JP2016082042A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of using a dead space effectively as the arrangement position of a temperature sensor for measuring the temperature of a coil, and capable of measuring that temperature accurately.SOLUTION: A reactor includes a coil having a wound part formed by winding a wire, a magnetic core having a portion arranged on the inside and outside of the wound part, a temperature sensor for measuring the temperature of the coil, and an opposite member facing the end face of the wound part. The temperature sensor is arranged in a space sandwiched between the end face of the wound part and the opposite member.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a reactor used for a component part of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that can effectively use a dead space as an arrangement position of a temperature sensor that measures the temperature of a coil and can accurately measure the temperature.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. The reactor includes a coil and a magnetic core, and is used in a converter mounted on a vehicle such as a hybrid vehicle. The reactor can cause an increase in loss mainly due to heat generation of the coil accompanying energization. Therefore, the reactor of Patent Document 1 includes a temperature sensor that measures the temperature of the coil so that the current to the coil can be controlled according to the temperature of the coil. The coil is formed by arranging a pair of coil elements (winding portions) in which the windings are spirally wound in parallel (side by side) so that their axes are parallel to each other. The end face shape of each winding portion is a rectangular shape having a corner R portion with rounded corners. The temperature sensor is disposed in a trapezoidal space sandwiched between corner R portions opposed to each other in the pair of winding portions.

JP 2014-093375 A

  As described above, the temperature of the coil can be accurately measured by bringing the temperature sensor close to the coil. As described above, the coil temperature can be measured with high accuracy, and further effective use of a different dead space as the position of the temperature sensor has been desired.

  The present invention has been made in view of the above circumstances, and one of its purposes is a reactor that can effectively use a dead space as an arrangement position of a temperature sensor for measuring the temperature of a coil and can accurately measure the temperature. Is to provide.

  The reactor which concerns on 1 aspect of this invention is provided with a coil, a magnetic core, a temperature sensor, and an opposing member. The coil has a winding part formed by winding a winding. A magnetic core has a part arrange | positioned inside and outside a winding part. The temperature sensor measures the temperature of the coil. The facing member faces the end surface of the winding part. A temperature sensor is arrange | positioned in the space pinched | interposed by the end surface of a winding part, and an opposing member.

  The reactor can effectively use the dead space as the position of the temperature sensor, and can accurately measure the coil temperature.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a top view which shows the reactor of Embodiment 1. It is a fragmentary sectional view which shows the state cut | disconnected by the (III)-(III) cutting line of the reactor shown in FIG. FIG. 3 is an exploded perspective view illustrating a manufacturing process of the reactor according to the first embodiment. It is a top view which shows the reactor of Embodiment 2. It is a top view which shows the reactor of Embodiment 3. It is a top view which shows the reactor of Embodiment 4. It is a top view which shows the reactor of Embodiment 5. It is a front view of the coil components with which the reactor of Embodiment 5 is equipped.

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

  (1) The reactor which concerns on 1 aspect of this invention is provided with a coil, a magnetic core, a temperature sensor, and an opposing member. The coil has a winding part formed by winding a winding. A magnetic core has a part arrange | positioned inside and outside a winding part. The temperature sensor measures the temperature of the coil. The facing member faces the end surface of the winding part. A temperature sensor is arrange | positioned in the space pinched | interposed by the end surface of a winding part, and an opposing member.

  According to said structure, the temperature of a coil can be measured accurately. This is because the space is formed by the end face of the winding portion and the opposing member, and thus the temperature sensor can be brought close to the coil by arranging the temperature sensor in the space. Further, since the temperature sensor is arranged in the space which is a dead space, the dead space can be effectively used.

  (2) As one form of the reactor, the winding part is wound spirally, the opposing member has an opposing surface that faces the end face of the winding part, and the space is the end face of the winding part. And an inclined space formed by a surface including the opposing surface of the opposing member and corresponding to the inclination created by the end face of the winding portion.

  According to said structure, it is easy to fix a temperature sensor in the said space. The inclined space is a space that tapers along one of the winding directions of the winding. For this reason, the temperature sensor is easily sandwiched between the end surface of the winding portion and the facing surface of the facing member.

  (3) As one form of the reactor, the coil includes a pair of winding portions that are arranged side by side so that their axes are parallel to each other, and a connection portion that connects the pair of winding portions at one end in the axial direction. Is provided. In this case, it is preferable that the temperature sensor is disposed in the space where the pair of winding portions are located on the sides facing each other.

  According to said structure, it is easy to perform optimal control of the electric current to a coil. This is because the space where the pair of winding portions are located on the sides facing each other is easy to detect the temperature with high accuracy. This is because, in particular, the space where the pair of winding portions are located on the sides facing each other is likely to have a higher coil temperature than the space located on the opposite side of the facing sides.

  (4) As one form of the reactor, when the above-described coil includes a pair of winding parts and a connecting part, the temperature sensor may be disposed in the space located on the connecting part side.

  According to said structure, it is much easier to perform optimal control of the electric current to a coil. The temperature of the coil is such that the space on the side where the pair of winding parts face each other and on the connecting part side is the space on the side where the pair of winding parts face each other and on the opposite side of the connecting part. This is because the coil temperature tends to be higher than that of the coil. The reason will be described later.

  (5) As one form of the said reactor, it is provided with the sensor fixing | fixed part which fixes a temperature sensor in space, and a sensor fixing | fixed part has foaming resin which expands by volume.

  According to said structure, while being easy to fix a temperature sensor in the said space, it is easy to maintain the fixed state favorably. This is because it is easy to fill the gaps in the space with the volume expansion of the foamed resin. In particular, it can be expected that the gap is substantially eliminated depending on the amount of foamed resin and the expansion coefficient. In some cases, it can be expected that the temperature sensor is brought into close contact with the end surface of the winding part or the opposing surface of the opposing member as the volume expands. When the foamed resin has a certain degree of adhesive force, the temperature sensor can be firmly fixed by this adhesive force, so that it is easier to maintain the contact state between the temperature sensor and the end surface of the winding part or the opposing surface of the opposing member. .

  The foamed resin is formed by volume expansion of an unfoamed resin in the process of manufacturing the reactor. That is, in the manufacturing process, an unfoamed resin having a thickness smaller than that of the foamed resin after manufacture can be used. Therefore, it is easy to provide the space in the space with the temperature sensor.

  (6) As one form of the reactor, when the sensor fixing unit described above is provided, the sensor fixing unit includes a foamed resin disposed on the facing member side with respect to the temperature sensor and an adhesive disposed on the winding unit side. It is mentioned to have. In this case, the temperature sensor is in contact with the adhesive by the volume expansion of the foamed resin.

  According to said structure, since it is easy to make a temperature sensor contact an adhesive agent by volume expansion of foamed resin, it is easy to maintain the contact state of a temperature sensor and a winding part favorably.

