JP2016096271A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of reducing a temperature difference between a bottom part side region of a case and an opening side region in a coil.SOLUTION: A reactor comprises: a coil 2 that has a winding part 2b formed by wounding a wire 2w in spiral; a magnetic core 3 that has a part to be arranged in the wiring part; a case 4 in which an assembling body 10 including the coil and the magnetic core is housed; and a radiation member 8A that is arranged so as to cover at least one part of an opening side region of the case in the wiring part. A bottom part of the case includes a metal region to which the assembling body is mounted. The radiation member has a base part 80, and a plurality of radiation projections 82 which is projected toward an outer of the case from an outside surface of the base part, and a resin is included in the radiation projection part and an opposite region opposite to the winding part of an inner side surface of the base part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a reactor that is used in a vehicle-mounted DC-DC converter or a component of a power converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a reactor that can reduce a temperature difference between a bottom side region and an opening side region of a case in a coil.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. Patent Documents 1 and 2 disclose a reactor used for a converter mounted on a vehicle such as a hybrid vehicle. Patent Document 1 is arranged between a pair of winding portions, a coil having a pair of winding portions, an annular magnetic core in which the coils are disposed, a case housing a combination of the coil and the magnetic core, and a pair of winding portions. A reactor including a temperature sensor that measures the temperature of the coil, an insulator that is interposed between the coil and the magnetic core and that holds the temperature sensor, and a sealing resin that fills the case is disclosed. .

  Patent Document 2 discloses a reactor in which a case and a sealing resin are omitted. The reactor includes a coil molded body in which the outer periphery of the coil is covered with a resin portion. The coil molded body includes heat radiating fins integrally formed with the resin portion.

JP 2012-253384 A JP 2011-009660 A

  It is desired to reduce the temperature difference between the bottom side region of the case and the opening side region of the coil with respect to the reactor in which the coil and the magnetic core are housed in the case.

  The coil used for the reactor usually generates heat when energized. This heat can cause thermal damage and stress to the reactor components around the coil. In order to reduce such adverse effects, a reactor that can be supplied with a large current that increases the amount of heat generated by the coil, for example, a reactor provided in an in-vehicle converter or the like, is attached to an installation target having a cooling structure and cooled. The When a case is installed on this installation target, in the coil housed in the case, the region close to the installation target, typically the bottom side region of the case is cooled by the installation target. On the other hand, in this coil, the region away from the installation target, typically the opening side region of the case, may be insufficiently cooled by the installation target due to heat generated in the case. As a result, the temperature difference between the bottom side region and the opening side region of the case in the coil increases. Due to this temperature difference, the above-mentioned adverse effects due to heat can occur. When the sealing resin is provided in the case, heat is easily generated if the thermal conductivity of the sealing resin is insufficient. A general sealing resin does not necessarily have a sufficient thermal conductivity, and a further improvement in heat dissipation is desired for a reactor including the sealing resin. If a metal case is used, the case itself has excellent thermal conductivity. However, since the opening side region of the case in the coil does not normally contact the case, it is not possible to efficiently dissipate heat from the opening side region to the outside of the case simply by providing a metal case. Adverse effects can occur.

  If the case is omitted, the heat inside the case is eliminated, but in this case, the coil and the magnetic core are exposed to the external environment. When it is desired to sufficiently protect the coil and the magnetic core from the external environment and mechanical protection, it is preferable to provide a case.

  Then, one of the objectives of this invention is providing the reactor which can reduce the temperature difference of the bottom part side area | region and opening side area | region of a case in a coil.

  A reactor according to an aspect of the present invention includes a coil having a winding portion formed by spirally winding a winding, a magnetic core having a portion disposed in the winding portion, the coil, and the magnetic core. And a heat radiating member disposed so as to cover at least a part of the opening side region of the case in the winding part. The bottom of the case includes a metal region on which the combination is placed. The heat dissipating member includes a base and a plurality of heat dissipating protrusions protruding from the outer surface of the base toward the outside of the case. Of the inner surface of the base portion, the region facing the winding portion and the heat dissipating protrusion include resin.

  Said reactor can reduce the temperature difference of the bottom part side area | region and opening side area | region of a case in a coil.

It is a schematic perspective view of the reactor of Embodiment 1. It is the longitudinal cross-sectional view which cut | disconnected the reactor of Embodiment 1 by the (II)-(II) cutting line shown in FIG. It is the partial cross-sectional view which cut | disconnected the reactor of Embodiment 1 by the (III)-(III) cutting line shown in FIG. 1, and shows the vicinity of a thermal radiation member. It is a disassembled perspective view of the reactor of Embodiment 1. FIG. It is a disassembled perspective view of the combined body containing the coil and magnetic core with which the reactor of Embodiment 1 is equipped. It is a schematic perspective view which shows another example (vertically arranged fin) of the thermal radiation member with which the reactor of Embodiment 1 is equipped. It is the schematic perspective view which looked at another example (vertically arranged fin) of the heat radiating member with which the reactor of Embodiment 1 is equipped from the inner surface. It is a schematic perspective view which shows the other example (bar-shaped fin) of the heat radiating member with which the reactor of Embodiment 1 is equipped. It is a schematic perspective view which shows the other example (bar-shaped fin) of the heat radiating member with which the reactor of Embodiment 1 is equipped. It is the longitudinal cross-sectional view which cut | disconnected the reactor of Embodiment 2 by the plane parallel to the axial direction of a coil. It is the partial cross section which cut | disconnected the reactor of Embodiment 2 by the plane orthogonal to the axial direction of a coil, and shows the vicinity of a thermal radiation member (with a comb tooth).

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.
(1) A reactor according to an aspect of the present invention includes a coil having a winding portion formed by winding a winding spirally, a magnetic core having a portion disposed in the winding portion, the coil, and the above A case that houses a combination including a magnetic core, and a heat radiating member that is disposed so as to cover at least a part of the opening side region of the case in the winding part. The bottom of the case includes a metal region on which the combination is placed. The heat dissipating member includes a base and a plurality of heat dissipating protrusions protruding from the outer surface of the base toward the outside of the case. Of the inner side surface of the base portion, a region facing the winding portion and the heat dissipation protrusion include a resin.

  In the reactor described above, the mounting region of the coil winding portion at the bottom of the case is generally made of metal, which is a material having excellent thermal conductivity, and the coil is housed in this case. Therefore, when the installation target to which the case is attached has a cooling structure or the like and can be cooled, the heat of the coil is transmitted to the installation target through the above-described installation region (metal region). As a result, the temperature of the bottom side region of the case at the coil winding portion can be lowered. And in said reactor, the heat radiating member is arrange | positioned in the opening side area | region of the case in the winding part of a coil. In particular, a plurality of heat-dissipating protrusions provided on the heat-dissipating member protrude toward the outside of the case, and have a sufficient contact area with the external environment outside the case. Therefore, the heat of the coil can be efficiently dissipated to the external environment through these heat radiation projections. As a result, the temperature of the opening side region of the case in the winding part can be lowered. Thus, said reactor can relieve | moderate the temperature difference of the bottom part side area | region and opening side area | region of a case in a coil. In other words, the reactor described above can dissipate the heat of the coil to both the installation target and the external environment even when the coil can become hot with energization, and extends from the bottom side of the case to the opening side of the coil. Easy to achieve a uniform low temperature. Therefore, the reactor described above can suppress adverse effects on characteristics due to the temperature rise of the coil, thermal damage of the components of the reactor around the coil, thermal stress, and the like.

  Further, in the above-described reactor, the portion of the heat dissipation member that is close to or can be in contact with the coil winding portion, specifically, the region facing the winding portion on the inner surface generally contains a resin that is an electrical insulating material. Moreover, it is excellent also in the electrical insulation between a winding part and a heat radiating member. In addition, the case where the case is made of metal because the heat dissipation member includes a resin, which is generally an electrical insulating material, in the vicinity of the inner peripheral surface or opening edge of the side wall portion of the case, specifically, the heat dissipation protrusion. However, it is excellent in electrical insulation between the case and the heat dissipation member. That is, the reactor described above is also excellent in electrical insulation between the coil, the case, and the heat dissipation member.

