JP2016092199A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor which has excellent insulation properties between a coil and a metal member oppositely arranged to the coil, and has excellent manufacturability.SOLUTION: A reactor comprises: a coil 2 having wounding parts 2a and 2b formed by wounding a straight-angle winding; and a magnetic core having a part (core piece 31m) arranged in an inner part of the wound part. The wound parts have bend parts (edge R parts 20 to 22.5) formed by edge-wise bending the straight-angle winding, and have insulation coating parts (edge coating parts 60, 61, and 62) attached so as to cover a region opposite to the metal member 4 oppositely arranged to an outer peripheral surface of the wound part in the bend parts.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 is excellent in insulation between a coil and a metal member disposed opposite to the coil, and also excellent in manufacturability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. Patent Document 1 discloses a reactor used in a converter mounted on a vehicle such as a hybrid vehicle, in which a coil formed by winding a coil in a spiral shape and a core piece disposed inside and outside the coil are combined in an annular shape. A combination with a magnetic core is housed in a metal case. Patent Document 1 discloses that a coil is housed in a mold and resin is injection-molded to make the coil a resin-molded part.

JP 2010-074150 A

  For the purpose of improving the heat dissipation of the reactor, a structure may be employed in which the coil is placed on a metal plate or the coil is housed in a metal case as described above. With respect to such a reactor, it is desired that the metal plate and the metal case disposed in the vicinity of the coil are excellent in insulation between the coil and the metal, and that the manufacturability is also excellent. .

  As described in Patent Document 1, if the coil is a resin molded part, for example, even if the coil is housed in a metal case, the resin molded part is between the coil and the bottom and side surfaces of the metal case. The resin which comprises is interposed as an insulating material. Therefore, the insulation between the coil and the metal case is excellent. However, in order to manufacture a resin molded part, a plurality of processes including housing the coil in a mold, compressing and holding the coil, and injecting resin are performed. Thus, when there are many processes and a coil is made into resin mold parts, it is inferior to manufacturability.

  Even if the coil is not a resin-molded part, if a coated wire comprising a conductor wire and an insulation coating covering the conductor wire is used as the winding constituting the coil, this insulation coating can be used as a coil and a metal case, etc. It can be used as an insulating material between the metal members. However, if the coil is an edgewise coil using a rectangular winding having a conductor wire having a rectangular cross section, the insulation coating may be locally damaged. When damaged, the insulation between the coil and the metal case deteriorates. Specifically, a curved portion formed by edgewise bending, for example, when the coil has an angular shape such as a rectangular cylindrical body, a corner portion, and when the coil is a cylindrical body, substantially the entire insulation coating is provided. There is a possibility that the outer side of the bend is pulled at the time of edgewise bending, resulting in local thinning or tearing. Therefore, a reactor that can be manufactured with high productivity while having excellent insulation between the coil and the above-described metal member even though the coil has a curved portion bent edgewise is desired.

  Then, one of the objectives of this invention is providing the reactor which is excellent also in productivity while being excellent in the insulation between a coil and the metal member arrange | positioned facing a coil.

  The reactor which concerns on 1 aspect of this invention is equipped with the coil which has a winding part formed by winding a flat coil | winding, and the magnetic core which has a part arrange | positioned in the said winding part. The winding part includes a curved part formed by edgewise bending the rectangular winding. Furthermore, this reactor is provided with the insulation coating part attached so that the opposing area | region with the metal member arrange | positioned facing the outer peripheral surface of the said winding part may be covered among the said curved parts.

  Said reactor is excellent in the insulation between a coil and a metal member, and also excellent in manufacturability.

It is a schematic perspective view which shows the reactor of Embodiment 1. FIG. It is sectional drawing which shows the state which cut | disconnected the reactor of Embodiment 1 by the (II)-(II) cutting line shown in FIG. It is a perspective view which shows an example of the resin molded product with which the reactor of Embodiment 1 is equipped, Comprising: What has an insulation coating part. It is a disassembled perspective view of the union body with which the reactor of Embodiment 1 is equipped. It is a coil with which the reactor of Embodiment 2 is provided, Comprising: It is a schematic perspective view which shows the state by which the insulation coating part was attached.

[Description of Embodiment 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 equipped with the coil which has a winding part formed by winding a flat coil | winding, and the magnetic core which has a part arrange | positioned in the said winding part. The winding part includes a curved part formed by edgewise bending the rectangular winding. Furthermore, this reactor is provided with the insulation coating part attached so that the opposing area | region with the outer peripheral surface of the said winding part and the metal member opposingly arranged among the said curved parts may be covered.

  The said metal member says what is arrange | positioned in the outer peripheral surface vicinity of the winding part of a coil. For example, a case for housing an assembly including the coil and the magnetic core, which has at least one of a metal bottom and a metal side wall, and a mounting surface on which the assembly is mounted is a metal Examples include a member made of metal (for example, a metal plate), a metal installation object for installing the above-described assembly, and the like. The reactor may include the case and the metal plate.

  The above-described insulating covering portion is a member independent of the coil, and is a member that is separately attached after winding the rectangular winding to form the coil. The insulation coating part is formed integrally with the coil, such as the one integrated with the conductor wire during the winding manufacturing, such as the insulation coating in the above-described coated wire, or the resin part of the resin mold part provided with the coil. Not a thing.

  Although the above reactor includes a coil having a curved portion bent edgewise, an insulating coating portion is attached to the curved portion. Therefore, in the above reactor, even if the insulation coating of the rectangular winding constituting the bending portion is damaged when the winding portion is formed, the bending portion becomes a starting point of creeping discharge to the metal member. Can be effectively prevented. Therefore, the reactor is excellent in insulation between the coil and the metal member and has high insulation reliability.

  Moreover, said reactor can be easily manufactured by attaching the insulation coating part prepared separately to the curved part of a winding part. Even when the insulating coating portion is formed of a resin, for example, the resin may be molded into a predetermined shape, and can be easily manufactured as compared with the case of manufacturing a resin molded part integrally including the above-described coil. From these points, the reactor described above is excellent in manufacturability.

