JP2016119419A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of firmly fixing an assembly to a mounting plate.SOLUTION: A reactor 1α comprises an assembly 1, which includes a coil 2 having winding portions 2A and 2B and magnetic cores 3, and a mounting plate 9 on which the assembly 1 is mounted. The reactor 1α holds the upper surface of an outside core portion 32 arranged outside the wiring portions 2A and 2B among the magnetic cores 3 and includes a stay 7 for fixing the position of the assembly 1 with respect to the mounting plate 9. The outside core portion 32 includes a core side engaging portion 3f formed on the upper surface thereof. The stay 7 includes a stay side engaging portion 7f which is engaged with the core side engaging portion 3f.SELECTED DRAWING: Figure 2

Description

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

  Magnetic parts such as reactors and motors are used in various fields. As such a magnetic component, for example, Patent Document 1 discloses a reactor used in a converter of a hybrid vehicle.

  Patent Document 1 discloses a reactor in which a combined body having a coil and a magnetic core is housed in a case. Patent Document 1 discloses that an installation surface portion (mounting plate) that is a bottom surface of a case is made of metal in order to efficiently release heat generated in the assembly to the outside. Furthermore, in the reactor of this patent document 1, in order to make it easy to let heat escape from an assembly to a case, forming the thermal radiation layer in the installation surface part (mounting board) of a case is disclosed.

  The heat dissipation layer can be composed of a ceramic sintered plate, an epoxy-based adhesive, or the like. In particular, by forming the heat dissipation layer with an adhesive such as a resin, the heat dissipation layer can have a function as a bonding layer for fixing the assembly to the installation surface portion (mounting plate). If the heat dissipation layer functions as a bonding layer, the adhesion between the coil of the assembly and the heat dissipation layer can be improved, and the heat of the assembly can be efficiently released to the installation surface portion (mounting plate) of the case.

JP 2011-243943 A

  With the development of electric vehicles in recent years, the use of reactors with high-frequency, large currents has been studied. Since a reactor used at a high frequency and high current tends to vibrate vigorously, a reactor capable of firmly fixing the combined body with a mounting plate is required.

  This invention is made | formed in view of the said situation, and the one of the objective is to provide the reactor which can fix an assembly to a mounting board firmly.

  The reactor which concerns on 1 aspect of this invention concerns on a reactor provided with the union body which has the coil which has a winding part, and a magnetic core, and the mounting board in which the said union body is mounted. The reactor includes a stay that presses an upper surface of an outer core portion arranged outside the winding portion of the magnetic core and fixes the position of the assembly with respect to the mounting plate. And a core-side engaging portion formed on the upper surface thereof, and the stay includes a stay-side engaging portion engaged with the core-side engaging portion.

  According to the reactor, the reactor can be firmly fixed to the installation plate.

It is an upper perspective view of the reactor of Embodiment 1. It is a disassembled perspective view of the reactor of Embodiment 1. FIG. It is a disassembled perspective view of the union body with which the reactor of Embodiment 1 is equipped. It is an upper perspective view of the reactor of Embodiment 2. It is a disassembled perspective view of the reactor of Embodiment 2. It is a disassembled perspective view of the union body with which the reactor of Embodiment 2 is equipped.

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

The reactor of <1> embodiment concerns a reactor provided with the assembly which has a coil which has a winding part, and a magnetic core, and the mounting board in which the said assembly is mounted. The reactor includes a stay that presses an upper surface of an outer core portion arranged outside the winding portion of the magnetic core and fixes the position of the assembly with respect to the mounting plate. And a core-side engaging portion formed on the upper surface thereof, and the stay includes a stay-side engaging portion engaged with the core-side engaging portion.

  By engaging the core side engaging portion and the stay side engaging portion as in the above configuration, the outer core portion can be firmly fixed by the stay. This is because the displacement between the outer core portion and the stay is less likely to occur due to the engagement of both the engaging portions.