  In addition, the above-described reactor includes a coil and a magnetic core housed in a case, and can protect the coil and the magnetic core from an external environment and mechanical protection.

  (2) As an example of the reactor described above, a mode is provided that includes a sealing resin that is filled in the case and includes a portion that fixes the winding portion and the heat dissipation member.

  Although the said form is provided with sealing resin, the winding part of a coil and a heat radiating member are firmly fixed by a part of this sealing resin, and the heat of a winding part can be efficiently transmitted with a heat radiating member, and heat dissipation Excellent. When the sealing resin is filled with no gap between the winding part and the heat radiating member, the thermal conductivity is superior to the case where there is the gap, that is, the case where air inferior in thermal conductivity is present. . From these points, the said form can further reduce the temperature difference of the bottom part side area | region and opening side area | region of a case in a coil.

  (3) As an example of the reactor, a plurality of interposing protrusions, wherein the heat radiating member protrudes from a region facing the winding portion on the inner side surface of the base portion, and is interposed between the turns of the winding portion. The form provided with is mentioned.

  In the above configuration, the heat dissipation member itself can substantially directly receive the heat of the winding portion of the coil by the interposition protrusion interposed between the turns. Since the interposition protrusion functions as a heat dissipation path, the above configuration can dissipate the heat of the coil from the winding part to the outside of the case more efficiently, and is further excellent in heat dissipation. From this point, the said form can further reduce the temperature difference of the bottom part side area | region and opening side area | region of a case in a coil. Furthermore, since these interposing protrusions are extended from a region facing the winding portion of the heat radiating member and contain a resin, they can also function as an electrical insulating material between the turns, and can be wound by interposing between the turns. It is possible to prevent expansion and contraction in the axial direction and deformation in the radial direction of the turning portion. That is, these interposition protrusions can also function as a shape maintaining member or a dimension maintaining member of the winding part. Due to the stability of the shape of the winding part, the stability of characteristics can be expected.

  (4) As an example of the reactor, a temperature sensor that measures the temperature of the coil is provided, the coil has a pair of winding portions that are arranged in parallel so that their axes are parallel, and the heat dissipation A form with which the member is provided with the sensor arrangement | positioning part which positions the said temperature sensor between said pair of winding parts is mentioned.

  Since the said form can measure the temperature of a coil with a temperature sensor, based on a measurement result, the control of the electricity supply state to a coil etc. can be performed appropriately. In particular, the above embodiment uses a part of the heat radiating member for positioning of the temperature sensor, so that the temperature sensor can be stably arranged at a predetermined position and the temperature of the coil can be measured more appropriately. Furthermore, the above-described form does not require a temperature sensor positioning member, and the number of parts is small, and the arrangement of the heat dissipating member and the temperature sensor positioning can be performed simultaneously, so that the number of assembly steps is small and the manufacturability is excellent.

  (5) As an example of the above reactor, the heat radiating member may be an integrally molded product of a high thermal conductive resin having a thermal conductivity of 1 W / m · K or more.

  The above-mentioned form is an integrally molded product in which the heat radiating member has a base and a heat radiating projection, or an integral molded product having a base, a heat radiating projection and an interposing projection, and is made of a uniform material. The heat conduction inside can be performed uniformly. From this point, it is considered that the above embodiment can stably dissipate the heat of the winding part outside the case through the heat dissipation member, as compared with the case where the heat dissipation member is a set made of different materials. . Moreover, since the heat radiating member is an integrally molded product, the number of parts and the number of assembling steps are small, and the above form is excellent in manufacturability.

[Details of the embodiment of the present invention]
A specific example of a reactor according to an embodiment of the present invention will be described below with reference to the drawings. The same reference numerals in the figure indicate the same names.

[Embodiment 1]
-Overall structure The reactor 1A of Embodiment 1 is demonstrated with reference to FIGS. A reactor 1A of Embodiment 1 includes a coil 2 having a pair of winding portions 2a and 2b formed by spirally winding a winding 2w, and a magnetic core 3 having a portion disposed in the winding portions 2a and 2b. And a case 4 that houses the combination 10 including the coil 2 and the magnetic core 3, and a sealing resin 100 that fills the case 4. The reactor 1 </ b> A in this example further includes a temperature sensor 70 (FIG. 3) that measures the temperature of the coil 2. Reactor 1A is used by being attached so that bottom surface 4d (FIG. 2) of case 4 is in contact with the surface of installation object 1000 (FIG. 2) such as a converter case. The installation object 1000 includes, for example, a cooling structure (not shown), and cools the coil 2 and the like housed in the case 4 via the bottom plate portion 40 (FIG. 2) of the case 4. In the following description, the state shown in FIG. 1 and FIG. 2 is an installation state, the bottom surface 4d side of the bottom plate portion 40 of the case 4 is referred to as the lower side (installation side), and the opening side of the opposite case 4 is referred to as the upper side. There is. The installation state shown in FIG. 1 is an example. FIG. 2 is a longitudinal sectional view of the reactor 1 </ b> A cut along a plane parallel to the axial direction of the winding portion 2 a of the coil 2. FIG. 3 is a cross-sectional view of the reactor 1A cut along a plane orthogonal to the axial direction of the winding portions 2a and 2b, and shows the vicinity of the temperature sensor 70 in an enlarged manner.

  Reactor 1A of Embodiment 1 is a heat dissipating member arranged to cover at least a part of the opening side region (upper region) of case 4 among winding portions 2a and 2b of coil 2 housed in case 4. 8A, the heat radiating member 8A includes a plurality of heat radiating protrusions 82, the heat radiating member 8A includes a resin, and the case 4 includes a metal at the bottom (bottom plate portion 40). Hereinafter, each component will be described in order.

.. Coil As shown in FIG. 5, the coil 2 includes a pair of cylindrical winding portions 2a and 2b formed by spirally winding a single continuous winding 2w, and one coil 2w. A connecting portion 2r that is formed from a portion and connects both winding portions 2a and 2b. The winding parts 2a, 2b are arranged in parallel (side by side) so that their axes are parallel to each other. The winding 2w in this example is a covered rectangular wire (so-called enameled wire) having a flat wire conductor (copper or the like) and an insulating coating (polyamideimide or the like) on the outer periphery of the conductor, and the winding portions 2a and 2b are It is an edgewise coil.

  The winding portions 2a and 2b in this example are rectangular tube shapes with rounded corners, and the end surface shape of the winding portions 2a and 2b is a rectangular frame shape having corner R portions 20. Between the winding parts 2a and 2b arranged in parallel, as shown in FIG. 3, the corner R parts 20 and 20 arranged to face each other, and the outer peripheral surface of the winding parts 2a and 2b (the upper surface 20u which is the opening side surface of the case 4). Alternatively, a space having a trapezoidal cross section is formed by a virtual surface that connects the bottom surface (the bottom side surface) in the parallel direction. In this example, a downward trapezoidal space is used as a storage space for the temperature sensor 70. The trapezoidal space is an area where the coil 2 can be at the highest temperature, and can be said to be one of the locations suitable for measuring the temperature of the coil 2. The downward trapezoidal space is a space opened toward the opening side of the case 4 before the heat radiating member 8A is arranged, that is, a space opened upward. Therefore, the temperature sensor 70 can be easily disposed from above the coil 2 (winding portions 2a and 2b). Furthermore, the trapezoidal space is a dead space of the coil 2, and the dead space can be effectively used and the reactor 1 </ b> A can be downsized by using the location where the temperature sensor 70 is disposed.

  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.

.. Magnetic core As shown in FIG. 2, the magnetic core 3 includes a portion disposed in the winding portions 2 a and 2 b of the coil 2, and a portion where the coil 2 is not substantially disposed, and the outside of the winding portions 2 a and 2 b. And a portion arranged to protrude.