  (2) As an example of the reactor described above, a configuration in which the winding portion is a rectangular tubular body with rounded corners, and a region in which a facing region of the curved portion includes the corners is exemplified.

  The corner portion provided in the rectangular tube body is formed by edgewise bending a rectangular winding, so that its outer shape is not a sharp angle like a right angle but a rounded curved shape. Even a rounded corner is angular compared to the case where the wound portion is a cylindrical body, and tends to be a starting point for creeping discharge. In the above-described embodiment, since the insulating coating portion is attached to such a corner portion, creeping discharge can be effectively prevented, and the insulation between the coil and the metal member is excellent.

  (3) As an example of the reactor, there is a mode in which a case for storing the coil and the magnetic core is further provided, and the metal member includes at least one of a bottom portion and a side wall portion of the case.

  In the above form, although the bottom part of the case having a mounting surface for placing the coil winding part and the side wall part surrounding the outer periphery of the coil winding part are made of metal, the curved part of the winding part An insulating coating is attached to a region facing the mounting surface and a region facing the side wall. Therefore, the said form can prevent effectively the creeping discharge between a coil and the bottom part of a case, and the creeping discharge between a coil and the side wall part of a case, and is excellent in insulation. Moreover, since the said form is equipped with a case and the assembly which contains a coil and a magnetic core is accommodated in this case, the mechanical protection of an assembly, the protection from an external environment, and the metal part of a case as a heat dissipation path | route By doing so, it is possible to ensure good heat dissipation.

  (4) As an example of the above reactor, a form including a resin molded product including the insulating coating portion may be mentioned.

  Resin molded products are easy to handle and can be arranged easily, and can be easily manufactured by injection molding of the resin, and are more manufacturable as compared with resin molded parts integrally provided with the above-described coil. Since a part of such a resin molded product is an insulation coating portion, the above-described configuration facilitates attaching the insulation coating portion (the molded product) to the curved portion of the winding portion, and is excellent in manufacturability. Also excellent in manufacturability.

  (5) As an example of the above-described reactor, the coil includes a pair of the winding portions in parallel, and the insulating covering portion that covers the opposing regions of the curved portion provided in each winding portion, and both winding portions And a crossover portion that connects the insulating coating portions attached to each other.

  In this embodiment, it can be said that the insulating covering portions that respectively cover the curved portions of the winding portions are integrated by the crossover portion. Therefore, the said form is excellent in the stability of an arrangement | positioning state compared with the case where a plurality of insulation coating parts are provided separately, and the plurality of insulation coating parts are not easily displaced. The crossover portion is a member independent of at least one insulation coating portion, and is made of a resin in which the crossover portion and a plurality of insulation coating portions are integrally formed, in addition to integrating them by an adhesive or mechanical engagement. It can be a molded product. The form provided with this molded product is excellent in manufacturability because a plurality of insulating coating parts are simultaneously attached to a plurality of curved parts provided in both winding parts. Moreover, since this molded product has a large contact area with the coil, the arrangement state of the molded product is easy to be stabilized, and it is easy to attach from this point. Furthermore, as described in the above (4), the resin molded product itself is also excellent in manufacturability.

  (6) As an example of the reactor described above, the winding portion is a rectangular tubular body with rounded corners, the opposing region of the curved portion includes the angular portion, and one angular portion of the rectangular tubular body A resin molded product provided along another corner, and the resin molded product covers a window portion that exposes a planar portion on the outer peripheral surface of the rectangular tubular body, and a facing region of the curved portion. The form provided with the said insulation coating part is mentioned.

  The molded product of resin in this form includes, for example, a plurality of insulating coating portions that respectively cover a plurality of curved portions (corner portions) provided in one winding portion, and these are integrated. Therefore, the said form is excellent in manufacturability by attaching several insulation coating parts (a part of the said molded product) simultaneously with respect to several curved part. Moreover, the resin molded product of this form has a part arrange | positioned not only at the corner | angular part of a winding part but in a plane location. From this point, the molded product of the resin is along the outer peripheral shape of the winding portion, and the arrangement state is easy to be stabilized, and it is easy to attach from this point. Further, since the resin molded product of this embodiment includes a window portion, the planar portion of the winding portion exposed from the window portion can be used as a heat dissipation region for the coil, a resin filling region for fixing the coil, which will be described later, and the like. In addition, the amount of resin used can be reduced. In addition, as described in the above (4), the resin molded product itself is excellent in manufacturability.

  (7) As an example of the reactor described above, a form in which the insulating coating portion includes an insulating tape can be given.

  In the above configuration, the insulating coating (including the insulating tape) can be easily and accurately attached to the desired area by a simple operation of cutting the insulating tape into a desired shape and size and attaching it to a predetermined position. And excellent manufacturability. Moreover, it can be easily fixed at a predetermined position by the adhesive layer provided in the insulating tape, and misalignment hardly occurs.

[Details of the embodiment of the present invention]
Embodiments of the present invention will be specifically described below with reference to the drawings. The same reference numerals in the figure indicate the same names.

[Embodiment 1]
The reactor 1 of Embodiment 1 is demonstrated with reference to FIGS. In the following description, the state where the lower surface of the reactor 1 shown in FIG. This installation state is an exemplification, and can be set to an installation state in which the side surface and upper surface of the reactor 1 are the installation surface.

(Reactor)
-Overall structure As shown in FIG. 1, the reactor 1 of Embodiment 1 has the coil 2 which has the winding parts 2a and 2b formed by winding the coil | winding 2w helically, and the winding parts 2a and 2b of the coil 2 And a magnetic core 3 having a portion disposed inside and outside. Reactor 1 is used by being attached to an installation target (not shown) such as a converter case. A metal member is provided in the vicinity of the outer peripheral surface of the winding portions 2 a and 2 b of the coil 2. In FIG. 1, the state by which the metal member 4 was arrange | positioned at the installation surface side of the reactor 1 is illustrated. In the reactor 1, the winding 2w is a flat rectangular winding, and has a curved portion (corner R portions 20 to 22 and 25, which will be described later in this example, FIG. 2) formed by edgewise bending of the winding portions 2a and 2b. One feature is that it includes an insulating covering portion (at least one of corner covering portions 60 to 62 which are a part of an outer cover 6A described later in this example, FIGS. 2 and 3) attached to the curved portion. To do. Hereinafter, each component will be described in detail.

