnetic core (in a position that cannot be seen in FIG. 1) that forms an annular closed magnetic path, like a conventional reactor. It is used in a state where the lower surface of the paper is in contact with an installation target such as a cooling base. The coil 2 is a member having winding portions 2A and 2B formed by winding a winding. The magnetic core 3 includes an inner core portion 31 (described later with reference to FIG. 3) disposed inside the winding portions 2A and 2B, and the winding portions 2A and 2B without being covered by the winding portions 2A and 2B. And an outer core portion 32 (which will be described later with reference to FIG. 2) to form an annular closed magnetic circuit. The reactor 1α according to this embodiment includes a pair 1 of inner integrated parts 3A and 3B including an inner core portion 31 and a coil 2 (refer to FIG. 3 in particular). The point where the core portion 32 is joined by the outer resin portions 6A and 6B is a main difference from the conventional reactor. Hereinafter, each component with which the reactor 1 (alpha) is equipped is demonstrated in detail.

≪Assembly≫
In the description of the assembly 1, reference is mainly made to FIGS. 2 and 3, and FIG. 4 is referred to when necessary. The assembly 1 is configured by mechanically combining a coil 2 and a pair of inner integrated parts 3A and 3B.

[coil]
As shown in FIG. 3, the coil 2 in the present embodiment includes a pair of winding portions 2A and 2B and a connecting portion 2R that connects both the winding portions 2A and 2B. Each winding part 2A, 2B is formed in a hollow cylindrical shape with the same number of turns and the same winding direction, and is arranged in parallel so that the respective axial directions are parallel. Further, the connecting portion 2R is a portion bent in a U shape that connects the two winding portions 2A and 2B. The coil 2 may be formed by spirally winding a single winding without a joint. Alternatively, the windings 2A and 2B may be formed by separate windings, and the windings 2A and 2B You may form by joining the edge parts of a coil | winding by welding or crimping | compression-bonding.

  Each winding part 2A, 2B of this embodiment is formed in a rectangular tube shape. The rectangular tube-shaped winding parts 2A and 2B are winding parts whose end face shape is a square shape (including a square shape) with rounded corners. Of course, the winding portions 2A and 2B may be formed in a cylindrical shape. The cylindrical winding portion is a winding portion whose end face shape is a closed curved surface shape (an elliptical shape, a perfect circle shape, a race track shape, etc.).

  The coil 2 including the winding portions 2A and 2B is 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, magnesium, or an alloy thereof. Can be configured. In this embodiment, the windings 2A and 2B are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.

  Both end portions 2a and 2b of the coil 2 are extended from the winding portions 2A and 2B and connected to a terminal member (not shown). An external device such as a power source for supplying power is connected to the coil 2 through the terminal member. The pulling direction of the end portions 2a and 2b is not particularly limited, but in the present embodiment, it is the axial direction of the winding portions 2A and 2B.

[Inner integrated parts]
As shown in FIGS. 3 and 4, the inner integrated parts 3 </ b> A and 3 </ b> B include an inner core part 31 that is a part of the magnetic core 3 and an inner resin part 5 that covers at least a part of the inner core part 31. . Both the inner integrated parts 3A and 3B are members having the same shape as shown in FIG. 4. If the inner integrated part 3A is rotated 180 ° in the horizontal direction, the inner integrated part 3B is obtained. Accordingly, the same reference numerals as those of the inner integrated part 3A are attached to the respective parts of the inner integrated part 3B. In addition, both inner side integral components 3A and 3B do not necessarily have the same shape.

  One of the important features of the inner integrated parts 3A and 3B is that the inner resin portion 5 includes a joining rib 53 described later. Hereinafter, each configuration of the inner integrated parts 3A and 3B will be sequentially described. The joining rib 53 provided in the inner resin portion 5 will be described in detail later by providing items.