  (7) As one form of the said reactor, a groove part is formed in the end surface side of the winding part in an opposing member, and it is mentioned that the temperature sensor is arrange | positioned at the groove part.

  According to said structure, it is easy to arrange | position a temperature sensor in the said space. This is because by forming the groove portion on the end face side of the opposing member, it is possible to widen the space that can be stored as compared with the case where there is no groove portion. In addition, since the temperature sensor can be arranged close to the end face of the winding portion, the temperature of the coil can be measured with sufficient accuracy, as compared with the case where the groove portion is not provided.

  (8) As one form of the said reactor, it is mentioned that an opposing member is comprised by a part of core piece arrange | positioned out of a winding part among magnetic cores.

  According to said structure, the clearance gap between a coil and the said core piece can be used effectively.

  (9) As one form of the reactor, the facing member may include a resin mold portion that covers a surface of a core piece that is disposed outside the winding portion of the magnetic core.

  According to said structure, it is easy to suppress damage to the temperature sensor by friction with a temperature sensor and the said core piece. Moreover, the contact between the coil and the core piece can be suppressed, and the insulation between the two can be easily improved.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
[Overall structure of the reactor]
With reference to FIGS. 1-4, the reactor 1A of Embodiment 1 is demonstrated. The reactor 1A includes a coil 2 having a pair of winding portions 2a and 2b formed by winding a winding 2w, a magnetic core 3 having portions disposed inside and outside the coil 2, and a temperature at which the temperature of the coil 2 is measured. And a sensor 7 (FIG. 2). The main feature of the reactor 1A is that the temperature sensor 7 is arranged in a specific dead space where the temperature can be measured with high accuracy. Specifically, an opposing member that faces the end surfaces of the winding portions 2a and 2b is provided, and the temperature sensor 7 is disposed in a space that is sandwiched between the opposing member and the end surfaces of the winding portions 2a and 2b. Hereinafter, the main characteristic part of reactor 1A, the structure of the related part, and the main effects will be described in order, then each structure will be described in detail, and finally the method for manufacturing reactor 1A will be described. Here, the installation target side of reactor 1A is the installation side (lower side), and the opposite side is the opposing side (upper side). The same reference numerals in the figure indicate the same names.

[Composition of main features and related parts]
[coil]
The coil 2 is formed from a pair of winding portions 2a and 2b formed by spirally winding a single continuous winding 2w having no joint portion, and a part of the winding 2w. 2b for connecting 2b (FIGS. 1, 2, and 4). The winding 2w is a covered rectangular wire (so-called enameled wire) including a flat wire conductor (copper or the like) and an insulating coating (polyamideimide or the like) covering the outer periphery of the conductor. The winding parts 2a and 2b are edgewise coils obtained by edgewise winding the covered rectangular wire. Each winding part 2a, 2b is a hollow cylindrical body having the same number of turns, and the end face shape of each winding part 2a, 2b is a shape obtained by rounding the corners of the rectangular frame. The winding portions 2a and 2b are arranged side by side (in parallel) so that their axial directions are parallel to each other.

  The connecting portion 2r is configured by bending a part of the winding 2w into a U shape on the upper side of one end side in the axial direction of the coil 2 (FIG. 1, right side of FIG. 4, upper side of FIG. 2, left side of FIG. 3). ing. Both end portions 2e of the winding 2w forming each winding portion 2a, 2b are on the upper side of the opposite side to the connecting portion 2r side (the other end side in the axial direction of the coil 2, hereinafter referred to as the terminal side). To be extended in parallel to the axial direction of the coil 2. Both end portions 2e are connected to terminal members (not shown) on conductors exposed by peeling off the insulation coating at the ends. The coil 2 is connected to an external device (not shown) such as a power source for supplying power to the coil 2 through this terminal member.

  As will be described in detail later, each winding part 2a, 2b forms a space 27G between the opposing member (here, the frame part 315) (FIGS. 2 and 3). The temperature sensor 7 is disposed in the space 27G, and the temperature sensor 7 and the end face of the coil 2 are in contact with each other. The contact of the temperature sensor 7 with the end face of the coil 2 is not only when the temperature sensor 7 and the end face of the coil 2 are in direct contact, but between the temperature sensor 7 and the end face of the coil 2, It includes the case of contacting through a solid material such as a protective member (both described later). The solid substance is preferably made of a material having excellent thermal conductivity.

[Counter member]
As described above, the opposing member forms a space 27G between the winding portions 2a and 2b. The facing member has a facing surface that faces the end surfaces of the winding portions 2a and 2b. The facing surface may be a flat surface or a curved surface. When the opposing surface is configured as a flat surface, it may be formed in parallel to the end faces of the winding portions 2a and 2b, or may be formed to be orthogonal to the axial direction of the winding portions 2a and 2b. Here, the said opposing surface is comprised with the plane orthogonal to the axial direction of winding part 2a, 2b. This opposing member is comprised by the frame part 315 formed in series in the middle resin mold part 310m (after-mentioned) of the magnetic core 3 mentioned later in detail. The frame portion 315 is interposed between end surfaces of the winding portions 2a and 2b and an inner end surface 32e of a core piece 32m (described later), and faces the end surfaces of the winding portions 2a and 2b. It has a facing surface 315c formed by a plane orthogonal to the axial direction of 2b (FIGS. 2 and 4). Other configurations of the frame portion 315 will be described later. The opposing member may be an outer core portion (core piece 32m or side resin mold portion 320m) of the magnetic core 3, or a frame member that is not integrated with the middle resin mold portion 310m (for example, Modification 3 described later). ).

[space]
The space 27G is a space in which the temperature sensor 7 can be arranged. The space 27G is formed by a surface including the end surfaces of the winding portions 2a and 2b and the facing surface 315c of the frame portion 315 when the coil 2 and the magnetic core 3 (described later) are combined. Specifically, the space 27G is a direction orthogonal to both the axial direction of the coil 2 (winding portions 2a and 2b) and the parallel direction of the winding portions 2a and 2b (vertical direction in FIG. 2, vertical direction in FIG. 3). Direction). When the facing surface 315c is parallel to the end surfaces of the winding portions 2a and 2b (particularly when the opposing surface 315c is configured by a plane parallel to the end surfaces), this space 27G is one opening (before the paper surface of FIG. 2, the upper surface of FIG. 3). Is a space having a substantially uniform thickness from the opening to the other opening (the back side in FIG. 2 and the bottom side in FIG. 3). When the facing surface 315c is orthogonal to the axial direction of the winding portions 2a and 2b (particularly when the opposing surface 315c is configured by a plane orthogonal to the axial direction), the space 27G has end faces (final turns) of the winding portions 2a and 2b. Corresponds to the tilt to create. That is, it is an inclined space that tapers from the one opening to the other opening. Here, the space 27G is the inclined space.