Coil The coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding a single continuous winding 2w as shown in FIGS. And a connecting portion 2r that is formed from a part and connects the two winding portions 2a and 2b. The coil 2 includes a pair of winding portions 2a and 2b in parallel (side by side) so that the respective axes are parallel to each other. Both ends of the winding 2w are drawn out from the winding portions 2a and 2b in appropriate directions and attached with terminal fittings (not shown) or the like, and are electrically connected to an external device (not shown) such as a power source. Connected to.

  In particular, in the reactor 1 of the first embodiment, a rectangular winding with a rectangular cross section is used as the winding 2w, and the winding portions 2a and 2b are edgewise coils formed by edgewise winding. The rectangular winding in this example is a coated rectangular wire (so-called enameled wire) including a rectangular conductor wire (such as a rectangular copper wire) and an insulating coating (such as polyamideimide) covering the outer periphery of the conductor wire.

  The winding parts 2a and 2b in this example are both the same shape, and are rectangular cylinders with rounded corners (FIG. 4). The end face shape is a square ring with rounded corners (FIG. 2). The rounded corner portion is a curved portion formed by edgewise bending the winding 2w (flat rectangular winding), and may be hereinafter referred to as a corner R portion. Each of the winding portions 2a and 2b has four corner R portions. Specifically, as shown in FIG. 2, the installation surface side (lower side) and inner corner R portion 20, the installation surface side and outer corner R portion 21, and the installation surface is the opposite side (upper side) and outer corner. The R portion 22 has a corner R portion 25 opposite to the installation surface and inside. The outer peripheral surfaces of the winding portions 2a and 2b are four curved surfaces that form the outer peripheral surfaces of the corner R portions 20 to 22 and 25, and four flat surfaces connecting adjacent curved surfaces, that is, a lower surface that is an installation surface, an installation surface And an outer surface and an inner surface connecting the upper and lower surfaces.

  The curved portion of this example is formed by edgewise bending the winding 2w (flat rectangular winding) substantially at a right angle. Although the bending radius r is slightly larger than the width w of the rectangular winding, it tends to be smaller than when the winding portion is a cylindrical body having the same inner peripheral area, and the coil 2 can be said to be somewhat angular. . The bending radius r varies depending on the shape and size of the winding part and can be selected as appropriate.

Magnetic core 3 includes a plurality of columnar core pieces 31m, 32m,... And a plurality of gap members 31g interposed between the core pieces 31m, 31m and between the core pieces 31m, 32m, as shown in FIG. … And. In this example, U-shaped core pieces 32m and 32m as viewed from above in FIG. 4 are arranged so that the U-shaped openings face each other, and a rectangular parallelepiped core piece 31m is disposed between the core pieces 32m and 32m. And a plate-like gap member 31g are arranged and assembled in an annular shape. The magnetic core 3 assembled in an annular shape forms a closed magnetic path when the coil 2 is excited. Part of the core piece 31m and the U-shaped core piece 32m in the magnetic core 3 constitutes a portion (hereinafter sometimes referred to as a storage portion) disposed in the winding portions 2a and 2b of the coil 2. The remaining portion of the U-shaped core piece 32m constitutes a portion protruding from the coil 2 where the coil 2 is not disposed.

  The core pieces 31m and 32m are made of a soft magnetic material. The core pieces 31m and 32m are formed 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 insulating coating, or soft magnetic powder. A composite material containing resin and resin can be used. In this example, the green compact is used. The gap material 31g is made of a material (for example, a nonmagnetic material such as alumina) having a smaller relative permeability than the core pieces 31m and 32m.

  The core piece 31m in this example has a rectangular parallelepiped shape with rounded corners (see also FIG. 2). The core piece 32m includes a rectangular parallelepiped block with rounded corners and a pair of protruding portions protruding from the block. The block is exposed from the coil 2 and constitutes a portion where the coil 2 is not disposed (FIG. 1). The protruding portion protrudes toward the coil 2 from an inner end surface 32e (here, an inverted T-shaped plane) facing the end surfaces of the winding portions 2a and 2b in the block. These projecting portions together with the core piece 31m constitute a storage portion that is inserted and arranged in the winding portions 2a and 2b. Each protruding portion has a rectangular parallelepiped shape with rounded corners, like the core piece 31m. The core piece 32m also includes a portion that protrudes in the opposite direction to the pair of protruding portions, that is, on the side away from the coil 2. Specifically, the central portion in the parallel direction of the winding portions 2a and 2b in the block protrudes in the opposite direction from the portions on both sides sandwiching the central portion. By providing the projecting portion of the central portion, the core piece 32m has the same thickness as that of the central portion and the thickness of both side portions, and is excellent in moldability.

  Moreover, in the magnetic core 3 of this example, the installation surface (lower surface) of the block in the U-shaped core piece 32m protrudes from the core piece 31m. The amount of protrusion is adjusted so that when the coil 2 and the magnetic core 3 are assembled, the installation surface (lower surface) of the winding portions 2a and 2b of the coil 2 is close to the surface 4f (FIG. 2) of the metal member 4. Has been. More specifically, as shown in FIG. 2, the distance between the installation surface of the winding portions 2a and 2b and the surface 4f of the metal member 4 is substantially equal to the thickness of the outer cover 6A. The amount of protrusion is adjusted. Therefore, the installation surface of the block in the core piece 32 m constitutes a part of the installation surface of the assembly including the coil 2 and the magnetic core 3. As a result, the reactor 1 can stably arrange the combined body on the metal member 4, and in addition to the coil 2, a part of the magnetic core 3 can also be close to the metal member 4, thereby improving heat dissipation. Furthermore, in this example, since a part of the outer cover 6A is interposed between the coil 2 and the metal member 4, the insulation between the coil 2 and the metal member 4 can be improved, and a resin layer 42 described later can be provided. Easy to form.