[[Inner core]]
The inner core portion 31 included in the inner integrated parts 3A and 3B is a laminated columnar body in which substantially rectangular parallelepiped core pieces 31m containing a magnetic material and gap members 31g having a lower magnetic permeability than the core pieces 31m are alternately connected. It is. In addition, the inner core part 31 may be comprised with one columnar core piece. The entire inner core portion 31 may be accommodated inside the winding portions 2A and 2B, or at least a part of one end side and the other end side in the axial direction protrude from the winding portions 2A and 2B. Also good. The core piece 31m constituting the inner core portion 31 is made of a compacted body using a soft magnetic powder represented by an iron group metal such as iron or an alloy thereof, or a resin containing soft magnetic powder. A composite material, a laminate in which a plurality of magnetic thin plates (for example, electromagnetic steel plates) having an insulating coating are laminated, and the like can be used. A nonmagnetic material such as alumina can be used for the gap material 31g. In addition, the gap material 31g can be formed of a resin that forms the inner insulating portion 52 described later.

[[Inner resin part]]
The inner resin portion 5 molded on the inner core portion 31 includes an end insulating portion 51 fixed to an end surface on one end side in the axial direction of the inner core portion 31, and a peripheral surface (a surface other than the end surface) of the inner core portion 31. ) And inner ribs 6A and 6B, which will be described later, and inner ribs 3A and 3B (assembly 1) are joined to each other. The inner integrated parts 3A and 3B can also be formed by connecting the separately prepared end insulating part 51 and the inner core part 31 covered with the inner insulating part 52 by bonding or fitting.

[[[End insulation]]]
As shown in FIG. 2, the end insulating portion 51 is interposed between the end surfaces of the winding portions 2 </ b> A and 2 </ b> B and the outer core portion 32, and positions the inner core portion 31 and the outer core portion 32 as well as the coil. The insulation between 2 and the outer core part 32 is ensured.

  As shown in FIG. 4, the mounting position of the outer core portion 32 in the end insulating portion 51 is set on the outer surface which is the surface (see the inner integrated part 3 </ b> A) on which the outer core portion 32 is disposed in the end insulating portion 51. Positioning portions 511 and 512 to be defined are formed (see also FIG. 2). The positioning portions 511 and 512 are protrusions protruding from the outer surface of the end insulating portion 51, and the entire shape thereof is formed in a bracket shape. The portions surrounded by these bracket-like positioning portions 511 and 512 are slightly recessed from the other portions, and by storing a part of the end surface of the outer core portion 32 in the recessed portion (storage space 51s). The position of the outer core portion 32 in the end insulating portion 51 is determined.

  The positioning portions 511 and 512 improve the bonding strength between the outer resin portions 6A and 6B (see FIG. 1), which will be described later, and the end insulating portions 51 provided in the inner integrated parts 3A and 3B, and the outer resin from the assembly 1 It also has a role of a drop-off suppressing part that suppresses the drop-off of the parts 6A and 6B. Specifically, as shown by the dotted circles in FIG. 4, the cross sections of the positioning portions 511 and 512 are formed in an approximately L shape, that is, the projecting direction end portions of the positioning portions 511 and 512 are outward ( It is bent in the opposite direction to the storage space 51s. Furthermore, the intermediate part of the width direction (parallel direction of the inner core parts 31 and 31) in the positioning parts 511 and 512 protrudes in a bowl shape on the side where the outer core part 32 is disposed. The portion protruding like a bowl has a role of improving the function of the positioning portions 511 and 512 as a drop-off suppressing portion.

  A plurality of protruding portions 51p protruding from the bottom surface are formed on the bottom surface of the storage space 51s. These protrusions 51p are for supporting the outer core portion 32 fitted in the storage space 51s with a gap from the bottom surface of the storage space 51s (see also FIG. 2). By supporting the outer core portion 32 with a space from the bottom surface of the storage space 51s, when the outer core portion 32 is integrated with the end insulating portion 51 (the assembly 1) by the resin mold portions 6A and 6B described later, Resin can be spread between the end surface of the outer core portion 32 and the bottom surface of the storage space 51s. Therefore, the gap formed between the inner core portion 31 and the outer core portion 32 can be filled with resin.