<2> As the reactor of the embodiment, the core side engaging portion is formed in a concave shape, and the stay side engaging portion is formed in a convex shape that matches the concave shape of the core side engaging portion. Can be mentioned.

  The engagement strength between the outer core portion and the stay can be increased when the core-side engagement portion is concave and the stay-side engagement portion is convex, rather than the opposite. Further, since the outer core portion is generally lower in strength than a stay made of metal or the like, the core side engagement portion is less likely to be damaged when the core side engagement portion is made convex than the convex shape. .

<3> As the reactor of the embodiment, the mounting plate may include a columnar fixing portion that is disposed so as to surround the assembly and to which the stay is fixed.

  By providing the columnar fixing portion that surrounds the combined body, the position of the combined body on the mounting plate can be accurately determined. Further, when the combined body vibrates, the columnar fixing portion surrounding the combined body becomes a stopper, and it is possible to suppress an excessive stress from acting on the bonding layer that joins the combined body to the mounting plate.

<4> As an example of the reactor including the columnar fixing portion, the upper end surface of the columnar fixing portion and the upper surface of the outer core portion may be on the same plane.

  According to the said structure, an assembly can be fixed to a mounting board using a flat stay. The flat stay is easy to attach to the upper surface of the outer core portion, and it is easy to fix the stay to the columnar fixing portion. Further, if the stay is flat and does not have a bent portion, problems such as bending of the stay due to stress accompanying vibration of the combined body are unlikely to occur.

As a reactor of <5> embodiment, the form provided with the joining layer which joins the said assembly to the above-mentioned mounting board between the said assembly and the above-mentioned mounting board can be mentioned.

  By forming the bonding layer between the combination body and the mounting plate, it is possible to more firmly fix the combination body to the mounting plate and to suppress the positional deviation of the combination body on the mounting plate.

<6> As the reactor of the embodiment, the outer core portion may include a composite material including soft magnetic powder and resin.

  The composite material can easily adjust its magnetic properties by adjusting the amount of soft magnetic powder relative to the resin. Therefore, according to the composite material, an inner core portion having desired magnetic characteristics can be easily produced. Since the inner core portion made of the composite material is formed by cast molding, injection molding, or the like, it is easy to form the core side engaging portion in the outer core portion.

<7> As the reactor according to the embodiment, the outer core portion includes a magnetic body and an outer resin mold portion formed on a surface of the magnetic body, and the core-side engaging portion is provided on the outer resin mold portion. Can be mentioned.

  By forming the core-side engagement portion in the outer resin mold portion, the magnetic path cross-sectional area of the magnetic body that determines the magnetic characteristics of the outer core portion is not reduced. Moreover, since it is easy to form a core side engaging part in the outer side resin mold part comprised with resin, formation of a core side engaging part does not impair the productivity of an outer core part greatly. Examples of the magnetic body include a powder compact formed by pressure-molding a raw material powder containing soft magnetic powder.

-Details of embodiment of this invention Hereinafter, embodiment of the reactor of this invention is described based on drawing. The same reference numerals in the figure indicate the same names. In addition, this invention is not necessarily limited to the structure shown by embodiment, and is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included.

<Embodiment 1>
≪Reactor overall structure≫
With reference to FIGS. 1-3, the reactor 1 (alpha) of Embodiment 1 is demonstrated. 1 is an upper perspective view of the reactor 1α, FIG. 2 is an exploded perspective view of the reactor 1α, and FIG. 3 is an exploded perspective view of an assembly 1 provided in the reactor 1α.

  A reactor 1α according to this embodiment shown in FIG. 1 has a configuration in which a combined body 1 having a coil 2 and a magnetic core 3 is fixed on a mounting plate 9 with a bonding layer 8. The main difference of the reactor 1α of this embodiment from the conventional reactor is that the stay 7 that fixes the combination 1 on the mounting plate 9 is engaged with the outer core portion 32 that is a part of the magnetic core 3. The point is the configuration. Hereinafter, each structure of the reactor 1α will be described in detail.