  The number, shape, size, composition, and the like of the core pieces and gap members provided in the magnetic core 3 can be changed as appropriate. For example, the core piece 32m can have a rectangular parallelepiped shape, and the above-described protruding portion can be the core piece 31m. Instead of the gap material 31g, an air gap can be used, or the gap can be omitted.

..Metal member: Case At least one of cases (not shown) in which a metal member disposed in the vicinity of the outer peripheral surface of the coil 2 in the reactor 1 houses a combination including the coil 2 and the magnetic core 3, for example. The form which is a part is mentioned. Reactor 1 of this form is typically provided with a case that houses an assembly, and this case is attached to the installation target. The reactor 1 including a case can secure good heat dissipation due to protection of the assembly from the environment, mechanical protection, and at least part of the case made of metal.

  The case typically includes a bottom portion having a mounting surface for the assembly including the coil 2 and the magnetic core 3, and a side wall portion that stands from the bottom and surrounds the periphery of the combination, and faces the bottom portion. A box with an open side is mentioned. If the mounting surface is at least a flat surface, the assembly can be stably mounted and the resin layer 42 can be easily formed when the resin layer 42 described later is provided.

  An example of the case is one that is entirely made of metal. In this case, the metal member 4 shown in FIG. 1 corresponds to the bottom of a metal case (the side wall is not shown). Metals are generally excellent in thermal conductivity and strength as compared to resins. Therefore, reactor 1 provided with a metal case can use the whole case for a heat dissipation path, is excellent in heat dissipation, or can protect a combination satisfactorily. As the metal constituting the case, it is excellent in thermal conductivity, and lightweight aluminum or aluminum alloy can be suitably used. Other metals include magnesium and magnesium alloys. A metal case is typically an integrally formed case (hereinafter, sometimes referred to as an integral case).

  As another case, a form in which the bottom part and the side wall part are detachable independent members can be cited (hereinafter referred to as a combination case). Examples of the combination case include a case in which at least one of the bottom portion and the side wall portion is made of metal. When a combination product of an insulating material such as a resin is included, the case is excellent in insulation and lightweight. In the combination case, the side wall portion is removed to make only the bottom portion, and the assembly can be placed and the resin layer 42 can be formed with the inner bottom surface of the case serving as the placement surface exposed. Therefore, the reactor 1 provided with a combination case is excellent in productivity. If the side wall is a resin molded product, the insulation between the coil 2 and the side wall of the case is excellent. If the bottom is a molded product of resin, the insulation between the coil 2 and the bottom of the case is excellent.

  As the metal constituting the combination case, the metal described in the above-mentioned integrated case can be used. Examples of the insulating material constituting the combination case include resins such as polybutylene terephthalate (PBT) resin, urethane resin, polyphenylene sulfide (PPS) resin, and acrylonitrile-butadiene-styrene (ABS) resin. The bottom and side walls made of resin can be easily manufactured by a known molding method such as injection molding.

  A more specific form of the combination case includes, for example, a case where the bottom portion is formed of a metal plate and the side wall portion is formed of a molded product of an insulating material such as a resin. In this case, the metal member 4 shown in FIG. 1 corresponds to the bottom of the combination case (the side wall is not shown). As another combination case, a case where the bottom portion is a molded product of an insulating material such as a resin and the side wall portion is made of metal (not shown) can be cited. Other combination cases include those in which both the bottom and side walls are made of metal. This case can be handled in the same manner as the above-mentioned metal integrated case.

... Metal plate As another metal member arranged in the vicinity of the outer peripheral surface of the coil 2 in the reactor 1, for example, it has a mounting surface on which an assembly including the coil 2 and the magnetic core 3 is mounted, The form which is a metal plate attached to is mentioned. The reactor 1 of this form typically includes a metal plate on which the assembly is placed, and the metal plate is attached to the installation target. In the reactor 1 of this form, the metal member 4 shown in FIG. 1 corresponds to a metal plate.

  The metal plate functions as, for example, a heat radiating member or a fixing member to the installation target. In this form, the periphery of the combination is not covered with the side wall of the case and the sealing resin described later, and is exposed. Therefore, when the installation target includes a cooling structure using, for example, a liquid refrigerant, the combination (particularly, the coil 2) is directly exposed to the liquid refrigerant and cooled.

  As the metal constituting the metal plate, the metal described in the above-mentioned integrated case can be used. The front and back surfaces of the metal plate are typically flat. If it is a flat surface, it is easy to perform the mounting operation of the assembly, the forming operation of the resin layer 42, and the like as described above. Since this form does not have a side wall part compared with the form provided with the above-mentioned case, further weight reduction can be achieved.

... Installation object As another metal member arrange | positioned in the outer peripheral surface vicinity of the coil 2 in the reactor 1, the converter case etc. in which the reactor 1 is installed are mentioned, for example. In the reactor 1 of this form, an assembly including the coil 2 and the magnetic core 3 is directly attached to the installation target. In the reactor 1 of this form, the metal member 4 shown in FIG. 1 corresponds to a converter case (mounting surface thereof).

... Others In place of the above-described metal plate, only the mounting region of the assembly including the coil 2 and the magnetic core 3 is composed of metal, and the other region is composed of a non-metal, and this composite plate The metal part of the plate can be the metal member 4. The metal which comprises a metal part can utilize the metal described by the term of the above-mentioned integral case. As the constituent material of the non-metallic part, non-metallic inorganic materials such as ceramics can be used. In this case, high heat dissipation and insulating properties can be expected.

..Outer cover The reactor 1 is formed along the outer periphery of the winding portions 2a and 2b of the coil 2 and includes a resin molded product covering a part of the outer peripheral surface of the winding portions 2a and 2b. Here, the molded product of the resin is referred to as an outer cover 6A.

... Shape The outer cover 6A in this example is a W-shaped cross section that covers a rectangular parallelepiped outer shape formed by the winding portions 2a and 2b of the coil 2, as shown in FIG. The outer cover 6A is provided along the three corner R portions 20, 21, 22 among the four corner R portions of the winding portions 2a, 2b, and arc-shaped corner covering portions 60, 61 covering these portions. , 62 and a plurality of flat plate pieces that are arranged along the outer surface or the installation surface of each of the winding portions 2a, 2b and connect adjacent corner covering portions 60, 61 or 61, 62 to each other.