  Further, in the present embodiment, since the protruding portions 51p are distributed at a plurality of locations, a resin flow path is formed between the protruding portions 51p, and the end surface of the outer core portion 32 and the storage space 51s. It becomes easy to spread resin between the bottom of the. The resin flow can be adjusted by the arrangement of the protruding portions 51p, and the resin can be filled without unevenness. The protruding height from the bottom surface of the protruding portion 51p can be appropriately selected so that a gap having a predetermined length is formed between the inner core portion 31 and the outer core portion 32. Moreover, the arrangement | positioning location of the protrusion part 51p can be suitably selected according to the viscosity of resin, etc. so that resin may flow smoothly into the clearance gap between the inner core part 31 (end part insulation part 51) and the outer core part 32. FIG.

  A window 51w is formed in a portion corresponding to the end surface of the inner core portion 31 in the bottom surface of the storage space 51s, and the end surface of the inner core portion 31 is exposed from the window 51w. Therefore, when the outer core portion 32 is integrated with the end insulating portion 51 in the resin mold portions 6A and 6B, the resin flows into the window 51w, and the resin gap is formed between the inner core portion 31 and the outer core portion 32. Is formed.

  An insertion hole 51h is formed in a portion corresponding to the inner core portion 31 of the other inner integrated part 3B (3A) in the bottom surface of the storage space 51s of the one inner integrated part 3A (3B). The insertion hole 51h of the inner integrated part 3A (3B) is a hole for inserting a narrow portion 522 of the inner integrated part 3B (3A) described later.

  A cylindrical portion 51c and a partition portion 51d are formed on the inner side surface (the surface on the side on which the inner core portion 31 is fixed), which is the surface of the end insulating portion 51 opposite to the storage space 51s. The cylindrical part 51c protrudes from the inner surface and forms the aforementioned insertion hole 51h.

  The partition portion 51 d is provided so as to protrude from the inner side surface of the end insulating portion 51 at a position between the cylindrical portion 51 c and the inner core portion 31 covered with the inner insulating portion 52. The partition 51d is interposed between the winding portions 2A and 2B when the inner integrated parts 3A and 3B are assembled to the coil 2, and maintains the separated state of the winding portions 2A and 2B (see FIG. 3). See also). By this separation, the insulation between the winding parts 2A and 2B can be reliably ensured.

[[[Inner insulation]]]
On the other hand, the inner insulating portion 52 formed of the inner resin portion 5 similarly to the end insulating portion 51 covers the peripheral surface of the inner core portion 31 over the entire length in the longitudinal direction. That is, the inner insulating portion 52 ensures insulation between the coil 2 (see FIG. 3) and the inner core portion 31. The inner insulating portion 52 includes a thick portion 521 extending from the end insulating portion 51 to a predetermined length, and a narrow portion 522 continuous with the thick portion 521. The narrow portion 522 is thinner than the outer diameter of the thick portion 521, and the outer shape of the narrow portion 522 is equal to the inner shape of the thick portion 521. That is, the narrow portion 522 is formed thinner than the thick portion 521. The outer shape of the narrow portion 522 substantially matches the inner shape of the cylindrical portion 51c described above, so that the narrow portion 522 can be inserted into the cylindrical portion 51c of the other inner integral part. Therefore, when the inner integrated part 3A and the inner integrated part 3B are brought close to each other, the narrow part 522 and the cylindrical part 51c of the inner integrated parts 3A and 3B are fitted together, and the inner integrated parts 3A and 3B are connected in an annular shape. It becomes a state. At this time, the step formed between the thick portion 521 and the narrow portion 522 is stopped against the end portion of the cylindrical portion 51c, so that the relative positions of the inner integrated parts 3A and 3B are set to predetermined positions. Determined.

[[[Joint rib]]]
The joining rib 53 protrudes toward the outer core portion 32 and is embedded in outer resin portions 6A and 6B (see FIG. 1), which will be described later, to firmly join the outer resin portions 6A and 6B and the inner integrated components 3A and 3B. It is a functional member. The joining rib 53 in this example is provided on the end surface of the narrow part 522, and when the narrow part 522 of the inner integral part 3B (3A) is fitted into the cylindrical part 51c of the inner integral part 3A (3B), The joining rib 53 does not interfere with the fitting. Note that the number of the joining ribs 53 is not particularly limited, and may be two or more.