≪Union body≫
In the description of the combination 1 in which the coil 2 and the magnetic core 3 are mechanically combined, reference is mainly made to FIG. 3 which is an exploded perspective view of the combination 1.

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

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

  The coil 2 including the winding portions 2A and 2B is a coated wire having an insulating coating made of an insulating material on the outer periphery of a conductor such as a flat wire or a round wire made of a conductive material such as copper, aluminum, magnesium, or an alloy thereof. Can be configured. In this embodiment, the windings 2A and 2B are formed by edgewise winding a rectangular wire made of copper and a conductor made of enamel (typically polyamideimide). Yes.

  Both end portions 2a and 2b of the coil 2 are extended from the winding portions 2A and 2B and connected to a terminal member (not shown). An external device such as a power source for supplying power is connected to the coil 2 through the terminal member.

[Magnetic core]
The magnetic core 3 in this example is configured by combining a substantially U-shaped first divided core 3 </ b> A and a second divided core 3 </ b> B and two gap members 33. The first divided core 3A and the second divided core 3B have the same configuration. These divided cores 3A and 3B differ from the prior art in that they have a core-side engaging portion 3f described later.

  Gap members 33 and 33 are interposed between the tip of the forked portion of the first split core 3A and the tip of the forked portion of the second split core 3B, so that the split cores 3A, The annular magnetic core 3 formed by combining 3B can be divided into inner core portions 31 and 31 and outer core portions 32 and 32 for convenience.

[[Inner core]]
The inner core portion 31 is a portion of the magnetic core 3 that is disposed inside the winding portion 2A (2B) of the coil 2. Here, the inner core portion 31 in this example means a portion of the magnetic core 3 that has an axial direction along the axial direction of the winding portions 2A and 2B of the coil 2. For example, portions of the magnetic core 3 that are closer to the winding parts 2A and 2B than the broken lines shown in FIGS. 1 to 3 protrude outside the winding parts 2A and 2B from the end surfaces of the winding parts 2A and 2B. Although it is, it is the inner core part 31.

  The shape of the inner core portion 31 is a shape along the inner shape of the winding portion 2A (2B), and in the case of this example, is a substantially rectangular parallelepiped shape. In this example, one inner core portion 31 is formed by one protruding portion of the first divided core 3A, one protruding portion of the second divided core 3B, and the gap member 33 sandwiched between these protruding portions. ing.

  The inner core portion 31 of this example is composed of a composite material including soft magnetic powder and resin. Soft magnetic powder is an aggregate of magnetic particles composed of an iron group metal such as iron or an alloy thereof (Fe-Si alloy, Fe-Ni alloy, etc.). An insulating coating made of phosphate or the like may be formed on the surface of the magnetic particles. On the other hand, examples of the resin include thermosetting resins such as epoxy resin, phenol resin, silicone resin, and urethane resin, polyamide (PA) resin such as polyphenylene sulfide (PPS) resin, nylon 6 and nylon 66, polyimide resin, and fluorine resin. A thermoplastic resin such as a resin, a room temperature curable resin, or a low temperature curable resin can be used.

  Unlike this example, the inner core part 31 can also be configured to include a magnetic body and an outer resin mold part formed on the surface thereof. Examples of the magnetic material include a powder compact formed by press-forming raw material powder containing the soft magnetic powder, and a laminate obtained by laminating magnetic steel plates. Examples of the resin constituting the outer resin mold part include PA resins such as PPS resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), nylon 6 and nylon 66, polybutylene terephthalate (PBT) resin, acrylonitrile A thermoplastic resin such as a butadiene / styrene (ABS) resin can be used. In addition, thermosetting resins such as unsaturated polyester resins, epoxy resins, urethane resins, and silicone resins can be used. These resins may contain ceramic fillers such as alumina and silica to improve the heat dissipation of the outer resin mold part.

  Here, as the gap material 33, a nonmagnetic material such as ceramics such as alumina or resin such as polypropylene can be used. In addition, the gap member 33 can be formed of an adhesive that bonds the projecting portions of the two split cores 3A and 3B.