  The length along the circumferential direction of each winding part 2a, 2b of the coil 2 in the arc-shaped corner covering parts 60, 61, 62 is connected to the inner surface and the installation surface (lower surface) of the winding parts 2a, 2b. The circumferential length of the curved surface portion, the circumferential length of the curved surface portion connected to the installation surface and the outer surface, and the circumferential length of the curved surface portion connected to the opposite surface (upper surface) and the outer surface of the installation surface Substantially equal. The length along the axial direction of the winding portions 2a, 2b in the arc-shaped corner covering portions 60, 61, 62 is substantially equal to or slightly longer than the axial length of the winding portions 2a, 2b. Therefore, each corner covering portion 60, 61, 62 can reliably cover the outer surfaces of the corner R portions 20, 21, 22 of the winding portions 2a, 2b. Each flat plate piece connects both end portions in the axial direction of the respective corner covering portions 60, 61, 62. Accordingly, a rectangular frame is formed by the adjacent corner covering portions 60 and 61 and the pair of flat plate pieces, and the corner covering portions 61 and 62 and the pair of flat plate pieces, respectively. The outer cover 6A includes a window portion 67 formed by the inner peripheral edge of the rectangular frame. When the outer cover 6 </ b> A is attached to the coil 2, a planar portion on the outer peripheral surface of each of the winding portions 2 a and 2 b, that is, a part of the outer surface (FIG. 1) and a part of the installation surface are exposed from the window 67.

  Further, the outer cover 6A is an integrally molded product provided with a crossover portion 65 for connecting the corner covering portions 60, 60 attached to the corner R portions 20, 20 on the installation surface side and inner sides of the winding portions 2a, 2b, respectively. It is. When such an outer cover 6A is attached to the coil 2, the corner R portion 22 above and outside one winding portion 2a of the coil 2, the outer surface of the winding portion 2a, the installation surface side and the corner R portion 21 outside. , Over the installation surface of the winding part 2a, the installation surface side and the inner corner R part 20, subsequently, the installation surface side and inner corner R part 20 of the other winding part 2b, the installation surface of the winding part 2b, The corner covering portion 62, the flat plate piece, the corner in the outer cover 6A are arranged in order over the installation surface side and the outer corner R portion 21, the outer surface of the winding portion 2b, and the upper and outer corner R portion 22 of the winding portion 2b. A covering portion 61, a flat plate piece, a corner covering portion 60, a transition portion 65, a corner covering portion 60, a flat plate piece, a corner covering portion 61, a flat plate piece, and a corner covering portion 62 are provided.

... Constituent material The outer cover 6A functions as an insulation between the coil 2, in particular, the corner R portions 20 to 22 of the winding portions 2a and 2b, and the above-described metal member disposed in the vicinity of the outer peripheral surface of the coil 2. One of them. Therefore, an insulating material such as a resin can be suitably used as the constituent material of the outer cover 6A. Specific examples of the insulating material include PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 and nylon 66, and thermoplastic resin such as PBT resin. The outer cover 6A can be easily manufactured by a known molding method such as injection molding of the above resin.

... Thickness The thickness of the outer cover 6A can be selected as appropriate, and a form in which the entire thickness is uniform as shown in FIG. 3 is representative. The outer cover 6A can have portions with different thicknesses. For example, if the thickness of the corner covering portions 60 to 62 is thicker than other portions, the insulating property can be further improved. In the mounted state of the reactor 1, the thickness of the flat plate piece constituting the installation surface side region is such that the installation surface of the winding portions 2 a and 2 b of the coil 2 and the coil 2 such as the surface 4 f of the metal member 4 are mounted. It corresponds to the distance between the mounting surface. If the mounting surface is made of metal, that is, one surface of the metal member 4, the distance (thickness of the flat plate piece) is set to a size desired for insulation between the coil 2 and the metal member 4. Is preferred. The thickness of the flat plate piece may be adjusted so as to satisfy desired insulating properties. If the thickness of the area on the installation surface side in the outer cover 6A is too thick, the reactor 1 becomes bulky, and therefore it is preferable to adjust in a range that does not cause an excessive increase in size. The average thickness of the outer cover 6A is, for example, about 0.5 mm to 4 mm.

... Attachment state of outer cover to coil When the reactor 1 is provided with the above-mentioned metal integral case or combination case, the metal bottom portion and the outer peripheral surface of both winding portions 2a, 2b of the coil 2 Both side wall portions are arranged to face each other. And in the reactor 1 of this form, two corner | angular R parts 20 by the side of the installation surface which is an opposing area | region with metal bottom parts among the corner | angular R parts 20-22, 25 with which both winding part 2a, 2b is equipped. The corner covering portions 60 and 61 are respectively attached to 21, and the corner covering portions 61 and 62 are respectively attached to the outer two corner R portions 21 and 22 which are regions facing the metal side wall portions. Each of these corner covering portions 60 to 62 functions as an insulating covering portion that covers a facing region between the outer peripheral surface of the winding portions 2a and 2b and the metal case disposed to face the outer peripheral surface.

  When the reactor 1 includes a combination case having the above-described metal bottom, or includes the above-described metal plate or composite plate, or when directly installed on an installation target such as a metal converter case, both the coils 2 A metal bottom portion, a metal plate, an installation target, and the like are disposed to face the outer peripheral surfaces of the winding portions 2a and 2b. And in the reactor 1 of this form, two corner | angular R parts by the side of an installation surface which is an opposing area | region with the said metal bottom parts etc. among the corner | angular R parts 20-22, 25 with which both winding part 2a, 2b is equipped. Corner covering portions 60 and 61 are attached to 20 and 21, respectively. Each of these corner covering portions 60 and 61 functions as an insulating covering portion that covers a region facing the above-described metal bottom portion that is disposed to face the outer peripheral surfaces of the winding portions 2a and 2b. In this form, it can be set as the outer cover which is not provided with the corner | angular covering part 62 attached to the upper corner | angular R part 22. FIG. The outer cover is, for example, a molded product having a W-shaped cross section including a corner covering portion 60, 60, 61, 61, a flat plate piece that connects the adjacent corner covering portions 60, 61, and a transition portion 65. Is mentioned. Since this molded product is supported on the mounting surface or fixed by the resin layer 42, it is difficult to shift the position even if it is not separately fixed with an adhesive or the like. On the other hand, as shown in this example, the outer cover 6A including the corner covering portion 62 has a large contact area with respect to the coil 2, is easy to stabilize the arrangement state, and substantially from the coil 2 without using an adhesive or the like. Do not fall off.