  As shown in FIG. 2, the joining rib 53 provided on the end surface of the narrow portion 522 of the inner integral part 3B protrudes from the insertion hole 51h of the inner integral part 3A when the inner integral parts 3A and 3B are fitted together. To do. Therefore, when the outer core portion 32 is integrated with the assembly 1 by the resin mold portion 6A (see FIG. 1), the joining rib 53 of the inner integrated part 3B is embedded in the resin mold portion 6A. On the other hand, the joining rib 53 provided in the narrow part 522 of the inner integrated part 3A protrudes from the insertion hole 51h of the inner integrated part 3B at a position not visible in FIG. Therefore, when the outer core part 32 is integrated with the assembly 1 by the resin mold part 6B (see FIG. 1), the joining rib 53 of the inner integrated part 3A is embedded in the resin mold part 6B. That is, the outer resin part 6A is integrated with the end insulating part 51 of the inner integrated part 3A and the narrow part 522 of the inner integrated part 3B in a state including the outer core part 32, and the outer resin part 6B is integrated with the outer core part 32. Are integrated into the end insulating portion 51 of the inner integral part 3B and the narrow part 522 of the inner integral part 3A. In addition, since the inner integrated parts 3A and 3B are fitted into the coil 2, all the constituent members are mechanically integrated in some form, and the respective constituent members are connected very firmly. become.

  The inner side surface of the joining rib 53 (the surface pointed to by the end of the lead wire in FIG. 2) when the inner side integral parts 3A and 3B are fitted together includes the inner side surfaces of the bent portions of the positioning portions 511 and 512 described above. Riding on a virtual plane. Therefore, the joining rib 53 of this example has the position of the outer core part 32 with respect to the end insulating part 51 in the width direction of the assembly 1 (parallel direction of the winding parts 2A and 2B) together with the positioning parts 511 and 512 described above. It also has a function to decide.

  The joining rib 53 may be formed in the illustrated flat plate shape, but preferably includes a retaining portion 531 as shown in FIG. The retaining portion 531 has a shape that prevents the outer resin portions 6A and 6B (see FIG. 1) from separating from the inner resin portion 5, that is, when the outer resin portions 6A and 6B are pulled away from the inner resin portion 5. The shape has a hook. In the example of FIG. 5, a groove 53 g extending in a direction intersecting with the protruding direction of the bonding rib 53 (a direction orthogonal in the illustrated example) is formed at a position slightly closer to the base from the tip of the bonding rib 53. A portion on the front end side with respect to the groove 53g of 53 is a retaining portion 531. The upper and lower ends of the groove 53g may be cut out to improve the bonding strength by the retaining portion 531.

  Here, the number of the grooves 53g is not necessarily one, and another groove may be formed on the surface where the grooves 53g are formed. Further, as shown in the partially enlarged view of FIG. 6, another groove may be formed on the surface opposite to the surface on which the groove 53g is formed. In the example of FIG. 6, the grooves 53g are formed on the front and back of the joining rib 53, and the front and back grooves 53g are connected by cutting out the upper end and the lower end of the groove 53g. By setting it as such a structure, the joint strength by the securing part 531 can be improved further.

  The retaining portion 531 is not limited to the configuration formed by the groove 53g. For example, the thickness of the tip of the joining rib 53 can be made thicker than the other parts, and the thickened part (the part protruding from the other part) can be used as the retaining part. When the protruding direction of the retaining portion is the center side of the inner core portion 31 in FIG. 5, that is, the retaining portion protruding from the front surface of the joining rib 53, the narrow portion 522 is inserted into the insertion hole 51h. The retaining part does not get in the way. Of course, a retaining portion that protrudes from the back surface of the joining rib 53 may be formed. In that case, although it becomes slightly difficult to insert the narrow portion 522 into the insertion hole 51h, the bonding strength by the retaining portion can be further improved.