  2 and 5, the magnetic core 3 in this example includes a plurality of columnar core pieces 31m and 32m, a plurality of gap members interposed between the core pieces 31m and 31m, and between the core pieces 31m and 32m. 31g. Core pieces 32m, 32m that are U-shaped when viewed from above in FIG. 5 are arranged so that the U-shaped openings face each other. Between these core pieces 32m and 32m, a pair of laminates of the core piece 31m and the gap material 31g are arranged side by side (in parallel). With this arrangement, the magnetic core 3 is assembled in an annular shape, and forms a closed magnetic path when the coil 2 is excited. The core piece 31m and the gap member 31g in the magnetic core 3 and a part of the U-shaped core piece 32m (protruding portions described later) constitute portions disposed in the winding portions 2a and 2b of the coil 2 (see FIG. 2) The remaining portion (a block to be described later) of the U-shaped core piece 32m constitutes a portion protruding from the coil 2 without the coil 2 (winding portions 2a and 2b) (FIG. 2).

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

  The core piece 31m in this example has a rectangular parallelepiped shape with rounded corners, and the gap member 31g is a rectangular flat plate with rounded corners. The core piece 32m of this example has a rectangular parallelepiped block with rounded corners as shown in FIG. 5, and a pair of protruding portions protruding from the block. The protruding portion protrudes toward the coil 2 side from the inner end surface 32e facing the end surface of the coil 2 (winding portions 2a, 2b) in the block. Each protruding portion has a rectangular parallelepiped shape with rounded corners, like the core piece 31m. The core piece 32m further includes a portion protruding in a direction opposite to the pair of protruding portions, that is, a side away from the coil 2 (refer to the left core piece 32m in FIG. 5 in particular). Specifically, the central portion in the parallel direction of the winding portions 2a and 2b in the block protrudes from the portions on both sides sandwiching the central portion. By having such a protruding portion, the thickness of the central portion of the core piece 32m (block + the thickness of the protruding portion at the center) and the thickness of the portions on both sides (block + the winding portions 2a and 2b are inserted). The projecting part) is comparable, and the core piece 32m is excellent in moldability.

  In addition, the above-described block of the U-shaped core piece 32m has a surface (lower surface) facing the inner bottom surface 4i of the bottom plate portion 40 of the case 4 when the coil 2 and the magnetic core 3 are assembled as shown in FIG. The coil 2 is formed so as to be flush with the surface (lower surface) facing the inner bottom surface 4 i of the case 4. That is, the surface (lower surface) facing the inner bottom surface 4i of the case 4 in the assembly 10 is constituted by one surface (lower surface) of the coil 2 and one surface (mainly the lower surface of the block) of the core piece 32m of the magnetic core 3. . Since the magnetic core 3 has such a specific shape, in the reactor 1A, both the coil 2 and the magnetic core 3 are stably disposed and supported by the bottom plate portion 40 of the case 4, and the bottom plate portion 40 can be a heat dissipation path.

  The number, shape, size, composition, and the like of the core pieces 31m, 32m and the gap material 31g can be appropriately changed. For example, the core piece 32m can have a rectangular parallelepiped shape, and the above-described protruding portion can be the core piece 31m. An air gap may be used instead of the gap material 31g, or the gap material 31g may be omitted.

.. Intervening Member The reactor 1A (combination body 10) of this example includes an interposing member 5 interposed between the coil 2 and the magnetic core 3 as shown in FIG. 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 divided members 50a and 50b divided in the axial direction of the winding portions 2a and 2b of the coil 2. Each of the divided members 50a and 50b includes an inner interposition part 51 interposed between the magnetic core 3 and the part accommodated in the winding parts 2a and 2b, the end face of the coil 2, and the inner end face of the core piece 32m. 32e is provided with an end face interposition part 52 interposed therebetween. The inner interposition part 51 is comprised from the some curved board piece arrange | positioned along the corner | angular R part 20 of winding part 2a, 2b. The end portions of the inner interposed portions 51, 51 of the divided members 50a, 50b are formed so as to engage with each other. The end surface interposition part 52 is a frame-shaped flat plate part having two through holes 52h and 52h through which a pair of projecting parts provided in the core piece 32m are inserted. The shape of the interposition member 5 is an example, and can be changed as appropriate. For example, the lengths of the inner intervening portions 51 in both divided members 50a and 50b are equal (different in this example), the end portions of the inner intervening portions 51 do not have an engaging portion, 51 and the end surface interposition part 52 are not integrated, but can be configured such that each is an independent member.

  The constituent material of the interposition member 5 is, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin such as nylon 6 or nylon 66, polybutylene terephthalate (PBT). ) Resins such as thermoplastic resins such as resins. The interposition member 5 can be easily produced by a known molding method such as injection molding of the above resin. As the interposition member 5, a member having a known shape and composition (sometimes called a bobbin or an insulator) can be used.

.. Case As shown in FIG. 2, the case 4 is erected from the bottom plate portion 40 so as to surround the periphery of the combination body 10 and a flat bottom plate portion 40 having a placement area on which the combination body 10 is placed. It is a rectangular box that has a rectangular frame-shaped side wall portion 41 that is open and opens on the side opposite to the bottom plate portion 40 (upper side).

  The case 4 in this example is a metal box in which a bottom plate portion 40 and a side wall portion 41 are integrally formed. In the bottom plate portion 40, not only the mounting region of the assembly 10 is a metal region, but the entire bottom plate portion 40 is made of metal. Since metal generally has higher thermal conductivity than resin, the entire bottom plate portion 40 can be used as a heat dissipation path. As a result, the reactor 1 </ b> A can efficiently transfer the heat of the coil 2 from the bottom side region of the case 4 in the coil 2 to the installation target 1000 via the bottom plate part 40, and at least lower the temperature of the bottom side region of the coil 2 described above. it can. In addition, the case 4 of this example includes pedestals (FIG. 4) of fixing members (not shown) such as stays that fix the combined body 10 to the case 4 at the four corners of the inner periphery. If the pedestal is omitted, the inner peripheral shape of the case 4 is simplified.

  Examples of the constituent material of the case 4 include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron and austenitic stainless steel. When formed of aluminum, magnesium, or an alloy thereof, the case 4 can be lightened. In particular, aluminum or an aluminum alloy is preferable because it has a high thermal conductivity and is excellent in heat dissipation.

.. Resin layer As shown in FIGS. 2 and 4, the reactor 1 </ b> A in this example is a space between the facing surface (lower surface) of the assembly 4 and the inner bottom surface 4 i of the case 4 and the inner bottom surface 4 i of the case 4. A resin layer 42 interposed between the two is provided. One of the functions of the resin layer 42 is to improve the insulation between the winding portions 2 a and 2 b of the coil 2 and the bottom plate portion 40 of the case 4. Specifically, the resin layer 42 increases the insulation between the bottom side region (mainly the lower surface) of the case 4 in the coil 2 and the metal region that is the mounting region of the coil 2 in the case 4, that is, as an electrical insulating layer. There is a function. Another function of the resin layer 42 is to firmly fix the combined body 10 to the bottom plate portion 40 using the adhesiveness of the resin itself, that is, a function as a bonding layer. The lower surface of the combination 10 and the inner bottom surface 4i of the case 4 are both substantially planar, and the resin layer 42 is formed in a plane so that the combination 10 The case 4 can be in surface contact. Therefore, the heat of the coil 2 is easily transmitted to the bottom plate portion 40 through the resin layer 42, and the combined body 10 is stably supported by the bottom plate portion 40 and is firmly fixed by the resin layer 42.

  The constituent material of the resin layer 42 is preferably a resin having heat resistance to such an extent that it does not soften with respect to the maximum temperature achieved when the reactor 1A is used, particularly one containing an adhesive, and more preferably a resin excellent in electrical insulation. Specific examples include thermosetting resins such as epoxy resins, silicone resins, and unsaturated polyesters, and thermoplastic resins such as PPS resins and LCPs. The constituent material of the resin layer 42 can contain a filler having a high thermal conductivity such as alumina or silica (see the section of the heat dissipation member) from the viewpoint of improving the heat dissipation. In consideration of the thermal conductivity of the resin layer 42, the thermal conductivity of the constituent material is preferably 0.1 W / m · K or higher, more preferably 1 W / m · K or higher, particularly 2 W / m · K or higher. The resin layer 42 can be formed, for example, by using a sheet-like material, or by applying or spraying a raw material resin or the like on the inner bottom surface 4 i of the bottom plate portion 40.