[[Outer core]]
The outer core portion 32 has a shape that connects the ends of the pair of inner core portions 31 and 31. In this example, the outer core portion 32 has a trapezoidal column shape. The center part in the parallel direction of winding part 2A, 2B in the outer core part 32 protrudes rather than another part. The magnetic path cross-sectional area of the central part is substantially the same as the magnetic path cross-sectional area of the inner core part 31 described above. In addition, the surface on the mounting plate 9 (see FIG. 1) side of the outer core portion 32 is flush with the surface on the mounting plate 9 side of the winding portions 2A and 2B of the coil 2. For this reason, the outer core portion 32 comes into contact with the mounting plate 9 via a bonding layer 8 described later.

  The outer core part 32 may also be comprised with the molded object of a composite material similarly to the inner core part 31, and may be comprised with the magnetic body provided with an outer side resin mold part. Both the inner core portion 31 and the outer core portion 32 may be made of a composite material or a magnetic material, the inner core portion 31 is made of a composite material, and the outer core portion 32 is made of a magnetic material, or vice versa. You can also. However, as in this example, in the case of the split cores 3A and 3B configured by the outer core portion 32 and a part of the pair of inner core portions 31 and 31, the inner core portion 31 and the outer core portion 32 are the same. Consists of materials.

[[Core side engaging part]]
Two core-side engaging portions 3f and 3f are formed on the upper surfaces of the portions to be the outer core portions 32 in the first divided core 3A and the second divided core 3B, respectively. The core side engaging portion 3f is a concave hole into which a stay side engaging portion 7f provided in the stay 7 described later is fitted. When the outer core portion 32 is made of a composite material, the core side engaging portion 3f may be formed directly on the outer core portion 32. When the outer core portion 32 is formed of a compacted body covered with the outer resin mold portion, the core side engaging portion 3f may be formed in the outer resin mold portion.

  The number of core-side engaging portions 3f formed on one outer core portion 32 is two in this example, but may be one, or may be three or more. Considering the ease of formation and the dispersion of stress acting on the core side engaging portion 3f, it is preferable that the number of core side engaging portions 3f be two as shown in the figure.

  In this example, the core-side engaging portion 3f has a mortar shape that gradually narrows from the opening toward the deepest portion. By using the mortar-shaped core side engaging portion 3f, it is possible to avoid stress concentration on the local side of the core side engaging portion 3f, and to prevent the core side engaging portion 3f from being damaged. it can. However, the shape of the core side engaging portion 3f is not limited to a mortar shape, and for example, the core side engaging portion 3f having the same cross-sectional shape in the depth direction from the opening portion toward the deepest portion may be used. .

  The depth of the core side engaging portion 3f (the distance from the opening to the deepest portion) is preferably 1.0 mm or more. By setting the depth of the core side engaging portion 3f to 1.0 mm or more, it is possible to sufficiently secure the engaging force between the core side engaging portion 3f and a stay side engaging portion 7f described later. Moreover, it is preferable that the depth of the core side engaging part 3f shall be 5.0 mm or less in order to suppress that the magnetic characteristic of the outer core part 32 falls by the core side engaging part 3f.

≪Mounting board≫
The mounting plate 9 (FIGS. 1 and 2) is a member that functions as a base when the reactor 1α is fixed to an installation target such as a cooling base. For this reason, the mounting plate 9 is required to have excellent mechanical strength. Further, the mounting plate 9 is required to play a role of releasing heat generated in the assembly 1 to the installation target when the reactor 1α is used. Therefore, the mounting plate 9 is required to have excellent heat dissipation in addition to mechanical strength. In order to meet such a demand, the mounting plate 9 is made of metal. For example, aluminum or an alloy thereof, magnesium or an alloy thereof can be used as a constituent material of the mounting plate 9. These metals (alloys) have the advantage of being excellent in mechanical strength and thermal conductivity, lightweight and non-magnetic.