  When reactor 1 is provided with the combination case which has the above-mentioned metal side wall part, a metal side wall part is opposingly arranged with respect to the outer peripheral surface of both winding parts 2a and 2b of coil 2. As shown in FIG. And in the reactor 1 of this form, two corner R parts 21 and 22 of the outer side which is an opposing area | region with metal side wall parts among corner | angular R parts 20-22, 25 with which both winding part 2a, 2b is equipped. The corner covering portions 61 and 62 are attached to each other. Each of these corner covering portions 61 and 62 functions as an insulating covering portion that covers a facing region between the outer peripheral surface of the winding portions 2a and 2b and the metal side wall portion disposed to face the winding portion 2a and 2b. In this form, it can be set as the outer cover which is not provided with the angle | corner coating | coated part 60 attached to the corner | angular R part 20 inside the installation surface side. This outer cover, for example, connects the corner covering portions 61, 61, 62, 62, the flat plate pieces connecting the adjacent corner covering portions 61, 62, and the cross-section] connected members by the flat plate pieces, For example, a molded product having a U-shaped cross section including a belt-like piece disposed so as to cross the installation surfaces of both winding parts 2a and 2b can be mentioned. Alternatively, each of the members having the above cross-section can be an independent resin molded product, and a pair of such molded products can be provided. The pair of molded products can be fixed to the winding parts 2a and 2b with an adhesive or the like. Alternatively, it is easy to stabilize the arrangement state by separately attaching a connecting material for connecting the pair of molded products. On the other hand, as shown in this example, the outer cover 6A including the corner covering portion 60 has a large contact area with the coil 2, and the arrangement state is easily stabilized without using an adhesive or the like.

  In addition, the flat piece on the installation surface side in the outer cover 6 </ b> A of this example includes an installation surface of the winding portions 2 a and 2 b of the coil 2, and a mounting surface on which a combination including the coil 2 and the magnetic core 3 is mounted. Intervene between. Therefore, the installation surfaces of the winding portions 2 a and 2 b do not directly contact the placement surface, and insulation from the metal member 4 can be secured even if the placement surface is the surface 4 f of the metal member 4. In this case, the flat plate on the installation surface side of the outer cover 6 </ b> A functions as an insulating material between the coil 2 and the metal member 4. Further, in this example, a resin layer 42 described later is interposed between the installation surface of the winding portions 2 a and 2 b and the mounting surface, and the above-described window portion 67 is used as a resin filling region of the resin layer 42. The thickness of the resin filled in the window 67 is substantially equal to the thickness of the flat plate piece. By filling the window 67 with the constituent resin of the resin layer 42, the installation surfaces of the winding parts 2a and 2b are made of metal by interposing the flat plate piece of the outer cover 6A and the constituent resin of the resin layer 42. The member 4 is well insulated.

.. Resin layer The reactor 1 of this example further includes a resin layer 42 between the installation surface of the combined body including the coil 2 and the magnetic core 3 and the mounting surface on which the combined body is mounted (FIG. 1, FIG. Figure 2). Examples of the constituent resin of the resin layer 42 include a thermosetting resin, a thermoplastic resin, a moisture curable resin, and a room temperature curable resin. More specifically, a silicone resin, a urethane resin, an epoxy resin, a PPS resin, an LCP, a PA resin, a polyamideimide resin, and the like can be given. Since these resins usually have insulating properties, even if the mounting surface is the surface 4f of the metal member 4, the coil 2 (particularly the winding portions 2a and 2b) and the metal member 4 are interposed by the resin layer 42. Can be insulated. When the resin layer 42 contains an adhesive, the coil 2 and the metal member 4 can be firmly fixed. When the resin layer 42 includes a metal filler or a ceramic filler having excellent heat conductivity, heat can be radiated from the coil 2 to the metal member 4 and the like, and the heat dissipation is excellent. The resin layer 42 preferably has the three functions of the insulating function, the fixing function, and the heat dissipation function as described above. Part of the constituent resin of the resin layer 42 is filled in the window portion 67 as described above, and the other portions are the corner covering portions 60 on the installation surface side and the inner side of the outer cover 6A as shown in FIGS. It is provided between 60 or outside of the corner covering portions 61, 61 on the installation surface side and the outside. Since the reactor 1 includes the outer cover 6 </ b> A, even if the resin layer 42 is formed only in the window portion 67, the reactor 1 is excellent in insulation between the coil 2 and the metal member 4. Note that the resin layer 42 may not be provided.

-Intervening member The reactor 1 of this example is provided with the interposing member 5 interposed between the coil 2 and the magnetic core 3 (FIG. 2, FIG. 4). The interposition member 5 has a function of enhancing the insulation between the coil 2 and the magnetic core 3 and is made of an insulating material for this function. The interposition member 5 in this example is formed by combining a pair of split members 50a and 50b that are split in the axial direction of the coil 2 as shown in FIG.

  One split member 50a includes a coil inner portion 51 interposed between the winding portions 2a and 2b of the coil 2 and the storage portion of the magnetic core 3, an end surface of the coil 2, and a U-shaped core piece 32m. This is an integrally molded product including a coil outer portion 52 interposed between the end surface 32e. The coil inner portion 51 is composed of a plurality of curved plate pieces arranged at the corners of the storage portion. The coil outer portion 52 is a flat frame portion having two through holes 52h and 52h through which the protruding portion of the U-shaped core piece 32m is inserted. The other split member 50b includes a coil outer portion 52, an engagement protrusion that protrudes from the coil side surface of the coil outer portion 52 toward the coil, and engages with an end portion of the curved plate provided in the one split member 50a. Is an integrally formed product. The shape of the interposition member 5 is an example, and can be changed as appropriate. For example, the form in which the coil inner part 51 and the coil outer part 52 are not integral, but are independent separate members, etc. are mentioned.