  The thickness of the space 27G (the length along the axial direction of the coil 2) is approximately the thickness of one winding 2w at a thick portion (here, the upper side). If this thick part is used as the insertion port of the temperature sensor 7 in the manufacturing process, the temperature sensor 7 can be easily inserted. When the opposing surface 315c is orthogonal to the axial direction of the winding portions 2a and 2b, the thickness of the space 27G is gradually reduced because it tapers along one of the winding directions of the winding 2w (FIG. 3). Therefore, when the temperature sensor 7 is inserted into the space 27G, the temperature sensor 7 is sandwiched in contact with both the end surfaces of the winding portions 2a and 2b and the opposing surface 315c of the frame portion 315 in the middle of the space 27G. Fixed (positioned). The width of the space 27G (the length along the parallel direction of the winding portions 2a and 2b) is the same length as the width of the winding 2w.

The space 27G is formed in a total of four locations, one on each of the connecting portion 2r side and the terminal side, on the side where the winding portions 2a and 2b face each other and on the opposite side. The reactor 1A includes a pair of winding portions 2a and 2b and frame portions 315 arranged on both end surfaces of the winding portions 2a and 2b. The end surfaces of the winding portions 2a and 2b are arranged on the terminal side and the connecting portion 2r side, respectively. Specifically, in both the winding portions 2a and 2b, a space 27G ₁ and a space 27G ₃ are formed between the right side of the terminal side end surface shown on the lower side of FIG. 2 and the facing surface 315c of one frame portion 315, respectively. Thus, a space 27G ₂ and a space 27G ₄ are formed between the left end face on the connecting portion 2r side shown in the upper side of FIG. 2 and the facing surface 315c of the other frame portion 315, respectively.

[Temperature sensor]
The temperature sensor 7 measures the temperature of the coil 2. The temperature sensor 7 is connected to a wiring 78 that transmits detection information to an external device (FIGS. 1 and 4). 2 and 3, the wiring is omitted for convenience of explanation. If a connector portion (not shown) for connecting to an external device is provided at the end of the wiring 78, the connection workability with the external device is excellent. Examples of the temperature sensor 7 include a thermosensitive element such as a thermistor, a thermocouple, and a pyroelectric element.

The arrangement space of the temperature sensor 7 is at least one of the _four spaces 27G _{1 to} 27G 4 described above. The arrangement space of the temperature sensor 7 is a space 27G ₁ (lower right in FIG. 2) on the terminal side right side of the winding part 2a, and a space 27G ₄ (upper left side in FIG. 2) on the left end face of the winding part 2b on the connecting part 2r side. ), It is easy to insert the temperature sensor 7.

The arrangement space of the temperature sensor 7 is a space 27G ₂ (upper center in FIG. 2) on the end face on the connecting portion 2r side in the winding part 2a and a space 27G ₃ on the right side of the terminal side in the winding part 2b (in the center of FIG. One of the following is preferable. This is because the spaces 27G ₂ and 27G ₃ are opposite portions of the winding portions 2a and 2b, and the temperature of the coil 2 is likely to be higher than the spaces 27G ₁ and 27G ₄ . Therefore, it is easy to perform optimal control of the current to the coil 2. Further, when the frame portion 315 includes a partition plate 319 (described later), the temperature sensor 7 is disposed in the spaces 27G ₁ and 27G ₄ even if it is affected by vibration during operation of the reactor 1A and the external environment. Compared to the above, the temperature sensor 7 is less likely to drop out of the spaces 27G ₂ and 27G ₃ . When the partition plate 319 is provided, the temperature sensor 7 is surrounded by the end surfaces of the winding portions 2a and 2b, the facing surface 315c of the frame portion 315, the partition plate 319, and the middle resin mold portion 310m, and the spaces 27G ₂ and 27G ₃ are formed. This is because a closed space is formed except for the insertion port (here, the upper side) of the temperature sensor 7.

Arrangement space of the temperature sensor 7, the space 27G ₂ of the left end surface of the connecting portion 2r side of the winding portion 2a is particularly preferred. This makes it easier to perform optimal control of the current to the coil 2. Space 27G _2, compared to the space 27G _3, because easily increases temperature of the coil 2 is. Space 27G ₃ is close to the terminal side of the space 27G _2, easily dissipated through the terminal members and beyond the leads. Further, as compared with the case of disposing the temperature sensor 7 in the space 27G _3, easy to perform the operation of connecting the terminal member (not shown) to the end 2e of the winding 2w. This is because if the space 27G ₂ is provided, the wiring 78 is separated from the end portion 2e, so that it is difficult to interfere with the connection work of the terminal member. Here, it is a space 27G ₂ of the end face left connecting portion 2r side position of the temperature sensor 7 in the winding portion 2a.

  Although the arrangement height of the temperature sensor 7 in the space 27G depends on the thickness of the space 27G and the thickness of the temperature sensor 7, it is preferable that the height be approximately the center of the height of the coil 2 as shown in FIG. If it does so, it will be easy to detect the temperature of the location where the coil 2 becomes high temperature easily. Therefore, it is easy to perform optimal control of the current to the coil 2.

  The thickness of the temperature sensor 7 (when including a protective member 72 described later, the thickness including the protective member 72) can be appropriately selected within a range smaller than the space 27G. Here, the thickness of the temperature sensor 7 refers to a length along the axial direction of the coil 2. The thickness of the temperature sensor 7 is, for example, such that the temperature sensor 7 is in contact with the end surfaces of the winding portions 2a and 2b and the facing surface 315c of the frame portion 315 at approximately the center of the height in the space 27G and is sandwiched between the two. It is mentioned that.

Fixed in the space 27G ₂ of the temperature sensor 7 is performed by sandwiching with the opposing surface 315c of the end surface and the frame 315 of the winding portion 2a as described above. Although details will be described in the second and subsequent embodiments, the sensor fixing unit such as an adhesive or foamed resin may be used. The temperature sensor 7 is inserted into the space 27G after the space 27G is formed by combining the coil 2 and the magnetic core 3.

  A protective member 72 that mechanically protects the temperature sensor 7 is preferably provided on the outer periphery of the temperature sensor 7. In particular, in the first embodiment, the temperature sensor 7 is sandwiched between the end surface of the winding portion 2a and the facing surface 315c of the frame portion 315, so that the collapse by both members is prevented. The protective member 72 may be a resin tube or a molded product made of resin mold and may be a columnar one. The protection member 72 is provided in a columnar shape as shown in FIGS. 2 and 4, and the temperature sensor 7 is embedded therein.

  Examples of the constituent material of the protection member 72 include a thermoplastic resin and a thermosetting resin. Thermoplastic resins include polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6, nylon 66, nylon 10T, nylon 9T, nylon 6T, poly Examples include butylene terephthalate (PBT) resin and acrylonitrile / butadiene / styrene (ABS) resin. Examples of the thermosetting resin include unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins. The protective member 72 can be easily formed by using an appropriate resin molding method such as injection molding or cast molding with the temperature sensor 7 as a core.