  The mounting plate 9 of this example includes four columnar fixing portions 91 formed so as to surround the combined body 1 (see particularly FIG. 2). The columnar fixing portion 91 serves as a pedestal for fixing an end portion of a stay 7 described later. The columnar fixing portion 91 may be formed integrally with the planar portion of the mounting plate 9 or may be formed by connecting a separately prepared portion to the planar portion. In this example, a screw hole 9 h is formed in the upper end surface of the columnar fixing portion 91, and the stay 7 can be fixed to the columnar fixing portion 91 by the screw 7 </ b> B. The columnar fixing portion 91 functions not only as a pedestal for fixing the stay 7, but also as a function for accurately determining the position of the assembly 1 on the mounting plate 9 and when the assembly 1 vibrates. Has a function to stop.

  Each of the four columnar fixing portions 91 is in a position corresponding to the four corners of the combined body 1, and the base side portion of each columnar fixing portion 91 is substantially in contact with the outer core portion 32 of the combined body 1. These columnar fixing portions 91 are separated from each other, and do not get in the way when the assembly 1 is placed on the placement plate 9 as shown in FIG.

  Each columnar fixing portion 91 becomes thinner from the base side toward the tip side. Therefore, the space on the upper end side of the columnar fixing portion 91 is widened, and the assembly 1 can be easily inserted into the space surrounded by the columnar fixing portion 91. Further, the inner side surface of the columnar fixing portion 91 has a shape along the outer surface of the outer core portion 32, so that the combination body 1 can be easily stopped when the combination body 1 vibrates.

  The upper end surface of the columnar fixing portion 91 is configured such that when the combined body 1 is mounted on the mounting plate 9 and the combined body 1 is fixed to the mounting plate 9 by the stay 7, They are aligned on the same plane as the upper surface (see FIG. 1). By adjusting the height of the columnar fixing portion 91 so that the upper end surface of the columnar fixing portion 91 and the upper surface of the outer core portion 32 are aligned, the assembly 1 is placed on the mounting plate 9 by the flat plate-like stay 7. Can be fixed.

  The reactor 1α can be fixed to an installation target such as a cooling base by, for example, forming a mounting hole (not shown) in the installation plate 9 and fixing the reactor 1α together with the installation plate 9 to the installation target.

≪Junction layer≫
A bonding layer 8 is formed between the mounting plate 9 and the assembly 1 to join the plates 1 and 9 together. The bonding layer 8 also has a function of conducting heat generated in the combined body 1 to the mounting plate 9 when the reactor 1α is used.

  The constituent material of the joining layer 8 shall have insulation. For example, thermosetting resins such as epoxy resins, silicone resins, and unsaturated polyesters, and thermoplastic resins such as PPS resins and LCPs can be used. You may improve the heat dissipation of the joining layer 8 by making these insulating resin contain the ceramic filler mentioned above. The thermal conductivity of the bonding layer 8 is preferably, for example, 0.1 W / m · K or more, more preferably 1 W / m · K or more, and particularly preferably 2 W / m · K or more.

  The bonding layer 8 may be formed by applying an insulating resin (ceramic filler-containing resin may be used) on the mounting plate 9, or affixing a sheet material of the insulating resin on the mounting plate 9. May be formed. It is preferable to use a sheet-like material as the bonding layer 8 because the bonding layer 8 can be easily formed on the mounting plate 9.

≪Stay≫
As shown in FIGS. 1 and 2, the stay 7 is a flat plate-like piece, the middle part thereof is in contact with the upper surface of the outer core part 32, and both end parts thereof are separate columnar shapes of the mounting board 9. It is fixed to the fixing part 91. In this example, screw holes 7 h for inserting screws 7 </ b> B are formed at both ends of the stay 7, and the stay 7 is screwed to the columnar fixing portion 91. When the stay 7 presses the upper surface of the outer core portion 32, the combined body 1 is firmly fixed on the mounting plate 9. The flat stay 7 is advantageous in that it does not easily cause problems such as bending when the assembly 1 vibrates in the plane direction of the mounting plate 9 and is easy to produce.