-Sensor member The reactor 1A of this example is provided with the sensor member 7 which has the temperature sensor 70 which measures the temperature of the coil 2 of the reactor 1A, as shown in FIG. The sensor member 7 includes a temperature sensor 70, a protection unit 72 that covers and protects the temperature sensor 70, and an external device (not shown) such as a control device that is connected to the temperature sensor 70 and detects sensing information (electric signal) of the temperature sensor 70. Wiring 78 for transmitting to In this example, the temperature sensor 70 is disposed between the pair of winding parts 2a and 2b of the coil 2, as shown in FIG. Details of the arrangement state of the temperature sensor 70 will be described in the section of the heat dissipation member.

  The temperature sensor 70 is a sensor capable of measuring temperature, for example, a thermosensitive element such as a thermistor, a thermocouple, or a pyroelectric element. In this example, a thermistor is provided.

  The protection unit 72 only needs to protect the temperature sensor 70, and the composition, shape, size, and the like can be selected as appropriate. In this example, the protection portion 72 is a cylindrical body, and the length of the cylindrical body is shorter than the axial length of the winding portions 2 a and 2 b of the coil 2.

  Examples of the constituent material of the protection part 72 include resins such as a thermoplastic resin and a thermosetting resin. Examples of the thermoplastic resin include PPS resin, PTFE resin, LCP, PA resin such as nylon 6, PBT resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like. Examples of the thermosetting resin include unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins. These resins generally have a higher thermal conductivity than air. Since the protective part 72 made of such resin is interposed between the coil 2 and the temperature sensor 70, the heat of the coil 2 is reduced compared to the case where air exists around the temperature sensor 70. Can be satisfactorily transmitted to the temperature sensor 70. Moreover, since these resins are generally electrical insulating materials, electrical insulation between the coil 2 and the temperature sensor 70 can be ensured. The protection part 72 can be easily formed by using an appropriate molding method such as injection molding with the temperature sensor 70 as a core.

..Heat radiating member The heat radiating member 8A is an independent member that can be attached to the coil 2, and is disposed on the opening side of the case 4 as shown in FIGS. Cover part of body 10. Specifically, the heat radiating member 8 </ b> A is arranged so as to cover at least part of the opening side region of the case in the winding portions 2 a and 2 b of the coil 2. The heat radiating member 8 </ b> A functions as a heat radiating path that covers the specific region of the coil 2 to transmit the heat of the coil 2 from the opening side of the case 4 to the outside of the case 4. In order to effectively perform this function, the heat radiating member 8A includes a plate-like base 80 disposed opposite to the opening side region of the case in the winding portions 2a and 2b, and the outside of the base 80 toward the outside of the case 4. And a plurality of heat-dissipating protrusions 82 provided in a protruding manner. And in order to improve both the electrical insulation with the coil 2 which has metal as a main body, and the electrical insulation with the metal case 4, the case in winding part 2a, 2b among the inner surfaces of the base 80. The region opposite to the opening side region and the heat dissipating protrusion are made of a material containing resin. The heat radiating member 8A in this example is an integrally molded product in which the base 80 and the heat radiating protrusion 82 are integrally formed of a high thermal conductive resin.

... Base 80 A base 80 of the heat radiating member 8 </ b> A is a region disposed closer to or in contact with the windings 2 a and 2 b as the covering region of the windings 2 a and 2 b of the coil 2 with respect to the opening side region of the case 4 is larger. Increases heat dissipation to the outside of the case 4. In addition, the larger the covering area, the higher the stability of the disposition state of the heat radiating member 8A with respect to the coil 2, and the improvement of the heat dissipation due to the increase in the formation area of the heat dissipation projections 82. In this example, as shown in FIGS. 1 and 2, the base 80 has a shape and a size so that substantially the entire winding portions 2 a and 2 b and the coupling portion 2 r of the coil 2 are not exposed from the opening of the case 4. Has been adjusted. Specifically, as shown in FIGS. 1 and 4, the base 80 has a rectangular part when viewed from above and a part protruding in a triangular shape from one peripheral edge, and the rectangular part is a winding part 2 a, 2b is covered, and a triangular portion covers the connecting portion 2r. The length of the base portion 80 is substantially equal to the axial length of the winding portions 2a and 2b (FIG. 2), and the width of the base portion 80 is the size of the winding portions 2a and 2b in the parallel direction (winding portion). The total width of 2a and 2b) is substantially equal (FIG. 3). The base 80 is thick enough to support the plurality of heat-dissipating protrusions 82, and the portion near the both ends in the width direction and the central portion are thicker than the other portions (FIG. 3). The length is the size along the axial direction (left and right direction in FIG. 2) of the winding portions 2a and 2b, and the width is the parallel direction of the winding portions 2a and 2b (left and right direction in FIG. 3). The size along Hereinafter, the same applies to the length and width of each component. Here, the thickness is a size in a direction (vertical direction in FIG. 3) orthogonal to both the length direction and the width direction.

  In this example, the outer side surface (opening side surface of the case 4) of the base portion 80 of the heat radiating member 8A is substantially flat. In this example, the inner side surface of the base portion 80 (the surface facing the winding portions 2a and 2b of the coil 2) has a shape substantially along the opening side region of the case 4 in the winding portions 2a and 2b. That is, the inner surface of the base portion 80 has two corners arranged on the opening side (upper side) of the case 4 among the four corner R portions 20 in one winding portion 2a (or 2b) as shown in FIG. Contour formed by the R portions 20 and 20 and the opening side surface (rectangular upper surface 20u) of the case 4 sandwiched between the upper corner R portions 20 and 20 among the outer peripheral surfaces of one winding portion 2a (or 2b). It is a shape along. This inner side surface extends from the outer corner R portion 20 of one winding portion 2a through the upper surface 20u to the inner corner R portion 20 and between the winding portions 2a and 2b. A curved surface continuous from the inner corner R portion 20 of the portion 2b to the outer corner R portion 20 through the upper surface 20u, and the two curved surfaces (concave surfaces) are continuous. The portion of the base portion 80 disposed between the winding portions 2a and 2b is formed such that the central portion of the base portion 80 in the width direction protrudes (downward) toward the winding portions 2a and 2b. The cross section is an inverted triangular shape along the space created between the portions 2a and 2b. When the heat radiating member 8 </ b> A having the inner side surface corresponding to the outer shape of the coil 2 is arranged in the coil 2, the heat radiating member 8 </ b> A is stably supported by the coil 2 and is in close contact with the region disposed in contact with the coil 2. It has many areas and can improve heat dissipation.

... Sensor arrangement part Furthermore, heat dissipation member 8A of this example equips a part of inner surface of base 80 with sensor arrangement part 87 which positions temperature sensor 70 between a pair of winding parts 2a and 2b of coil 2. . Specifically, on the inner side surface of the base portion 80, a cylindrical shape that includes a temperature sensor 70 as shown in FIG. 3 and later-described FIG. 7 in a part of an inverted triangular section disposed between the winding portions 2a and 2b. Corresponding to the outer shape of the protective portion 72, a portion cut out in a circular arc shape in cross section. The notched portion is provided at the end portion of the curved portion so as to be orthogonal to the hook-shaped curved portion corresponding to the length of the protective portion 72 and the axial direction of the winding portions 2a and 2b. 72 and a flat surface portion with which at least a part of the circular end face abuts. The hook-shaped curved surface portion and the contact surface are referred to as a sensor placement portion 87.

  In the reactor 1A, as shown in FIG. 3, among the spaces formed between the pair of winding portions 2a and 2b, the corner R portions 20 and 20 that are opposed to each other, and the sensor placement portion on the inner surface of the above-described base portion 80 A space surrounded by 87 is defined as a location where the temperature sensor 70 is disposed. Therefore, in the portion provided with the sensor arrangement portion 87 on the inner side surface of the base portion 80, the two recessed portions according to the opening side region of the case 4 in the winding portions 2a and 2b, and the position between the two recessed portions, And a small concave portion corresponding to the protection portion 72. When the heat radiating member 8A is fixed by the sealing resin 100 in a state where the protective portion 72 is fitted into the curved surface portion of the sensor placement portion 87 and the end surface of the protective portion 72 is abutted against the flat portion, the temperature sensor 70 is wound. The turning portions 2a and 2b are held in contact with or in close proximity to the corner R portions 20 and 20 that are arranged to face each other. Therefore, the heat of the coil 2 is satisfactorily transmitted to the temperature sensor 70 via the protection unit 72. The shape, size, number, and the like of the sensor placement portion 87 can be changed as appropriate according to the shape, size, number of sensor members 7 (protection portions 72).