[Effects of the main features of the reactor]
According to the reactor 1A, by arranging the temperature sensor 7 in the space 27G, the dead space can be effectively used as the arrangement position of the temperature sensor 7. In addition, since the temperature sensor 7 can be disposed close to the coil 2, the temperature of the coil 2 can be measured with high accuracy. In particular, the winding portion 2a of the arrangement space of the temperature sensor 7, the side opposing the 2b, and that the space 27G ₂ of the connecting portion 2r side, precisely the temperature of the prone position increases the temperature of the coil 2 It can be measured and it is easy to optimally control the current to the coil 2.

[Description of each configuration including other features]
[Magnetic core]
The magnetic core 3 is an inner core portion which is a portion disposed in the winding portions 2a and 2b, and a portion where the coil 2 is not substantially disposed and protrudes outside the winding portions 2a and 2b. And a closed magnetic path when the coil 2 is excited.

  Here, the inner core portion includes a plurality of columnar core pieces 31m, a gap portion 310g interposed between the core pieces 31m, and a part of the middle resin mold portion 310m provided so as to cover these laminates. The core component 310 is provided with (FIG. 4). The outer core portion includes a columnar core piece 32m (FIGS. 1 and 4), a side resin mold portion 320m (FIG. 1) covering the core piece 32m, and another portion of the middle resin mold portion 310m (a frame portion 315 described later). It is supposed to be equipped with. As shown in FIG. 4, when the outer core portion is assembled to the core component 310 in the manufacturing process, only the core piece 32m is provided, and the resin mold portions 310m and 320m are not provided. The magnetic core 3 is assembled with a pair of core pieces 32m so as to connect a pair of core components 310 arranged side by side, and in this state, a side resin mold part 320m is formed so as to cover each core piece 32m, thereby forming an annular body. It is a fixed molded product.

(Core piece)
The core pieces 31m and 32m form a magnetic path. The core pieces 31m and 32m include a soft magnetic material of 30% by volume or more, and more than 50% by volume. Specifically, a compacted body obtained by compression molding a soft magnetic metal powder such as iron or an iron alloy (Fe-Si alloy, Fe-Ni alloy, etc.) or a coating powder further provided with an insulation coating, soft magnetic powder and resin A composite material (molded and cured body) in which the resin is solidified (cured) can be used. In this example, the green compact is used. The number, shape, size, composition, and the like of the core pieces included in the magnetic core 3 can be changed as appropriate.

  The shape of the core piece 31m is a rectangular parallelepiped shape with rounded corners. The core piece 32m has an inner end face 32e to which a pair of core components 310 are connected. The inner end surface 32 e is a plane provided so as to be orthogonal to the axial direction of the coil 2. The shape of the core piece 32m is a dome shape (deformed trapezoidal shape) in which the cross-sectional area of the upper surface and the lower surface decreases from the inner end surface 32e outward. In a state where the coil 2 and the magnetic core 3 are assembled, the lower surface of the outer core portion (core piece 32m) protrudes from the lower surface of the core component 310 (core piece 31m). Therefore, the end surfaces of the winding portions 2a and 2b of the coil 2 face the inner end surface of the outer core portion (the inner end surface 32e of the core piece 32m). The installation surface of the coil 2 (the lower surfaces of the winding portions 2a and 2b) and the installation surface of the outer core portion (the lower surface of the side resin mold portion 320m) are substantially flush with each other. That is, the installation surface of the reactor 1A is mainly composed of the installation surface (lower surface) of the two outer core portions and the installation surface of the coil 2 (lower surfaces of the winding portions 2a and 2b).

(Resin mold part)
The resin mold portions 310m and 320m are formed by covering the core pieces 31m and 32m, forming the inner core portion (joining the plurality of core pieces 31m), joining the inner core portion and the outer core portion (the core pieces 31m and 32m Bonding) and the formation of the gap portion 310g and the like.

  The middle resin mold part 310m includes the following core coating part, a gap part 310g, and a frame part 315. The core covering portion is provided so as to cover the outer periphery except for a part along the outer shape in a state where the plurality of core pieces 31m are arranged at equal intervals. Here, a part of the end face of the core piece 31m located at one end of the core component 310 is not covered with the middle resin mold portion 310m but is exposed (see the core component 310 on the left side of FIG. 4). The gap portion 310g is filled in the gap between the adjacent core pieces 31m and functions as a gap. The frame portion 315 is interposed between the end surfaces of the winding portions 2a and 2b of the coil 2 and the inner end surface 32e of the core piece 32m. The core covering portion and the frame portion 315 are formed in series, and the shape of the middle resin mold portion 310m is L-shaped.

  As shown in FIG. 4, the frame portion 315 includes a portion covering a part of one end face of the laminate including the core piece 31 m constituting one inner core portion, and a core piece 31 m constituting the other inner core portion. And a through-hole 315h through which the stacked body is inserted. In addition to the above-described facing surface 315c, a partition plate 319 interposed between the winding portions 2a and 2b is provided on one surface of the frame portion 315. The partition plate 319 is formed over the entire vertical length of the frame portion 315. The other surface of the frame portion 315 faces the inner end surface 32e of the core piece 32m, and the side resin mold portion 320m of the outer core portion is joined. On the other surface of the frame portion 315, two upper and lower protrusions 316, a plurality of rectangular protrusions 317, and a locking portion 318 having an L-shaped cross section constituted by a part of the protrusions 316, Is formed. The upper and lower two protrusions 316 surround the outer edge of the core piece 32m on the inner end face 32e side, and position the core piece 32. The projecting portion 317 is in contact with the inner end surface 32e of the core piece 32m, and forms a gap between the frame portion 315 and the inner end surface 32e of the core piece 32m that promotes introduction of the constituent resin of the side resin mold portion 320m. The locking portion 318 increases the bonding strength with the core component 310 when the constituent resin of the side resin mold portion 320m enters. The locking portion 318 forms a filling space for the constituent resin between the other surface of the frame portion 315 and a piece parallel to the other surface.

  The side resin mold part 320m has a core coating portion that covers the outer peripheral surface of the core piece 32m (FIG. 1). The side resin mold part 320m has a gap part (not shown) that fills the gap between the core pieces 31m and 32m and functions as a gap.

  In addition, it replaces with the gap part by the constituent resin of resin mold part 310m, 320m, and it is set as the form provided with the gap material and air gap which consist of material with a relative permeability smaller than the core pieces 31m and 32m, or a form without a gap. be able to. Examples of the material having a small relative magnetic permeability include nonmagnetic materials such as alumina.

  In addition, as shown in FIGS. 1 and 2, the side resin mold part 320 m includes an attachment part 325 to which a bolt (not shown) for fixing the reactor 1 </ b> A to the installation target is attached. The attachment portion 325 is a plurality of projecting pieces projecting outward from the coil 2 in the core piece 32m (here, a total of four pieces), and includes a bolt hole 325h. The number of attachment portions 325, attachment positions, and the like can be changed as appropriate.