  Examples of the constituent material of the inner resin portion 5 described above include, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide 6 such as nylon 6 and nylon 66, PA Thermoplastic resins such as butylene terephthalate (PBT) resin and acrylonitrile / butadiene / styrene (ABS) resin can be used. In addition, thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. The resin may contain a ceramic filler to improve the thermal conductivity of the inner insulating portion 52. As the ceramic filler, for example, nonmagnetic powder such as alumina or silica can be used.

≪Outer core part≫
As shown in FIG. 2, a pair of outer core portions 32 and 32 are attached to the assembly 1. The outer core portion 32 is a member that forms the annular magnetic core 3 together with the inner core portion 31 provided in the inner integrated parts 3A and 3B described above. The shape of the outer core part 32 will not be specifically limited if it is a shape which can be connected with the end surface of a pair of inner core parts 31 and 31 arrange | positioned inside winding part 2A, 2B. For example, as shown in the drawing, the outer core portion 32 of a substantially dome-like columnar body can be used for the upper surface and the lower surface. In addition, a substantially rectangular parallelepiped outer core portion can be used.

  As with the core piece 31m of the inner core portion 31 shown in FIG. 4, the outer core portion 32 may be constituted by a laminated body in which electromagnetic steel plates are laminated, or a compacted body in which soft magnetic powder is pressure-molded. You may comprise, and may comprise with the composite material which disperse | distributed soft-magnetic powder in resin. The outer core portion 32 and the core piece 31m of the inner core portion 31 may have the same configuration or different configurations. As an example of the latter, for example, the inner core portion 31 may be formed of a green compact and the outer core portion 32 may be formed of a composite material.

≪Outside resin part≫
The assembly 1 and the outer core portion 32 shown in FIG. 2 are integrated by outer resin portions 6A and 6B as shown in FIG. In the present embodiment, a metal collar 6h is further integrated into the assembly 1 by the resin mold parts 6A and 6B. The collar 6h constitutes an attachment hole for fixing the reactor 1α to the installation target.

  The outer resin portions 6A and 6B cover almost the entire surface of one surface side (the side where the outer core portion 32 shown in FIG. 2 is disposed) of the end portion insulating portion 51 of the assembly 1. Therefore, as will be described in detail in the manufacturing procedure of the reactor 1α to be described later, the joining rib 53 shown in FIG. 2 is embedded in the outer resin portions 6A and 6B. The resin parts 6A and 6B are firmly connected. On the other hand, the outer resin portions 6A and 6B do not reach the other surface side (side on which the coil 2 is disposed). Therefore, the amount of resin used for the reactor 1α of this example can be significantly smaller than that of a conventional reactor such as a case storage type.

  The resin mold parts 6A and 6B can be formed by insert molding, for example. If the mold 1 and the outer core portion 32 are placed in the mold and the mold is filled with resin as the material of the outer resin portions 6A and 6B, the assembly 1 and the outer core portion 32 are integrated. The outer resin portions 6A and 6B to be converted can be formed.

  As the resin constituting the outer resin parts 6A and 6B, for example, a thermoplastic resin such as PPS resin, PTFE resin, LCP, PA resin (nylon 6, nylon 66, etc.), PBT resin, ABS resin can be used. . In addition, thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. Unsaturated polyester is advantageous in that it is difficult to break and is inexpensive. Further, these resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the outer resin portions 6A and 6B.

≪Other composition≫
The reactor 1α may include a bonding layer (not shown) in at least the coil 2 portion of the installation surface of the reactor 1α (surface facing the installation target to which the reactor 1α is attached). By providing the bonding layer, the coil 2 of the reactor 1α can be firmly fixed to the installation target, the movement of the coil 2 can be restricted, and the heat dissipation of the coil 2 (that is, the heat dissipation of the reactor 1α) is improved. Etc. Constituent material of the bonding layer contains an insulating resin, particularly ceramic filler, and has excellent heat dissipation (for example, thermal conductivity is 0.1 W / m · K or more, further 1 W / m · K or more, especially 2 W / M · K or more). Specific examples of the resin include a thermosetting resin such as an epoxy resin, a silicone resin, and an unsaturated polyester, and a thermoplastic resin such as a PPS resin and a liquid crystal polymer (LCP). When a sheet-like material is used as the bonding layer, the bonding layer is easily arranged.