  Further, the heat dissipating member 8A of this example is provided with a through hole 87h in the base portion 80 for drawing the wiring 78 connected to the temperature sensor 70 from the inner surface to the outer surface of the heat dissipating member 8A as shown in FIG. Specifically, the base portion 80 includes a through hole 87h in the vicinity of the peripheral edge disposed on the coupling portion 2r side of the coil 2 (see also FIG. 6 described later). The shape, size, number, and the like of the through holes 87h can be selected as appropriate as long as the wiring 78 can be inserted. For example, the size and shape of the through-hole 87 h is a circular hole having a diameter equivalent to the outer diameter of the columnar protection part 72, and the size and shape greater than the outer diameter of the columnar protection part 72. The protective part 72 can be inserted as a hole. In this case, the protection part 72 can be easily arranged in the vicinity of the sensor arrangement part 87 on the inner side surface from the outer side surface of the heat radiating member 8A through the through hole 87h. The movement of the wiring 78 inserted into the through hole 87h is restricted to some extent. From this point, the through hole 87h can also function as a movement restricting portion of the wiring 78. By increasing the number of through-holes 87h and inserting the wiring 78 into each hole, the movement of the wiring 78 can be controlled more reliably. In addition to the through hole 87h, the base portion 80 includes a hook portion (not shown) for hooking the wiring 78 and a connector support portion for locking a connector portion (not shown) connected to the end of the wiring 78. Can do. Instead of the through hole 87h, a notch may be used.

  In addition, the base portion 80 of this example includes two notches into which the respective end portions of the winding 2w are respectively fitted on the peripheral edge arranged on the end portion side of the winding 2w (FIG. 4).

  The shape and size of the base 80 can be changed as appropriate. For example, the surface area of the outer surface of the base portion 80 where the heat-dissipation protrusions 82 are not provided is curved to further increase the surface area, or the sensor arrangement portion 87 is omitted when the temperature sensor 70 is not provided. In order to reduce the length, the notch for fitting the end of the winding 2w can be omitted.

... Heat dissipation protrusions The heat dissipation protrusions 82 have a smaller width and length (connection area to the outer surface of the base 80), a longer protrusion height, a larger number, and a larger surface area. Excellent. In this example, a plurality of flat plate-like heat-dissipating projections 82 are aligned from the outer surface of the base 80. Specifically, as shown in FIGS. 1 and 3, the heat dissipation protrusion 82 is a rectangular flat plate having a width substantially equal to the size in the parallel direction of the winding portions 2 a and 2 b of the coil 2. The heat dissipation projections 82 are arranged in parallel at equal intervals in the axial direction of the winding portions 2a and 2b (see also FIG. 2). It is expected that the heat of the coil 2 can be dissipated well from the place where the temperature can be highest in the coil 2 by providing each of the heat dissipation protrusions 82 so as to straddle the pair of winding portions 2a and 2b. Further, this shape is expected to increase the rigidity of the heat dissipation member 8A. Furthermore, if the heat dissipation protrusions 82 are such a wide flat plate shape, the surface area of each heat dissipation protrusion 82 is large, the contact area with the atmosphere outside the case 4 can be increased, and heat dissipation can be improved. It is expected. Even if it is such a large area, if it is a rectangular flat plate shape, since it is a simple shape, it is excellent in moldability.

  The protrusion height of the heat dissipation protrusion 82 from the outer surface of the base 80 can be selected as appropriate. A higher height is preferable because the contact area of the heat dissipation protrusion 82 with the atmosphere outside the case 4 can be increased. As shown in this example, when the heat radiating member 8A is attached to the coil 2, the protruding height can be adjusted so that the ends (outer peripheral edges in this example) of all the heat radiating protrusions 82 protrude from the opening edge of the case 4. . In this case, the heat-dissipating protrusion 82 can always be in contact with the atmosphere outside the case 4 and is expected to have a high heat-dissipating effect. In this case, the protruding height may be selected within a range that does not cause an increase in the size of the reactor 1A. On the other hand, among the plurality of heat radiation protrusions 82, at least one of the heat radiation protrusions 82 does not protrude from the opening edge of the case 4, and the height of the protrusion can be adjusted to be equal to or less than the opening edge of the case 4. . In this case, among the plurality of heat-dissipating protrusions 82, the side wall 41 of the case 4 is higher and there may be one surrounded by the side wall 41. However, even these heat-dissipating protrusions 82 protrude from the upper surfaces 20u of the winding portions 2a and 2b of the coil 2, so that they can come into contact with the atmosphere outside the case 4 and a heat dissipation effect can be expected. Further, in this case, there are few protrusions from the case 4, and the protrusions can be made about the ends of the windings 2 w and the wiring 78, so that a small reactor 1 </ b> A can be obtained. The width and length of the heat dissipating protrusion 82 may be appropriately selected so that the contact area can be sufficiently increased. Moreover, it is preferable that the formation region of the heat dissipation projection 82 on the outer surface of the base portion 80 includes at least a portion that covers the winding portions 2 a and 2 b of the coil 3 in the base portion 80. The planar area of the formation region on the outer side surface is preferably equal to or greater than the product of the axial length of the winding portions 2a and 2b and the total width of the winding portions 2a and 2b as in this example.

  As other heat radiation protrusions 82, a plurality of plate-shaped heat radiation protrusions 82 are arranged from the outer surface of the base portion 80 in the same manner as the heat radiation member 8A, for example, as in the heat radiation member 8C shown in FIGS. The alignment direction can be different. In the heat radiating member 8A shown in FIG. 1 and the like, the plurality of heat radiating protrusions 82 are arranged side by side, whereas in the heat radiating member 8C shown in FIGS. 6 and 7, the heat radiating protrusions 82 are arranged vertically. Specifically, the heat dissipation protrusion 82 is a rectangular flat plate having a length substantially equal to the axial length of the winding portions 2a and 2b of the coil 2, and the longitudinal direction of each heat dissipation protrusion 82 is wound. The portions 2 a and 2 b are arranged so as to be parallel to the axial direction, and are arranged in parallel in the width direction of the base portion 80 at equal intervals. In addition, since the heat dissipation protrusion 82 has a flat plate shape, the heat dissipation member 8C is excellent in moldability as well as the heat dissipation member 8A described above. The base 80 of the heat radiating member 8C and the heat radiating member 8D shown in FIG. 8 to be described later is the same as the base 80 of the heat radiating member 8A shown in FIG.

  As the other heat radiation projections 82, for example, a plurality of rod-shaped heat radiation projections 82 can be arranged from the outer surface of the base portion 80 as in a heat radiation member 8D shown in FIGS. In the heat radiating member 8 </ b> D, round rod-shaped heat radiating protrusions 82 are arranged in parallel at equal intervals in both the axial direction of the winding portions 2 a and 2 b of the coil 2 and the width direction of the base portion 80. Although the size of one heat dissipation protrusion 82 is small to some extent, the heat dissipation member 8D is provided with a very large number of heat dissipation protrusions 82. As a result, the surface area can be greatly increased and the heat dissipation is excellent. The heat-dissipating protrusions 82 can be formed into a rectangular column shape such as a rectangular parallelepiped or a non-cylindrical shape such as an elliptical column in addition to a round bar.

  In addition, the heat radiating member 8A can be provided with a combination of heat radiating protrusions having different shapes and sizes. For example, the shape, size, number, etc. of the heat dissipation protrusions can be changed according to the temperature distribution of the coil 2 at the base 80. The region covering the space between the winding portions 2a and 2b of the coil 2 in the base 80 is likely to be high temperature, and the region covering the upper surface 20u of the winding portions 2a and 2b is high temperature, for example. Many heat-dissipating protrusions with reduced width and length or increased protrusion height are provided in the easy area, the surface area is locally increased, and the protrusion height is reduced in areas where the temperature does not increase so much. It is possible to provide heat dissipation protrusions or to reduce the number of heat dissipation protrusions.