  At least one of the above-described protrusion 316, protrusion 317, locking portion 318, partition plate 319, and attachment portion 325 can be omitted.

  Examples of the constituent resin of the resin mold portions 310m and 320m include the same thermoplastic resin and thermosetting resin as the constituent material of the protective member 72 described above. This constituent resin may contain a ceramic filler such as alumina or silica. If it does so, it will become resin mold part 310m, 320m excellent in heat conductivity, and the heat dissipation of reactor 1A can be improved.

[Heatsink]
The reactor 1A can include a heat radiating plate 8 that radiates heat from the combination of the coil 2 and the magnetic core 3 (FIG. 1). The heat radiating plate 8 is formed of a rectangular plate-like member having a size capable of contacting the entire installation surface of the assembly including the coil 2 and the magnetic core 3. Therefore, the reactor 1A can efficiently transfer the heat of the coil 2 and the magnetic core 3 to the installation target. When the mounting portion 325 described above is not provided, flange portions having through holes through which bolts and the like for fixing the heat radiating plate 8 to the installation target are inserted may be provided at the four corners of the heat radiating plate 8 (all not shown). . The thickness of the heat sink 8 can be selected as appropriate, and for example, about 2 mm to 5 mm. As the constituent material of the heat sink 8, a material having excellent thermal conductivity such as a metal such as aluminum or an alloy thereof or a nonmetal such as alumina can be used. The heat sink 8 and the combined body can be fixed by, for example, the resin layer 9.

[Resin layer]
It is mentioned that the resin layer 9 is provided so as to be in contact with at least the installation surface of the coil 2 among the installation surfaces of the assembly. By providing the resin layer 9, the coil 2 can be firmly fixed to the heat radiating plate 8 when the object to be installed or the above heat radiating plate 8 is provided. The stability of fixing to 8 can be achieved. The size of the resin layer 9 is such that it is interposed on the entire installation surface of the assembly. The constituent material of the resin layer 9 includes an insulating resin, particularly a ceramic filler, and has excellent heat dissipation (for example, the thermal conductivity is 0.1 W / m · K or more, further 1 W / m · K or more, In particular, 2 W / m · K or more) is preferable. Specific examples of the resin include thermosetting resins such as epoxy resin, silicone resin, and unsaturated polyester, and thermoplastic resins such as PPS resin and LCP.

[Reactor manufacturing method]
Reactor 1A includes, for example, the following preparation process, core component 310 manufacturing process, coil 2 and magnetic core (core component 310, core piece 32m) assembly process, side resin mold part 320m formation process, temperature sensor 7 It can manufacture with the manufacturing method of a reactor provided with an arrangement | positioning process. The outline of each process is as follows.

  In the preparation step, the coil 2, the core pieces 31m and 32m, and the temperature sensor 7 are prepared.

  In the core component manufacturing process, a plurality of core pieces 31m are spaced apart and covered with a middle resin mold portion 310m, and the resin is also filled between the core pieces 31m and 31m, and includes a frame portion 315 and a gap portion 310g. The core component 310 is produced.

  In the process of assembling the coil and the magnetic core, the core covering portion of the core component 310 is inserted into each of the winding portions 2a and 2b of the coil 2, and the core piece 32m is arranged so as to sandwich both the frame portions 315, and Assembled to make a braid.

  In the step of forming the side resin mold portion, the exposed portion of the core piece 32m of the assembly assembled in the above-described ring shape is covered with the side resin mold portion 320m, and an assembly in which the coil 2 and the magnetic core 3 are integrated is manufactured.

In step of arranging temperature sensors, plug the temperature sensor 7 in the space 27G _2, it is clamped between the opposing surfaces 315c of the end surface and the frame 315 of the winding portion 2a.

  Thereafter, the assembly is fixed on the heat sink 8 via the resin layer 9 as necessary.

  According to this manufacturing method, since the temperature sensor 7 can be disposed close to the coil 2 simply by inserting the temperature sensor 7 into the space 27G, it is easy to manufacture the reactor 1A that can accurately measure the temperature of the coil 2.

<< Embodiment 2 >>
With reference to FIG. 5, the reactor 1B of Embodiment 2 is demonstrated. The reactor 1B is different from the reactor 1A of the first embodiment in that the reactor 1B includes a sensor fixing portion 4B that fixes the temperature sensor 7 in the space 27G, and the other points are the same as the reactor 1A of the first embodiment. Hereinafter, the description will be focused on this difference, and the description of other configurations will be omitted. This also applies to the third and subsequent embodiments.

[Sensor fixing part]
The sensor fixing part 4B is composed of an adhesive 41. The application position of the adhesive 41 may be the opposing surface 315c of the frame portion 315 (opposing member) or the end surface of the winding portion 2a. Regardless of the application position, the adhesive 41 may be applied in advance and the temperature sensor 7 may be fixed before the coil 2 and the coil component 310 are combined. Here, the temperature sensor 7 is adhered by applying an adhesive 41 to the end faces of the winding portions 2a and 2b. Examples of the material of the adhesive 41 include a thermosetting resin similar to the resin of the resin layer 9 and a thermoplastic resin.

[Temperature sensor]
The thickness of the temperature sensor 7 can be reduced as compared with the first embodiment. Temperature sensor 7 the wound portion 2a, even without pinching the end surface and the frame 315 facing surface 315c of 2b, since easily maintain a fixed state of the temperature sensor 7 in the space 27G ₂ by the adhesive 41 better It is.

[Reactor manufacturing method]
In the manufacturing method described in the first embodiment, the reactor 1B is manufactured by performing an adhesive application process and a temperature sensor bonding process after the core component manufacturing process and before the coil and magnetic core assembly process. You can do it. That is, the manufacturing method of the reactor 1B includes a preparation process, a core component manufacturing process, an adhesive application process, a temperature sensor bonding process, a coil and magnetic core assembling process, and a side resin mold portion forming process. it can. In the adhesive application step, the adhesive 41 is applied to the end face of the winding portion 2a. In the temperature sensor bonding process, the temperature sensor 7 is pressed against the adhesive 41 to adhere to the end surface of the winding portion 2a. Then, the process after the assembly | attachment process of the coil demonstrated in Embodiment 1 and a magnetic core is performed except the arrangement | positioning process of the temperature sensor 7 demonstrated in Embodiment 1. FIG.

According to the reactor 1B, since the temperature sensor 7 is adhered and fixed by applying the adhesive 41 to the end face of the winding part 2a, the temperature sensor 7 is brought into close contact with the end face of the winding part 2a. Can be detected with high accuracy. Therefore, it is easy to perform optimal control of the current to the coil 2. Further, on the likely temperature sensor 7 is fixed in the space 27G ₂ by adhesive 41, it tends to maintain the fixed state satisfactorily. Therefore, it is easy to suppress the dropping of the temperature sensor 7 even if it is affected by vibration during operation of the reactor 1B or an external environment.