  Further, a heat radiating plate (not shown) can be provided at any location on the outer peripheral surface of the coil 2. For example, if the installation surface of the coil 2 (surface facing the installation target to which the reactor 1α is attached) is provided with a heat sink, the heat of the coil 2 can be transmitted well to the installation target through the heat sink, so the heat dissipation of the reactor 1α Can be enhanced. As the constituent material of the heat sink, a material having excellent thermal conductivity such as a metal such as aluminum or an alloy thereof or a non-metal such as alumina can be used. You may provide a heat sink in the whole installation surface of the reactor 1 (alpha). The heat radiating plate can be fixed to the coil 2 by the bonding layer described above, for example.

≪Reactor manufacturing procedure≫
A procedure for producing reactor 1α having the above-described configuration will be described with reference to FIGS.

[Production of assembly]
First, the assembly 1 shown in FIG. 2 is produced. For that purpose, as shown in FIG. 3, the coil 2 and the inner integrated parts 3A and 3B are prepared. And the part containing the inner core parts 31 and 31 of inner integrated components 3A and 3B is inserted in winding part 2A and 2B. At this time, the narrow part 522 of the inner integral part 3A is inserted into the insertion hole 51h of the inner integral part 3B, and the narrow part 522 of the inner integral part 3B is inserted into the insertion hole 51h of the inner integral part 3A. As shown in FIG. 2, both inner integrated parts 3A and 3B are connected in an annular shape. As shown in FIG. 2, the narrow portion 522 inserted into the insertion hole 51h protrudes from the bottom surface of the storage space 51s, and the joining rib 53 provided at the position of the narrow portion 522 also protrudes from the bottom surface of the storage space 51s. .

  Here, when the assembly 1 is manufactured, it is preferable that a foamed resin is disposed between the inner peripheral surface of the winding portions 2A and 2B and the outer peripheral surface of the inner insulating portion 52. After assembling the core members 3A and 3B to the coil 2, the relative position between the coil 2 and the core members 3A and 3B can be fixed by foaming the foamed resin.

[Integration of outer core part into assembly]
Next, as shown in FIG. 2, the outer core portion 32 is fitted into the storage space 51 s of the end insulating portion 51 in the assembly 1. When the outer core portion 32 is fitted, an adhesive may be applied to the end face of the outer core portion 32 on the fitting side.

  An integrated body of the assembly 1 and the outer core portions 32, 32 is disposed in the mold, and a metal collar 6h (see FIG. 1) constituting the attachment hole is disposed in the mold. Then, the mold is filled with a resin, and the resin is cured to form the outer resin portions 6A and 6B. At this time, the joining rib 53 protruding from the bottom surface of the storage space 51s of the end insulating portion 51 shown in FIG. 2 is embedded in the resin mold portions 6A and 6B, and the end insulating portion 51 and the resin mold portions 6A and 6B are embedded. Strongly connected. As a result, the inner core parts 31 and 31 (assembly 1) and the outer core parts 32 and 32 are firmly connected.

  In this example, as shown by the dotted circle in FIG. 4, the positioning portions 511 and 512 provided in the end insulating portion 51 are formed in an L shape, and the portion bent into the L shape. However, it plays a role like a barb of the fishhook, and improves the bonding strength between the end insulating portion 51 and the resin mold portions 6A and 6B. Further, a part of the central portion of the positioning portions 511 and 512 protrudes toward the outer core portion 32 in a bowl shape so that the contact area between the positioning portions 511 and 512 and the outer resin portions 6A and 6B is increased. Yes. Due to the increase in the contact area, the outer resin portions 6A and 6B are not easily dropped from the end insulating portion 51.

  Here, the resin filled in the mold reaches the gap between the outer core portions 32 and 32 and the end insulating portion 51. This is because the protruding portion 51p is formed on the bottom surface of the storage space 51s of the end insulating portion 51, so that the outer core portions 32, 32 are separated from the bottom surface. The resin that has spread across the gap improves the bonding strength between the outer resin portions 6A and 6B and the assembly 1.