... Constituent material As the constituent material such as the heat radiating member 8A, a high thermal conductive resin can be suitably used. Here, the high thermal conductive resin has a thermal conductivity of 1 W / m · K or more and includes about 30% by volume to 70% by volume of resin. Examples of such a high thermal conductive resin include a resin containing a filler having a high thermal conductivity. Specific examples of the resin include PPS resin, PTFE resin, LCP, PA resin such as nylon 6 and nylon 66, thermoplastic resin such as polyester resin such as PBT resin, and thermosetting resin such as epoxy resin and phenol resin. If the filler is a non-metallic inorganic material such as an inorganic compound such as ceramics, it is preferable because of excellent electrical insulation. Examples of the inorganic compound include oxides such as alumina and silica, nitrides such as silicon nitride, aluminum nitride, and boron nitride, and carbides such as silicon carbide. The higher the thermal conductivity of the high thermal conductive resin is, the higher the heat dissipation member 8A, etc., which is more excellent in heat dissipation. 1W or more, 2W / m · K or more, 3W / m · K or more, 5W / m · K or more. More preferred. Although the thermal conductivity of the high thermal conductive resin tends to increase as the filler content increases, if the content is too large, the moldability may be reduced. Considering the moldability of the heat radiating member 8A and the like, it is considered that a high thermal conductive resin of about 10 W / m · K or less is easy to use. The heat radiating member 8A and the like have a complicated three-dimensional shape, but can be easily and accurately formed by using a well-known molding method such as injection molding of a high thermal conductive resin.

-Sealing resin In the reactor 1A of this example, as shown in FIG. 1, FIG. 2, the case 4 is filled with sealing resin 100. In FIG. In the combination 10 housed in the case 4, substantially the entire coil 2 is embedded in the sealing resin 100 except for the end of the winding 2 w of the coil 2. In this example, as shown in FIG. 2, a part of the base 80 of the heat radiating member 8A is embedded, and the sealing resin 100 is filled in the case 4 to the extent that the entire heat radiating protrusion 82 is exposed. . The sealing resin 100 is also interposed between the opening side region of the case 4 in the winding portions 2a and 2b of the coil 2 and the region covering the opening side region of the coil 2 on the inner side surface of the base 80 of the heat radiating member 8A. (FIG. 3). A portion of the sealing resin 100 in which the base portion 80 is embedded or a portion interposed between the winding portions 2a and 2b and the base portion 80 functions as a portion that fixes the winding portions 2a and 2b and the heat dissipation member 8A.

  By adjusting the filling amount of the sealing resin 100, the above-described fixing function can be further enhanced. For example, the sealing resin 100 may be provided to such an extent that the vicinity of the connection portion with the base 80 in the heat dissipation protrusion 82 is embedded. That is, the sealing resin 100 can be provided so as to cover at least a part of the outer surface of the base 80. In this case, the contact area between the heat radiating member 8A and the sealing resin 100 is increased, and the inner surface and the outer surface of the base 80 are sandwiched between the sealing resins 100 so that the heat radiating member 8A is firmly held by the sealing resin 100. Can be realized. As a result, the winding portions 2a and 2b of the coil 2 and the heat dissipation member 8A can be firmly fixed. When the entire outer surface of the base 80 is exposed from the sealing resin 100 as in this example, it is expected that the heat dissipation is more excellent.

  In addition, the sealing resin 100 in this example also functions as a filler that fills a space that can occur around the sensor member 7 (FIG. 3). Since the periphery of the sensor member 7 is covered with the sealing resin 100 and the air gap (air) is reduced or preferably eliminated, the heat of the coil 2 is passed through the protection portion 72 of the sensor member 7 and the sealing resin 100. The temperature sensor 70 is well transmitted. Therefore, the reactor 1 </ b> A can measure the temperature of the coil 2 with high accuracy and stability as compared with the case where a substance having poor thermal conductivity such as air exists around the sensor member 7.

  For the sealing resin 100, for example, an epoxy resin, a urethane resin, a silicone resin, an unsaturated polyester resin, or the like can be used. From the viewpoint of improving heat dissipation, the sealing resin 100 can contain the above-described filler such as alumina or silica.

-Reactor manufacturing method The reactor 1A includes, for example, the following preparation process, assembly process, housing process, sealing resin filling process, heat radiation member disposing process, and sealing resin solidifying process. It can manufacture with the manufacturing method of. The outline of each process will be described.

  In the preparation step, the coil 2, the core pieces 31m and 32m, the gap material 31g, the interposition member 5, the case 4, the sensor member 7, and the heat radiating member 8A are prepared (FIGS. 4 and 5). The sensor member 7 is attached to the heat radiating member 8A. For example, the protection part 72 is arranged on the sensor arrangement part 87 of the base 80 of the heat radiating member 8A, and the wiring 78 is pulled out from the insertion hole 87h.

  In the assembly process of the combined body, the combined body 10 including the coil 2 and the magnetic core 3 is produced (FIG. 5). In this example, two laminates obtained by alternately laminating core pieces 31m and gap members 31g, U-shaped core pieces 32m and 32m, split members 50a and 50b of the interposition member 5, and winding of the coil 2 The assembly 2 is produced by assembling the parts 2a and 2b.

  In the storing process in the case, the combined body 10 is stored in the case 4 (FIG. 4). In this example, a resin layer 42 is interposed between the lower surface of the combined body 10 and the inner bottom surface 4 i of the case 4. If a resin sheet or the like is used for the resin layer 42, the arrangement workability is excellent. The resin layer 42 can also be formed by appropriately applying a resin to the inner bottom surface 4i. In this example, the combination 10 is further fixed in the case 4 by appropriately using bolts, screws (not shown), belt-like fixing members such as stays, and the like.

  In the sealing resin filling process, the unsolidified resin is filled into the case 4 in which the combination 10 is stored. At this time, since the heat dissipating member 8A is not disposed, filling and deaeration can be easily performed from a gap between turns from the coil 2.

  In the heat dissipating member arranging step, the heat dissipating member 8A is arranged at a predetermined position of the assembly 10 when the above-described filled resin is in an unsolidified state. In this example, the temperature sensor 70 is disposed between the corner R portions 20 and 20 of the winding portions 2a and 2b of the coil 2, and a part of the inner surface (the winding portions 2a and 2b) of the base portion 80 of the heat radiating member 8A. The heat dissipating member 8A is arranged so that the region facing 2b covers the opening side region of the case 4 in the winding portions 2a and 2b (FIGS. 2 and 3). The unsolidified resin pushed away by placing the heat radiating member 8A and the temperature sensor 70 appropriately fills the base 80 of the heat radiating member 8A, the periphery of the temperature sensor 70, and the like. There is a case where a part of the unsolidified resin fills a part of the heat radiation protrusion 82.

  In the sealing resin solidifying step, the above-mentioned unsolidified resin is solidified to form the sealing resin 100 (FIGS. 1 and 2). By the solidification of the sealing resin 100, the reactor 1A shown in FIG. 1 is obtained.

-Effect The reactor 1A of Embodiment 1 cools the bottom side of the case 4 by providing the heat radiating member 8A having a specific heat radiating protrusion 82 on the opening side of the case 4 in the winding portions 2a and 2b of the coil 2. Even if attached to the installation object 1000 to be obtained, the temperature difference between the bottom side region and the opening side region of the case 4 in the winding parts 2a and 2b can be reduced. In particular, in the reactor 1A, the coil 2 includes a pair of winding portions 2a and 2b in parallel, and a gap may be formed between the winding portions 2a and 2b, but the coil 2 and the heat dissipation member 8A are independent. Therefore, the heat dissipation protrusion 82 can be provided so as to cross this gap. Since the heat dissipation protrusion 82 can be disposed in the vicinity of the gap between the winding portions 2a and 2b where the temperature tends to increase, the reactor 1A can sufficiently reduce the temperature difference. Therefore, the reactor 1A can suppress the temperature rise over the entire coil 2, and adverse effects on the characteristics due to the local temperature rise and thermal stress due to the occurrence of local high temperature portions in the sealing resin 100, Thermal damage of components around the coil 2 can be suppressed. As a result, it can be said that the reliability and durability of the reactor 1A can be improved.