<< Embodiment 3 >>
With reference to FIG. 6, the reactor 1C of Embodiment 3 is demonstrated. Reactor 1C is different from sensor fixing portion 4B of reactor 1B of the second embodiment in the constituent members of sensor fixing portion 4C, and the other points are the same as reactors 1A and 1B of the first and second embodiments.

[Sensor fixing part]
The sensor fixing portion 4C is made of a foamed resin 42 that expands in volume. The foamed resin 42 is a resin that includes a plurality of bubbles and these bubbles. Foamed resin 42, by the resin by foaming to volume expansion, burying the space 27G ₂ is filled in the space 27G _2. This buried, to fix the temperature sensor 7 in the space 27G _2.

The arrangement position of the foamed resin 42 may be on the frame part 315 (opposing member) side with respect to the temperature sensor 7 or on the end face side of the winding parts 2a and 2b. In the former case, the foamed resin 42 is adapted to contact the facing surface 315c of the frame 315, the coil 2 a temperature sensor 7 are embedded in the space 27G ₂ (winding portions 2a, 2b) and are contacted. That is, the temperature sensor 7 is fixed in contact with the end surfaces of the winding portions 2a and 2b. In the latter case, the foamed resin 42 is wound portion 2a, as well as contact with the end faces of 2b, and temperature sensor 7 are embedded in the space 27G ₂ is contacted with the facing surface 315c of the frame portion 315. That is, the temperature sensor 7 is fixed in a state where it is in contact with the facing surface 315c. As described above, the temperature sensor 7 and the end surface of the coil 2 may be in direct contact with each other, or a solid material such as the foamed resin 42, the adhesive 41, and the protection member 72 is provided between the temperature sensor 7 and the end surface of the coil 2. You may make it contact through. In either case, easy to maintain the fixed state of the temperature sensor 7 in the space 27G _2. Further, depending on the amount of the foamed resin 42, the expansion coefficient, and the like, it is expected to contribute to prevention of expansion and contraction (vibration prevention) of the winding portions 2a and 2b due to a part of the foamed resin 42 interposed. Here, the arrangement position of the foamed resin 42 is set to the frame portion 315 side with respect to the temperature sensor 7. Since the temperature sensor 7 is brought into contact with the winding portions 2a and 2b by the volume expansion of the foamed resin 42, the temperature of the coil 2 can be easily measured with high accuracy.

The shape of the foamed resin 42 to volume expansion in the space 27G _2, is approximately along the shape in the space 27G _2. The size of the foamed resin 42 (fill volume) may be appropriately selected to the extent that can be embedded in the gap space 27G _2. Here, a part of the temperature sensor 7 is in contact with the end face of the winding part 2a, and the sensor fixing part 4C is formed so as to cover the other part of the temperature sensor 7. That is, the foamed resin 42 is mainly provided between the facing surfaces 315c and the temperature sensor 7 of the frame part 315, the temperature sensor 7 by burying the gap space 27G ₂ due to volume expansion on the end face of the winding portion 2a It is fixed.

  The material of the foamed resin 42 is preferably a material having excellent electrical insulation and a material having excellent heat resistance with respect to the maximum temperature reached by the coil 2 (150 ° C. or higher, more preferably 180 ° C. or higher). In addition, since the constituent resin can come into contact with a liquid refrigerant used for cooling the reactor 1C, it is preferable that the resin has excellent resistance to the liquid refrigerant. Specific materials for the foamed resin 42 include PPS resin, PA resin such as nylon, polyimide resin, and the like. If these resins have adhesive strength to some extent, the contact state between the coil 2 and the temperature sensor 7 can be more easily maintained.

  An unfoamed resin (not shown) can be suitably used as the raw material for the foamed resin 42. Unfoamed resin is easy to handle and is easy to prepare in a desired shape. In addition, since it is excellent in flexibility, it is easy to place it at an arbitrary location, and it is excellent in workability. A commercially available product or a known product can be used as the unfoamed resin. For example, if the thickness of the resin after foaming is 3 times or more, further 4.5 times or more, and even 5 times or more than the thickness of the resin before foaming, it is easy to fill the space 27G. Specifically, the expansion coefficient obtained by (thickness of resin after foaming / thickness of resin before foaming) is 3 or more, 4.5 or more, and 5 or more. When the expansion coefficient satisfies the above range, the unfoamed resin is sufficiently thin (for example, 0.2 mm or less), and the unexpanded resin and the temperature sensor 7 are used even in a narrow space such as the space 27G. At the same time, it can be inserted easily and has excellent workability.

[Reactor manufacturing method]
In the manufacturing method described in the first embodiment, the reactor 1C is manufactured by performing a temperature sensor, an unfoamed resin arrangement step, and a foaming step instead of the temperature sensor arrangement step after the resin mold portion 320m formation step. It can be done by going through. That is, the reactor manufacturing method includes a preparation process, a core part manufacturing process, a coil and magnetic core assembly process, a side resin mold portion forming process, a temperature sensor and unfoamed resin arrangement process, and a foaming process. A temperature sensor and unfoamed resin placement step, inserting the unfoamed resin in the space 27G ₂ with temperature sensor 7. In the foaming step, heat treatment necessary for foaming the unfoamed resin is performed to foam the unfoamed resin to form the foamed resin 42.

  According to the reactor 1C described above, since the foamed resin 42 is interposed between the temperature sensor 7 and the facing surface 315c, the temperature sensor 7 is brought into close contact with the end surface of the winding portion 2a to accurately detect the temperature of the coil 2. Easy to do. Therefore, it is easy to perform optimal control of the current to the coil 2. Moreover, it is easy to fix the temperature sensor 7, and it is easy to maintain the fixed state well, and it is easier to further prevent the temperature sensor 7 from dropping off.

<< Embodiment 4 >>
With reference to FIG. 7, the reactor 1D of Embodiment 4 is demonstrated. Reactor 1D is different from reactors 1B and 4C of reactors 1B and 1C in the second and third embodiments in the configuration of sensor fixing unit 4D, and is otherwise the same as reactors 1A to 1C in the first to third embodiments. .

[Sensor fixing part]
The sensor fixing portion 4D has both an adhesive 41 and a foamed resin 42. The positional relationship between the adhesive 41 and the foamed resin 42 may be opposite to each other across the temperature sensor 7. That is, when the application position of the adhesive 41 is the end face of the winding part 2 a and the arrangement position of the foamed resin 42 is the frame part 315 (opposing member) side, or the application position of the adhesive 41 is the opposing face of the frame part 315. 315c, and the case where the arrangement position of the foamed resin 42 is the end face side of the winding part 2a is mentioned. In any case, for easy temperature sensor 7 is brought into contact with the adhesive 41 by the volume expansion of the foamed resin 42, the fixed state of the temperature sensor 7 in the space 27G ₂ can be preferably maintained. In particular, in the former case, the temperature sensor 7 is brought into close contact with the end face of the winding part 2a, and the contact state with the winding part 2a is easily maintained. Here, the application position of the adhesive 41 is the end face of the winding part 2a, and the arrangement position of the foamed resin 42 is the frame part 315 side.