  Examples of the constituent material of the interposition member 5 include various resins described in the section of the constituent material of the outer cover 6A. The interposition member 5 can be easily manufactured by a known method such as injection molding of the above resin. Intervening members having a known shape and composition (sometimes called bobbins or insulators) can be used.

(Reactor manufacturing method)
The reactor 1 of Embodiment 1 provided with the outer cover 6A can be manufactured as follows, for example. One split piece 50a is arranged on one core piece 32m, and the core pieces 31m and the gap material 31g are alternately accommodated in the cylindrical frame-shaped coil inner part 51, and then the coil 2 is fitted on the outer periphery of the coil inner part 51, The other divided piece 50b and the other core piece 32m are arranged. The outer cover 6A is attached to the winding portions 2a and 2b at an appropriate time in this process. That is, the outer cover 6A can be attached either before or after the coil 2 and the magnetic core 3 are assembled.

  The outer cover 6A can be attached by, for example, elastically deforming and expanding the outer cover 6A so as to open between the corner covering portions 62 and 62 that are arranged to face each other, and fitting into the coil 2. In this example, the outer cover 6A is a frame-like body that includes the window portion 67 and does not have a portion that covers the end surfaces of the winding portions 2a and 2b of the coil 2, and thus can perform the above-described spreading operation. It has flexibility. This attachment method can be applied before and after the coil 2 and the magnetic core 3 are assembled.

  Alternatively, the outer cover 6A can be attached, for example, by inserting the outer cover 6A from the connecting portion 2r side of the coil 2 and sliding it in the axial direction of the coil 2 as shown in FIG. This attachment method can be applied before the coil 2 and the magnetic core 3 are assembled.

  In the case of forming the resin layer 42, an unsolidified resin is applied to an installation surface such as the surface 4 f of the metal member 4, and an assembly including the coil 2, the magnetic core 3, and the outer cover 6 </ b> A is formed. It is good to mount on unsolidified resin and to solidify suitably. By providing the flat plate piece on the installation surface side of the outer cover 6A as described above, it is possible to prevent the coil 2 from sinking into the unsolidified resin until it is solidified and coming into contact with the surface 4f of the metal member 4 or the like. . That is, the flat piece of the outer cover 6A can function as a support member for securing a predetermined distance between the coil 2 and the metal member 4 until the unsolidified resin is solidified.

(Main effect)
Although the reactor 1 of Embodiment 1 is provided with the coil 2 which has the curved part (corner R part 20-22, 25) bent edgewise by winding part 2a, 2b, it is with a metal member (4) in a curved part. Insulating covering portions (corner covering portions 60 to 62) are attached to the opposing regions (corner R portions 20 to 22). Therefore, even if the insulation coating of the coil | winding 2w which comprises a bending part may be damaged at the time of formation of winding part 2a, 2b etc., the reactor 1 is a starting point of the creeping discharge to a metal member. Can be effectively prevented. Therefore, the reactor 1 is excellent in insulation between the coil 2 and the metal member disposed to face the coil 2.

  In particular, in the reactor 1 of this example, a resin molded product (outer cover 6A) including an insulating coating part (corner covering parts 60 to 62) is used as one of the assembly parts, and the outer cover 6A is used as the winding parts 2a and 2b. It can be easily manufactured by mounting. The outer cover 6A can be easily manufactured by resin injection molding or the like. From these points, the reactor 1 is excellent in manufacturability.

  In particular, in the reactor 1 of this example, the coil 2 includes a pair of winding portions 2a and 2b, and a plurality of curved portions (corner R portions 20 to 22 and 25) in which both winding portions 2a and 2b are edgewise bent. However, the resin molded product (outer cover 6A) has a plurality of insulating covering portions (corner covering portions 60 to 62) integrated with a plurality of curved portions (corner R portions 20 to 22) provided in one winding portion. Prepare for. In addition, the outer cover 6A is an integrally molded product that integrally includes a plurality of insulating coating portions for both the winding portions 2a and 2b via the crossover portion 65. Therefore, in the reactor 1 including the outer cover 6A, a plurality of insulating coating portions are attached at a time to a plurality of curved portions included in both the winding portions 2a and 2b. Also from this point, the reactor 1 is excellent in manufacturability.

In particular, the reactor 1 of this example has the following effects by including the window portion 67 and the resin layer 42 in the resin molded product (outer cover 6A).
1. 1. Improvement in fixing strength between the coil 2 and a mounting surface such as the surface 4f of the metal member 4 by the resin layer 42 in the window 67. 2. Prevention of contact between the winding parts 2a and 2b and the placement surface (particularly the surface 4f of the metal member 4) by supporting the winding parts 2a and 2b. 3. Improved insulation between the coil 2 and the mounting surface (same as above) due to the contact prevention. 4. Reduce the amount of resin used in molded products. Improved heat dissipation by exposing part of the installation surface of the winding parts 2a and 2b and part of the outer surface, and improved bondability with the resin layer 42

-Other structural member The reactor 1 of Embodiment 1 can be changed into the following structures, or can be equipped with the following members. At least one of the following members may be omitted.

..Core covering material In place of the interposition member 5, the core pieces 31m and 32m of the magnetic core 3 or a laminate of the core piece 31m and the gap material 31g are covered with an insulating material such as the resin described above. Can do. In this configuration, the interposition member 5 can be omitted, the number of assembly parts can be reduced, and the assembly workability is excellent. Further, by making a plurality of core pieces and the like as one body, it is easy to handle an assembly part and the workability is excellent. Although the core covering material and the above-described interposition member 5 may be omitted, by providing these, the insulation between the coil 2 and the magnetic core 3 can be enhanced.