≪Effect≫
As described above, the reactor 1α of the present embodiment is excellent in productivity. Reactor 1α can be easily produced simply by producing assembly 1 in which core members 3A and 3B are assembled to coil 2 and molding outer core portions 32 and 32 with outer resin portions 6A and 6B. Because you can. In addition, since the amount of resin used at that time is significantly less than conventional mold type reactors and case storage type reactors, it is possible to reduce the time required for resin preparation and storage compared to conventional methods, The time for curing the resin can be shortened. Furthermore, a series of manufacturing operations of the reactor 1α can be performed without using an adhesive. In this case, the labor for preparing and storing the adhesive can be eliminated.

  Further, in the reactor 1α of the present embodiment, the joining rib 53 is embedded in the outer resin portions 6A and 6B, and the assembly 1 and the outer resin portions 6A and 6B are firmly connected. Therefore, when the reactor 1α is used. As far as vibration is concerned, the outer resin parts 6A and 6B do not fall off the assembly 1, and the inner core part 31 and the outer core part 32 are firmly connected.

  Furthermore, the reactor 1α according to the present embodiment is installed in the installation target in the assembled state shown in FIG. 1 without being housed in a case and embedded in potting resin or molded entirely with resin. be able to. This is because each member constituting the reactor 1α is combined with certainty. In this reactor 1α, since the coil 2 and the like are exposed, the reactor 1α can be efficiently cooled when used in a state where the reactor 1α is immersed in a liquid refrigerant or the like. For example, when reactor 1α is used in a hybrid vehicle, ATF (Automatic Transmission Fluid) or the like can be used as the liquid refrigerant. By cooling the reactor 1α with the liquid refrigerant, it is possible to suppress the operation of the reactor 1α from becoming unstable due to heat. As the liquid refrigerant, a fluorine-based inert liquid such as Fluorinert (registered trademark), a fluorocarbon refrigerant such as HCFC-123 or HFC-134a, an alcohol refrigerant such as methanol or alcohol, or a ketone refrigerant such as acetone is used. You can also

<Embodiment 2>
As an example of a reactor including an inner integrated part having a configuration different from that of the first embodiment, an inner integrated part constituted by one inner core part and an inner resin part covering the outer periphery thereof in a cylindrical shape will be described. In the description, FIG. 4 will be used for explanation.

  The inner integrated part of Embodiment 2 may be considered as a configuration in which the end insulating portion 51 is eliminated from the inner integrated part 3B of FIG. However, in the inner integrated part of the second embodiment, the narrow portion 522 and the joining rib 53 on the front side of the inner insulating portion 52 are also formed on the inner surface of the inner insulating portion 52 on the back side. The joining rib 53 on the back side of the paper surface is provided on the same side as the joining rib 53 on the near side of the paper surface. In the present embodiment, a pair of inner integrated parts having such a configuration is prepared. Since the pair of inner integral parts have the same shape, only one mold for producing the inner integral part is required.

  When using the inner integrated part, a pair of end insulating parts are prepared separately from the inner integrated part. The prepared end insulating portion is the same as the end insulating portion 51 shown in the upper part of FIG. 4 except that the end insulating portion in which the cylindrical portion 51c is formed on the side where the inner core portion 31 is arranged, that is, the partition portion 51d. A pair of glasses-like end insulating portions formed with two cylindrical portions 51c sandwiched therebetween may be used.

  When a reactor is manufactured using the above-described inner integrated component, first, the inner integrated component is inserted into each winding portion of the coil, and both end surfaces of the pair of inner integrated components are sandwiched between a pair of eyeglass-shaped end insulating portions. Form a braid. Then, the assembly is sandwiched between the pair of outer core portions, and the outer core portion is integrated with the assembly by the outer resin portion. At that time, the joining rib provided in the inner integrated part is embedded in the outer resin portion, and the assembly and the outer core portion are integrated.

<Embodiment 3>
As an example of a reactor including an inner integral part having a configuration different from those of the first and second embodiments, an inner integral part including two inner core parts will be described. In the description, FIG. 4 is used.