[Reactor manufacturing method]
The reactor 1D can be manufactured by performing the unfoamed resin placement step and the foaming step described in the third embodiment after the side resin mold portion forming step in the manufacturing method described in the second embodiment. That is, the reactor manufacturing method includes a preparation process, a core part manufacturing process, an adhesive application process, a temperature sensor bonding process, a coil and magnetic core assembly process, a side resin mold part forming process, and an unfoamed resin. Arrangement step and foaming step. In the unfoamed resin arrangement step, unfoamed resin is interposed between the temperature sensor 7 adhered to the end surface of the winding portion 2a and the facing surface 315c of the frame portion 315. Or in the manufacturing method demonstrated in Embodiment 2, the arrangement | positioning process of unfoamed resin is also performed in the assembly | attachment process of the coil and magnetic core after the adhesion process of a temperature sensor. And it can carry out by passing through the foaming process demonstrated in Embodiment 3 simultaneously with the formation process of the subsequent side resin mold part, and before and after that.

  According to the reactor 1D, since the foamed resin 42 fills the gap between the temperature sensor 7 and the facing surface 315c, the temperature sensor 7 is easily brought into close contact with the winding portion 2a, and the contact state is easily maintained. . For this reason, it is easier to optimally control the current to the coil 2, and the temperature sensor 7 is more easily prevented from dropping off.

<< Embodiment 5 >>
A reactor 1E according to the fifth embodiment will be described with reference to FIGS. Reactor 1E is mainly different from reactors 1A to 1D of Embodiments 1 to 4 in that a groove is formed on the end face side (opposing surface) of the winding portion of the opposing member.

[Counter member]
The facing member is constituted by a frame portion 315. A groove portion 315t is formed on the facing surface 315c of the frame portion 315. The temperature sensor 7 is disposed in the groove 315t. The width (the length along the parallel direction of the winding portions 2a and 2b) and the depth (the length along the axial direction of the coil 2) of the groove portion 315t may be such that the temperature sensor 7 can be fitted. Here, as shown in an enlarged view in a one-dot chain line circle in FIG. 8, the width of the groove 315 t is made slightly larger than the temperature sensor 7, and the depth of the groove 315 t is about half the thickness of the temperature sensor 7. The length of the groove portion 315t (the length along the vertical direction) can be appropriately selected according to the desired arrangement height of the temperature sensor 7. The length of the groove portion 315t may be from the upper part of the frame portion 315 to the middle, and may be a groove portion 315t having a closed end, or the length of the groove portion 315t may be the length over the entire length of the frame portion 315, and there is no closed end. It is good also as the groove part 315t. Here, as shown in FIG. 9, the length from the upper part of the frame part 315 to the approximate center (substantially upper half of the frame part 315) is a groove part 315t having a closed end. Since the groove portion 315t has a closed end, the temperature sensor 7 can be easily disposed in the space 27G. In FIG. 9, for convenience of explanation, components other than the coil component 310 are omitted. The formation of the groove portion 315t may be performed simultaneously with the molding of the middle resin mold portion 310m, or may be performed separately by machining such as cutting. Instead of the groove portion 315t, a slit extending through the front and back in the thickness direction of the frame portion 315 may be formed.

[space]
Space 27G ₂ has an end face of the winding portion 2a, and the opposing surface 315c of the frame 315, is formed in the groove 315T. Compared to the space 27G of the first to fourth embodiments, the space 27G is wider by the amount of the groove 315t, and thus the temperature sensor 7 can be easily disposed in the space 27G.

[Temperature sensor]
The temperature sensor 7 is positioned at the closed end of the groove 315t. Although the temperature sensor 7 is not in close contact with the end surface of the winding part 2a, the temperature sensor 7 can be disposed close to the end surface of the winding part 2a to some extent, so that the temperature of the coil 2 can be measured with sufficient accuracy. The temperature sensor 7 is preferably fixed by a sensor fixing portion 4E.

[Sensor fixing part]
The sensor fixing portion 4E is preferably provided so as to be in contact with both the temperature sensor 7 and the end surfaces of the winding portions 2a and 2b. Then, it is easy to fix the temperature sensor 7 to the groove portion 315t by the sensor fixing portion 4E, and the sensor fixing portion 4E can be used as a temperature transmission path of the coil 2 to the temperature sensor 7, and the temperature of the coil 2 can be adjusted. Easy to measure accurately. For the sensor fixing portion 4E, only one of the above-described adhesive and foamed resin may be used, or both the adhesive and the foamed resin may be used. Here, both an adhesive and a foamed resin are used. Specifically, as shown in the enlarged view surrounded by a one-dot chain line circle in FIG. 8, the application position of the adhesive 41 is in the groove 315t, and the arrangement position of the foamed resin 42 is the end face side of the winding part 2a. Can be mentioned. In this case, the adhesive bonding 41, the temperature sensor 7 by the burying of the gap space 27G ₂ due to volume expansion of the foamed resin 42 can be fixed in the groove portion 315T. In addition, the temperature of the coil 2 can be easily transmitted to the temperature sensor 7 by the foamed resin 42 coming into contact with the end surface of the winding portion 2a.

[Reactor manufacturing method]
The manufacturing method of the reactor 1E is different in that the object to be applied in the adhesive application step of the manufacturing method described in the fourth embodiment is the groove portion 315t of the frame portion 315. Otherwise, the manufacturing method described in the fourth embodiment. It is the same.

According to reactor 1E described above, by forming the groove 315T on the opposite surface 315c of the frame 315, so it is possible to increase the space 27G ₂ as compared to the case without the groove 315T, arranged a temperature sensor 7 in the space 27G ₂ Easy to do. Further, since the temperature sensor 7 can be arranged close to the end surface of the winding portion 2a to some extent, the temperature of the coil 2 can be measured with sufficient accuracy.

<< Modification 1 >>
In the first embodiment, the configuration in which the formation time of the middle resin mold portion 310m is different from the formation time of the side resin mold portion 320m has been described. As a modified example 1, the outer core part is also a core part including a core piece 32m and a side resin mold part 320m, like the inner core part, and a pair of (inner) core parts 310 and a pair of (outer) core parts. A total of four core parts can be assembled. In this embodiment, the opposing member can be constituted by the outer core component (side resin mold part). In this form, each core part can be manufactured, and the shape of the object to be coated becomes simple, so that the productivity of the assembled part is excellent. When the core parts are provided with engaging portions that engage with each other, the assembled state can be maintained firmly.

<< Modification 2 >>
In the modification 1, the form provided with a total of four columnar core components was demonstrated. In the second modification, a set of L-shaped core components in which a laminate including the core piece 31m constituting one inner core portion and the one core piece 32m are assembled in an L shape and integrally held in the resin mold portion. And a U-shaped core component in which two laminates constituting one inner core part and one core piece 32m are assembled in a U shape and are integrally held in a resin mold part, and one outer part It can be set as the form provided with a core component.