  And since the heat radiating member 8A contains the resin which is an electrical insulating material, between the heat radiating member 8A (inner side surface of the base 80) and the winding parts 2a and 2b of the coil 2, and the heat radiating member 8A (heat radiating protrusion 82). Excellent electrical insulation between the case 4 and the case 4 (inner peripheral surface or opening edge of the side wall 41). In particular, in the reactor 1A, since the heat radiating member 8A is mainly composed of a resin and a ceramic filler excellent in thermal conductivity and electrical insulation, the reactor 1A is more excellent in electrical insulation.

In addition, the reactor 1A of this example has the following effects.
-Since the winding parts 2a and 2b of the coil 2 and the heat radiating member 8A are fixed by the sealing resin 100, heat transfer between the winding parts 2a and 2b and the heat radiating member 8A can be performed satisfactorily, and thus heat radiation. Excellent in properties.
Since the temperature sensor 70 is provided and the temperature sensor 70 is held at a predetermined position by the sensor placement portion 87 of the heat radiating member 8A, the temperature of the coil 2 can be measured with high accuracy. Since the sealing resin 100 can reduce a gap that may occur around the temperature sensor 70 (protection unit 72), the temperature of the coil 2 can be measured with high accuracy.
・ Since the heat radiating member 8A is an integrally molded product of highly heat conductive resin, it has a high heat conductivity and a heat radiating path with uniform thermal characteristics compared to the case where the heat radiating member is an assembly of multiple parts. Excellent heat conductivity from the point that it can be done. Also from this point, heat dissipation is excellent.
-Since the heat dissipating member 8A is an integrally molded product of a high thermal conductive resin, it has advantages such that it can be easily molded and is excellent in manufacturability, easy to handle, and excellent in workability such as arrangement and conveyance.
The case 4 can protect the assembly 10, especially the coil 2 and the magnetic core 3 from the external environment (dust, corrosion, etc.) and mechanical protection.
-Since case 4 is a metal integral molding, it is excellent in the intensity | strength of case 4 itself and the intensity | strength of the reactor 1A whole can be raised.
By providing the sealing resin 100, the combined body 10 can be fixed to the case 4, and the electrical / mechanical protection of the combined body 10, protection from the external environment, and the magnetic core 3 caused by energization of the coil 2 It is possible to reduce vibration and noise caused by the vibration.
Since the heat dissipation protrusion 82 is disposed in the region where the temperature is likely to be the highest, even if another heat dissipation member is not disposed in the region (side surface) of the coil 2 facing the side wall 41 of the case 4. The heat of the coil 2 can be dissipated efficiently. Therefore, it is difficult to increase the size and the size can be reduced.

[Embodiment 2]
With reference to FIG. 10, FIG. 11, the reactor 1B of Embodiment 2 is demonstrated. In the first embodiment, as the heat radiating members 8A, 8C, and 8D, the configuration has been described in which the inner surface has a shape corresponding to the outer shape in which the winding portions 2a and 2b of the coil 2 are gathered together. In the reactor 1B of the second embodiment, the shape of the heat radiating member 8B is different from that of the heat radiating member 8A and the like, and protrusions protruding from the outer surface and the inner surface of the base 80 of the heat radiating member 8B (heat radiating protrusions 82, intervening protrusions). 84) is the main difference from the first embodiment. The inner shape of the heat radiating member 8B also corresponds to the interval between the turns in the winding portions 2a and 2b. Hereinafter, this difference will be described in detail, and a detailed description of overlapping configurations and effects will be omitted. 10 shows a longitudinal sectional view of the reactor 1B cut along a plane parallel to the axial direction of the winding portion 2a of the coil 2. FIG. FIG. 11 is a cross-sectional view of the reactor 1B cut along a plane perpendicular to the axial direction of the winding portions 2a and 2b, and shows the vicinity of the heat dissipation member 8B in an enlarged manner. The temperature sensor 70 is omitted.

-Overall configuration The basic configuration of the reactor 1B is the same as the reactor 1A of the first embodiment. Briefly, as shown in FIG. 10, a reactor 1B includes a coil 2 having a pair of winding portions 2a and 2b (FIG. 11) formed by winding a winding 2w in a spiral shape, and a winding portion 2a, 2b, a magnetic core 3 having a portion arranged in 2b, a case 4 housing a combination 10 including the coil 2 and the magnetic core 3, a sealing resin 100 filled in the case 4, and a winding portion 2a , 2b, a heat radiating member 8B disposed so as to cover at least a part of the opening side region (upper region) of the case 4 is provided.

Heat dissipation member The heat dissipation member 8B includes a plate-like base 80 and a plurality of heat dissipation protrusions 82 protruding from the outer surface of the base 80 toward the outside of the case 4. The heat dissipating member 8B further protrudes from the inner surface of the base portion 80 from a region facing the winding portions 2a and 2b of the coil 2, and a plurality of intervening protrusions 84 interposed between the turns of the winding portions 2a and 2b. Is provided. That is, it can be said that the heat radiating member 8 </ b> B has protrusions for improving heat dissipation on both the inside and outside of the base 80. As in the first embodiment, the inner side surface of the base portion 80 in this example has an m-shape generally along the outer shape of the winding portions 2a and 2b of the coil 2, and each intervening protrusion 84 projecting from the inner side surface. Is interposed between turns. The heat radiating member 8B in this example is an integrally molded product in which a base 80, a plurality of heat radiating protrusions 82, and a plurality of intervening protrusions 84 are integrally formed of a high thermal conductive resin.

..Interposition protrusion The interposition protrusion 84 is interposed between the turns of the winding portions 2a and 2b of the coil 2, reduces a gap that may be generated between the turns, and is used as a heat dissipation path for heat from the coil 2. In consideration of heat dissipation, it is preferable that the interposition protrusion 84 exists in contact with the turn or indirectly through the sealing resin 100.

The shape, size, and the like of the interposition protrusion 84 can be selected as appropriate.
In terms of size, for example, the thickness of the intervening protrusion 84 can be made thinner than a predetermined interval between the turns (interval in the natural length of the coil 2). In this case, it is possible to reduce the gap between turns by inserting the interposition protrusion 84. Further, in this case, when inserting the interposition protrusion 84 between the turns, it is difficult to contact the winding 2w forming the turn, and damage due to the contact is hardly caused.
Alternatively, for example, the thickness of the intervening protrusion 84 can be equal to or greater than a predetermined interval between turns. In this case, the turn and the interposition protrusion 84 can be in contact with each other, and the heat dissipation is excellent. Further, in this case, each interposition protrusion 84 is sandwiched between adjacent turns, and the heat radiating member 8 </ b> B is firmly held by the coil 2. Therefore, in this case, the coil 2 and the heat radiating member 8B are firmly fixed without omitting the sealing resin 100 or using a separate adhesive or the like.
Alternatively, for example, the protruding length of the interposing protrusion 84 can be made substantially equal to the width of the winding 2w that forms the turn, or the width of the interposing protrusion 84 can be increased. In this case, the contact area between the turn and the interposition protrusion 84 can be increased, and the heat dissipation is excellent.
Alternatively, for example, the protruding length of the interposing protrusion 84 can be shortened, or the width of the interposing protrusion 84 can be reduced. In these cases, the interposition protrusion 84 can be easily inserted between turns, and the assembly workability is excellent.

  When describing the shape of the interposition protrusion 84, it is considered that a flat plate or the like is easy to use like the heat dissipation protrusion 82 described in the first embodiment. As shown in FIG. 11, the intervening protrusion 84 in this example is a rectangular flat plate, the width of which is about the width of the upper surface 20u of the winding portions 2a, 2b of the coil 2, and the protruding length is the winding length. It is about half the width of 2w.

-Reactor manufacturing method The reactor 1B of Embodiment 2 can be manufactured with the manufacturing method of the reactor demonstrated in Embodiment 1, for example. Particularly, in the heat dissipating member disposing step, the interposing protrusion 84 of the heat dissipating member 8B is inserted between the turns of the winding portions 2a and 2b of the coil 2, and the heat dissipating member 8B is disposed on the coil 2. Since the sealing resin 100 is in an unsolidified state, the interposition protrusion 84 can be easily inserted.