  The inner integral part of Embodiment 3 is an inner integral part 3B of FIG. 4 in which a columnar body made of an inner core part 31 covered with an inner insulating part 52 is also formed on the side where the cylindrical part 51c is disposed. This is an integral part, that is, a substantially U-shaped inner integral part in which two inner core parts 31 are connected by an end insulating part 51. The columnar joint ribs 53 provided in place of the cylindrical portion 51c are arranged outside the columnar bodies in the parallel direction. That is, the columnar body on the right side of the paper surface is formed so that the columnar bodies arranged in parallel are targeted with the partition 51d interposed therebetween.

  When using the above-mentioned inner integral part, one end insulating portion is prepared separately from the inner integral part. The prepared end insulating portion may be the eyeglass-shaped end insulating portion described in the second embodiment.

  When a reactor is manufactured using the above-described inner integrated component, first, the inner integrated component is inserted into both winding portions of the coil, and the inner surface of the inner integrated component is an eyeglass-shaped end. The assembly is formed by assembling the partial insulation portion. Then, the assembly is sandwiched between the pair of outer core portions, and the outer core portion is integrated with the assembly by the outer resin portion. At that time, the joining rib provided in the inner integrated part is embedded in the outer resin portion, and the assembly and the outer core portion are integrated.

  The reactor according to the above-described embodiment has an application condition in which energization conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and usage frequency: about 5 kHz to 100 kHz, typically an electric vehicle. It can be suitably used as a component part of a vehicle-mounted power conversion device such as a hybrid vehicle. In this application, it is expected that an inductance satisfying 10 μH or more and 2 mH or less when the DC current is 0 A and 10% or more of the inductance when the maximum current is applied is 10% or more can be suitably used.

  The reactor of this invention can be utilized for the components of power converters, such as a bidirectional | two-way DC-DC converter mounted in electric vehicles, such as a hybrid vehicle, an electric vehicle, and a fuel cell vehicle.

DESCRIPTION OF SYMBOLS 1 (alpha) Reactor 1 Assembly 2 Coil 2A, 2B Winding part 2R Connection part 2a, 2b End part 3 Magnetic core 31 Inner core part 32 Outer core part 31m Core piece 31g Gap material 3A, 3B Inner integral part 5 Inner resin part 51 End Part insulating part 511, 512 Positioning part 51c Tube part 51d Partition part 51h Insertion hole 51p Protrusion part 51s Storage space 51w Window 52 Inner insulation part 521 Thick part 522 Narrow part 53 Joint rib 53g Groove 531 Detachment part 6A, 6B Outer resin 6h color

Claims (5)

A reactor comprising a coil having a winding part, and a magnetic core having an inner core part arranged inside the winding part and an outer core part arranged outside the winding part,
An inner integral part having an inner resin part covering at least a part of the inner core part and the inner core part;
An outer resin part that covers at least a part of the outer core part and integrates the outer core part into the inner integral part;
With
The said inner side resin part protrudes toward the said outer side core part, and is a reactor provided with the joining rib embed | buried under the said outer side resin part.   The reactor according to claim 1, wherein the joining rib includes a retaining portion formed in a shape that prevents the outer resin portion from separating from the inner resin portion. The coil has a pair of winding portions arranged in parallel,
The magnetic core is an annular core having a pair of inner integral parts corresponding to each of the winding parts and a pair of outer core parts disposed at both ends of the pair of inner integral parts. Yes,
The inner resin portion of each inner integral part is:
An end insulating portion that covers an end surface on one end side of the inner core portion and is interposed between the end surface of the winding portion and the outer core portion;
An inner insulating portion covering the peripheral surface of the inner core portion,
The reactor according to claim 1, wherein the joining rib is provided on an end surface of the inner insulating portion on the other end side of the inner core portion.   4. The reactor according to claim 3, wherein the end insulating portion provided in one of the inner integrated parts includes an insertion hole through which a portion of the other inner integrated part provided with the joining rib is inserted.   5. The reactor according to claim 3, wherein the end insulating portion includes a drop-off suppressing portion that protrudes to a side where the outer core portion is disposed in the end insulating portion and is embedded in the outer resin portion.

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