<< Modification 3 >>
In the first embodiment, the configuration in which the magnetic core 3 includes the resin mold portions 310m and 320m that cover the core pieces 31m and 32m has been described. In addition, it can replace with the form which is not provided with the resin mold part, and the resin mold part, and can be set as the form provided with the interposition insulation member. The intervening insulating member includes, for example, a cylindrical member interposed between the winding portions 2a and 2b and the inner core portion including the plurality of core pieces 31m, the end faces of the winding portions 2a and 2b, and the core pieces 32m. What is provided with the frame member interposed between the end surfaces 32e is mentioned. The frame member has a flat plate shape like the frame portion 315, and is provided with a pair of through holes through which the pair of inner core portions are inserted. In this case, the opposing member that forms the space 27G with the end surfaces of the winding portions 2a and 2b is constituted by the frame member. In other words, the frame member has an opposing surface constituted by a plane orthogonal to the end surfaces of the winding portions 2a and 2b and orthogonal to the axial direction of the winding portions 2a and 2b. In these forms, it can be set as the form provided with the individual case which accommodates the assembly containing the coil 2 and the magnetic core 3. FIG. Or it can be set as the form provided with an individual case and sealing resin with which it fills in an individual case. Then, mechanical protection of reactor 1A and protection from the external environment can be achieved.

  The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, a reactor including a coil having only one winding portion and a magnetic core called an EE type core or an EI type core can be used.

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

1A, 1B, 1C, 1D, 1E reactor 2 coils 2a, 2b wound portion 2r connecting portion 2w winding 2e end _{27G, 27G 1, 27G 2,} 27G 3, 27G 4 space 3 magnetic cores 31m, 32m core piece 32e Inner end face 310 Core part 310m Middle resin mold part 310g Gap part 315 Frame part 315c Opposing surface 315h Through hole 315t Groove part 316 Projection 317 Projection part 318 Locking part 319 Partition plate 320m Side resin mold part 325 Mounting part 325h Bolt hole 425 4C, 4D, 4E Sensor fixing part 41 Adhesive 42 Foamed resin 7 Temperature sensor 72 Protective member 78 Wiring 8 Heat sink 9 Resin layer

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is a top view which shows the reactor of Embodiment 1. It is a fragmentary sectional view which shows the state cut | disconnected by the (III)-(III) cutting line of the reactor shown in FIG. FIG. 3 is an exploded perspective view illustrating a manufacturing process of the reactor according to the first embodiment. It is a top view which shows the reactor of Embodiment 2. It is a top view which shows the reactor of Embodiment 3. It is a top view which shows the reactor of Embodiment 4. It is a top view which shows the reactor of Embodiment 5. It is a front view of the core part provided in the reactor embodiment 5.

[Sensor fixing part]
The sensor fixing part 4B is composed of an adhesive 41. The application position of the adhesive 41 may be the opposing surface 315c of the frame portion 315 (opposing member) or the end surface of the winding portion 2a. Even if the coating position is one, while applying the previously adhesive 41 prior to combining the coil 2 and the core component 310, may be fixed to the temperature sensor 7. Here, the temperature sensor 7 is adhered by applying an adhesive 41 to the end face of the winding portion 2a . Examples of the material of the adhesive 41 include a thermosetting resin similar to the resin of the resin layer 9 and a thermoplastic resin.

[Counter member]
The facing member is constituted by a frame portion 315. A groove portion 315t is formed on the facing surface 315c of the frame portion 315. The temperature sensor 7 is disposed in the groove 315t. The width (the length along the parallel direction of the winding portions 2a and 2b) and the depth (the length along the axial direction of the coil 2) of the groove portion 315t may be such that the temperature sensor 7 can be fitted. Here, as shown in an enlarged view in a one-dot chain line circle in FIG. 8, the width of the groove 315 t is made slightly larger than the temperature sensor 7, and the depth of the groove 315 t is about half the thickness of the temperature sensor 7. The length of the groove portion 315t (the length along the vertical direction) can be appropriately selected according to the desired arrangement height of the temperature sensor 7. The length of the groove portion 315t may be from the upper part of the frame portion 315 to the middle, and may be a groove portion 315t having a closed end, or the length of the groove portion 315t may be the length over the entire length of the frame portion 315, and there is no closed end. It is good also as the groove part 315t. Here, as shown in FIG. 9, the length from the upper part of the frame part 315 to the approximate center (substantially upper half of the frame part 315) is a groove part 315t having a closed end. Since the groove portion 315t has a closed end, the temperature sensor 7 can be easily disposed in the space 27G. In FIG 9, for convenience of explanation, except core parts 310 are omitted. The formation of the groove portion 315t may be performed simultaneously with the molding of the middle resin mold portion 310m, or may be performed separately by machining such as cutting. Instead of the groove portion 315t, a slit extending through the front and back in the thickness direction of the frame portion 315 may be formed.

Claims (9)

A coil having a winding portion formed by winding a winding;
A magnetic core having a portion disposed inside and outside the wound portion;
A temperature sensor for measuring the temperature of the coil;
An opposing member facing the end face of the winding part,
The said temperature sensor is a reactor arrange | positioned in the space pinched | interposed by the end surface of the said winding part, and the said opposing member. The winding part is wound spirally,
The opposing member has an opposing surface that opposes an end face of the winding portion,
2. The reactor according to claim 1, wherein the space is an inclined space that is formed by a surface including an end surface of the winding portion and the opposing surface of the facing member and corresponds to an inclination formed by the end surface of the winding portion. . The coil includes a pair of winding portions that are arranged side by side so that their axes are parallel to each other, and a connecting portion that connects the pair of winding portions on one end side in the axial direction,
The said temperature sensor is a reactor of Claim 1 or Claim 2 arrange | positioned in the said space where the said pair of winding part is located in the mutually opposing side.   The reactor according to claim 3, wherein the temperature sensor is disposed in the space located on the connection portion side. A sensor fixing part for fixing the temperature sensor in the space;
The reactor according to any one of claims 1 to 4, wherein the sensor fixing portion includes a foamed resin that expands in volume. The sensor fixing portion has the foamed resin disposed on the facing member side with respect to the temperature sensor and an adhesive disposed on the winding portion side,
The reactor according to claim 5, wherein the temperature sensor is in contact with the adhesive by volume expansion of the foamed resin. A groove portion is formed on the end surface side of the winding portion in the facing member,
The reactor according to claim 1, wherein the temperature sensor is disposed in the groove.   The reactor according to any one of claims 1 to 7, wherein the facing member is configured by a part of a core piece arranged outside the winding portion of the magnetic core.   The reactor of any one of Claims 1-7 comprised with the resin mold part which the said opposing member covers the surface of the core piece arrange | positioned out of the said winding part among the said magnetic cores.

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