-Effect Since the reactor 1B of Embodiment 2 is equipped with the heat radiating member 8B which is a molded object of highly heat conductive resin, there exists an effect similar to Embodiment 1. FIG. To describe typical effects, the reactor 1B can reduce the temperature difference between the bottom side region and the opening side region of the case 4 in the winding portions 2a and 2b of the coil 2, and also the inner surface and winding of the heat radiating member 8B. It is excellent in electrical insulation between the turn portions 2a and 2b and between the heat radiation protrusion 82 of the heat radiation member 8B and the inner peripheral surface and the opening edge of the side wall portion 41 of the case 4.

  In particular, the reactor 1B has an interposition protrusion 84 interposed between the turns of the winding portions 2a and 2b of the coil 2. Therefore, the heat of the coil 2 is good outside the case 4 by the heat dissipation protrusion 82 from the interposition protrusion 84 through the base portion 80. The heat dissipation is superior. Further, since the interposition protrusion 84 is an electrical insulating material made of a high thermal conductive resin, the electrical insulation between the winding portions 2a, 2b (turns) and the heat radiating member 8B (interposition protrusion 84) is excellent. Since not only the base portion 80 but also the interposing protrusions 84 are embedded in the sealing resin 100, the heat radiating member 8B is firmly held by the sealing resin 100, and the winding portions 2a and 2b and the heat radiating member 8B are both encapsulating resin. 100 is firmly fixed. Also from this point, the reactor 1B is more excellent in heat dissipation.

[Modification 1]
In the first and second embodiments, the form in which the case 4 is an integrally formed product of metal has been described. In addition, the bottom plate part 40 and the side wall part 41 are independent members, and can be combined to form one case. In this embodiment, the constituent material of the bottom plate portion 40 and the constituent material of the side wall portion 41 can be made different. For example, the bottom plate portion 40 can be made of metal and the side wall portion 41 can be made of resin. In this case, the resin layer 42 is formed in a state in which the case 4 is lightweight and the side wall 41 is removed, which is excellent in electrical insulation between the coil 2 and the side wall 41 and between the heat radiation member 8A and the side wall 41. And the combination 10 can be placed and the workability is excellent. On the other hand, when the side wall part 41 is made of resin, the heat of the coil 2 is easily generated in the case 4 as compared with the case where the side wall part 41 is made of metal. However, even in this case, since the heat radiating member 8A is provided, the temperature difference between the bottom side region of the case 4 and the opening side region in the coil 2 can be reduced.

  When the side wall 41 is made of resin, examples of the constituent resin include PBT resin, urethane resin, PPS resin, and ABS resin. The resin side wall 41 can be easily manufactured by a known molding method such as injection molding.

  Or the baseplate part 40 and the side wall part 41 are independent members, and both can be made of metal. In this case, metals having different compositions can be used for the bottom plate portion 40 and the side wall portion 41.

  Or only the mounting area | region of the coil 2 in the baseplate part 40 is a form which is a metal, ie, a metal area | region is provided only in a part of the baseplate part 40, and another part can be made into resin.

[Modification 2]
In the first and second embodiments, the form in which the sealing resin 100 is filled in the case 4 has been described. In addition, the sealing resin 100 can be omitted. In this case, it is preferable to fix the coil 2 and the heat radiating member 8A and the like with an adhesive or the like because both can be firmly fixed and the gap between the two can be reduced.

[Modification 3]
In the first and second embodiments, the configuration in which the heat radiating member 8A and the like are integrally molded mainly composed of resin has been described. In addition, a part of the base portion 80 may include a portion made of a material having higher thermal conductivity than the resin, that is, a non-metallic inorganic material such as metal or alumina (see the above-mentioned filler section). In this case, it is expected that the heat dissipation can be further improved. Even when metal is included in a part of the base portion 80, a region that can come into contact with the coil 2 in the heat radiating member, that is, a region facing the winding portions 2a and 2b on the inner side surface of the base portion 80, and the case 4 (particularly metal The heat dissipation projection 82 and the like which are disposed in close proximity to or in contact with the side wall 41) include an electrically insulating material such as resin, so that electrical insulation between the coil 2, the heat radiating member and the case 4 can be achieved. Excellent.

  A flat plate or the like can be used as the metal or non-metallic inorganic material included in the base 80. By using this flat plate as a core and insert-molding the above-described high thermal conductive resin or the like, a heat radiating member including a flat plate of a metal or a non-metallic inorganic material in a part of the base 80 can be easily manufactured.

[Test Example 1]
The reactor 1A of Embodiment 1 was produced, and the temperature difference between the bottom side region and the opening side region of the case 4 in the winding portions 2a and 2b of the coil 2 was measured. As a comparison, a reactor having the same configuration was manufactured except that the heat radiating member 8A was not provided, and the temperature difference was measured in the same manner.

  In this test, both the reactor 1A of the first embodiment and the comparative reactor are energized to the coil with the bottom of the case placed on the simulation target, and the temperature Td of the bottom side region of the case at the coil winding portion. And the temperature Tu of the opening side region were measured. The simulation target is a simulation of an installation target having a cooling structure. The temperatures Td and Tu were measured by placing temperature sensors between the two corner R portions located on the bottom side of the case in the winding portion and between the two corner R portions located in the opening side region of the case. . In this test, the case is made of an aluminum alloy in which a bottom plate portion and a side wall portion are integrally formed, and the heat radiating member 8A is a high thermal conductive resin with a thermal conductivity of 1 W / m · K to 10 W / m · K. It was set as the integral molded product manufactured by injection molding using the thermoplastic resin which satisfy | filled and contained the ceramic filler.

  As a result, based on the temperature difference (Tu−Td) in the comparative reactor, the temperature difference (Tu−Td) in the reactor 1 </ b> A of the first embodiment was 5 ° C. lower and the temperature difference was smaller. From this test, it is confirmed that the reactor 1 </ b> A according to the first embodiment including a specific heat radiating member at a specific location can reduce a temperature difference between the bottom side region and the opening side region of the case in the winding portions 2 a and 2 b of the coil 2. It was done.

  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. For example, it can be set as the reactor provided with a coil with only one winding part.

  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.

1A, 1B Reactor 10 Combination 100 Sealing resin 1000 Installation object 2 Coil 2w Winding 2a, 2b Winding part 2r Connecting part 20 Corner R part 20u Upper surface (opening side of case)
3 Magnetic core 31m, 32m Core piece 31g Gap material 32e Inner end face 4 Case 4d Bottom face 4i Inner bottom face 40 Bottom plate part 41 Side wall part 42 Resin layer 5 Interposition member 50a, 50b Dividing material 51 Inner interposition part 52 End face interposition part 52h Through hole 7 Sensor member 70 Temperature sensor 72 Protection part 78 Wiring 8A, 8B, 8C, 8D Heat radiation member 80 Base 82 Heat radiation protrusion 84 Interposition protrusion 87 Sensor arrangement part 87h Insertion hole

Claims (5)

A coil having a winding portion formed by spirally winding a winding;
A magnetic core having a portion disposed in the winding portion;
A case for housing a combination including the coil and the magnetic core;
A heat dissipating member arranged to cover at least a part of the opening side region of the case in the winding part,
The bottom of the case includes a metal region on which the combination is placed,
The heat dissipating member includes a base and a plurality of heat dissipating protrusions protruding from the outer surface of the base toward the outside of the case,
Of the inner side surface of the base portion, a region facing the winding portion and the heat dissipation protrusion are a reactor including a resin.   The reactor of Claim 1 provided with the sealing resin with which the said case is filled and which has a part which fixes the said winding part and the said heat radiating member.   The said heat radiating member is provided in the inner surface of the said base part from the opposing area | region with the said winding part, and is provided with the some interposition protrusion interposed between the turns of the said winding part. The reactor described in. A temperature sensor for measuring the temperature of the coil;
The coil has a pair of the winding portions arranged in parallel so that the axes thereof are parallel to each other,
The reactor according to any one of claims 1 to 3, wherein the heat radiating member includes a sensor arrangement portion that positions the temperature sensor between the pair of winding portions.   The reactor according to any one of claims 1 to 4, wherein the heat radiating member is an integrally molded product of a high thermal conductive resin having a thermal conductivity of 1 W / m · K or more.

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