.. Sensor A sensor (not shown) that measures the physical quantity of the reactor such as a temperature sensor, a current sensor, a voltage sensor, or a magnetic flux sensor can be provided.

.. Heat radiation plate A heat radiation plate (not shown) can be provided in an arbitrary portion of the outer peripheral surface of the coil 2 except the installation surface, for example, the upper surface of FIG. As the constituent material of the heat sink, the metal or non-metallic inorganic material described in the section of the metal member can be used. For example, the heat radiating plate may be fixed with an adhesive or the like.

[Embodiment 2]
In the first embodiment, the example in which the insulating coating portions (corner coating portions 60 to 62) are part of the resin molded product has been described. In addition, as shown in FIG. 5, an insulating tape 6B can be used. In FIG. 5, only the coil 2 having the curved portion bent edgewise as described in the first embodiment is shown. Further, FIG. 5 illustrates a state in which the insulating tape 6B is attached to the curved portions (corner R portions 20, 21) on the installation surface side in the winding portions 2a, 2b of the coil 2 over the entire length in the axial direction. To do. In this form, when the placement surface on which the assembly including the coil 2 and the magnetic core is placed is the surface 4f (FIG. 2) of the metal member 4, etc., among the curved portions of the winding portions 2a and 2b, An insulating tape 6 </ b> B is provided in a region facing the metal member 4. As described in the first embodiment, when a metal case is provided, the insulating tape 6B may be attached to the corner R portion 22 as well.

  If the insulating tape 6B is used, the insulating coating portion can be easily and accurately attached to a predetermined position of the winding portions 2a and 2b with a predetermined amount regardless of the size and shape of the coil 2. Further, if the insulating tape 6B is used, it is not necessary to separately manufacture a resin molded product. Therefore, the reactor of Embodiment 2 is more excellent in manufacturability.

[Modification 1]
In the first embodiment, the form in which the outer cover 6 </ b> A has the transition portion 65 has been described. In addition, it does not have the transition part 65 as an outer cover, but can use the molded product attached to each winding part 2a, 2b as an independent member, respectively. Each molded product has an L shape including the corner covering portions 60, 61, 62 and flat plate pieces connecting them. Since this molded product is fitted into three corner R portions 20 to 22 among the four corner R portions 20 to 22 and 25 included in the winding portions 2a and 2b, the resin layer is further provided when the resin layer 42 is provided. Since it is fixed by 42, the arrangement state is easy to stabilize, and even if it is not separately fixed with an adhesive or the like, it is difficult to drop off from the coil 2.

  Alternatively, the flat plate piece and the crossing portion 65 described above are not provided, and the corner covering portions 60, 61, and 62 can be formed as independent molded products, that is, arc pieces made of resin. These arc pieces are preferably fixed to the corner R portions 20 to 22 with an adhesive or the like, for example.

[Modification 2]
In the first and second embodiments, the form in which the winding portions 2a and 2b of the coil 2 are square cylindrical bodies has been described. In addition, the winding parts 2a and 2b can be formed into polygonal cylindrical bodies other than squares, or can be formed into a shape with many curved surfaces such as a cylindrical body, an elliptical cylindrical body, or a racetrack-shaped cylindrical body. In the case of a shape having many curved surfaces as described above, the curved portion of the winding portion is projected onto the metal member 4, and the projection area of the curved portion is preferably set as a region facing the metal member 4. It is preferable to provide an insulating covering portion so as to cover the facing region.

[Modification 3]
In the first and second embodiments, the mode in which the coil 2 includes the pair of winding portions 2a and 2b has been described. In addition, when there is one winding part and a region facing the metal member exists in the curved part of the wound part, an insulating coating part can be attached to the curved part.

[Modification 4]
It can be set as the form provided with both the resin molded product provided with an insulation coating part, and the insulating tape 6B demonstrated in Embodiment 2. FIG. For example, when there is a place where it is difficult to place a resin molded product, the insulating tape 6B may be attached to this place. By combining the resin molded product and the insulating tape, the insulating coating portion can be easily attached to coils of various shapes.

  The present invention is not limited to these exemplifications, but is defined by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

  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 used as a component of a power conversion device.

DESCRIPTION OF SYMBOLS 1 Reactor 2 Coil 2a, 2b Winding part 2r Connection part 2w Winding 20, 21, 22, 25 Corner | angular R part 3 Magnetic core 31m, 32m Core piece 31g Gap material 32e Inner end surface 4 Metal member 4f Surface 42 Resin layer 5 Interposition Member 50a, 50b Division material 51 Coil inner part 52 Coil outer part 52h Through hole 6A Outer cover 60, 61, 62 Corner covering part 65 Transition part 67 Window part 6B Insulating tape

Claims (7)

A coil having a winding portion formed by winding a flat winding;
A magnetic core having a portion disposed in the winding portion,
The winding part includes a curved part formed by edgewise bending the rectangular winding,
A reactor provided with the insulation coating part attached so that the opposing area | region with the metal member arrange | positioned facing the outer peripheral surface of the said winding part may be covered among the said curved parts. The winding part is a rectangular tubular body with rounded corners,
The reactor according to claim 1, wherein an opposing region of the curved portion includes the corner portion. A case for housing the coil and the magnetic core;
The reactor according to claim 1, wherein the metal member includes at least one of a bottom portion and a side wall portion of the case.   The reactor of any one of Claims 1-3 provided with the molded article of resin containing the said insulation coating part. The coil includes a pair of winding portions in parallel,
Any one of Claims 1-4 provided with the said insulation coating part which each covers the opposing area | region of the said curved part with which each winding part is provided, and the transition part which connects the said insulation coating parts attached to both winding parts. The reactor according to claim 1. The winding part is a rectangular tubular body with rounded corners,
The facing region of the curved portion includes the corner portion,
A resin molded product provided from one corner of the rectangular tube body to another corner,
The molded article of the resin includes any one of a window portion that exposes a planar portion on an outer peripheral surface of the rectangular tube-like body, and the insulating coating portion that covers a facing region of the curved portion. The reactor according to item 1.   The reactor according to any one of claims 1 to 6, wherein the insulating coating portion includes an insulating tape.

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