  A stay-side engaging portion 7 f that fits into a core-side engaging portion 3 f formed on the upper surface of the outer core portion 32 is formed in a portion of the stay 7 that contacts the upper surface of the outer core portion 32. The stay side engaging portion 7f of this example is formed by recessing the stay 7 with a press or the like. The side opposite to the recessed side (the side visible on the paper surface) protrudes from the flat portion of the stay 7. This convex portion is used as the stay side engaging portion 7f.

  The number, shape, and protrusion amount of the stay side engaging portions 7f may be matched with the core side engaging portions 3f formed on the upper surface of the outer core portion 32. By doing so, the flat portion of the stay 7 comes into surface contact with the upper surface of the outer core portion 32 when the stay side engaging portion 7f is engaged with the core side engaging portion 3f. As a result, the position of the stay 7 is difficult to shift with respect to the outer core portion 32, and the fixed state of the combined body 1 on the mounting plate 9 is stabilized.

  A resin coating may be formed on the back surface of the stay 7 (the surface facing the outer core portion 32). By forming the resin coating, it is possible to avoid the outer core portion 32 from coming into direct contact with the metal stay 7, and it is possible to suppress damage around the core side engaging portion 3f. In this case, the depth of the core side engaging portion 3f = the protrusion amount of the stay side engaging portion 7f + the thickness of the resin coating.

≪Other composition≫
In addition to the above configuration, the reactor 1α according to the first embodiment is disposed between the outer peripheral surface of the inner core portion 31 and the inner peripheral surfaces of the winding portions 2A and 2B, and the inner core portion 31 and the winding portions 2A and 2B. You may provide the adhesive sheet which adhere | attaches. Since the relative position between the coil 2 and the magnetic core 3 can be fixed by the adhesive sheet, the relative position between the coil 2 and the magnetic core 3 due to vibration or the like can be suppressed.

  The adhesive sheet can be made of an insulating resin having adhesiveness, for example, a thermosetting resin such as an epoxy resin, a silicone resin, or an unsaturated polyester, or a thermoplastic resin such as a PPS resin or LCP. The thermal conductivity of the adhesive sheet may be improved by incorporating these ceramic fillers into the insulating resin. Moreover, an adhesive sheet can also be comprised with a foamed resin. In the case of an adhesive sheet made of foamed resin, it is easy to insert the protruding portions of the split cores 3A and 3B into the winding portions 2A and 2B after the adhesive sheets are attached to the split cores 3A and 3B. The coil 2 and the magnetic core 3 can be fixed by inserting the protruding portion into the winding portions 2A and 2B and then foaming the foamed resin.

≪Reactor effect≫
Reactor 1α described above is firmly fixed on combination plate 9 even if combination 1 vibrates during its operation. It includes the outer core portion 32 because the stay side engaging portion 7 f of the stay 7 that fixes the assembly 1 on the mounting plate 9 is engaged with the core side engaging portion 3 f of the outer core portion 32. This is because the vibration of the combined body 1 is suppressed by the stay 7.

<Embodiment 2>
In the second embodiment, a reactor 1β including a coil 2 having only one winding part 2C will be described with reference to FIGS.

  As shown in FIGS. 4 and 5, the reactor 1β of the present example has a configuration in which the combined body 1 formed in a substantially rectangular parallelepiped shape is disposed on the mounting plate 9 via the bonding layer 8. The difference between the reactor 1β and the reactor 1α of the first embodiment is the shapes of the coil 2 and the magnetic core 3 constituting the combined body 1. Hereinafter, each structure of the reactor 1β will be described focusing on differences from the first embodiment.

  As shown in FIG. 6, the coil 2 provided in the combined body 1 includes one winding part 2 </ b> C. The end 2b of the coil 2 is routed to the end 2a side and drawn out in the same direction as the end 2a.

  The magnetic core 3 provided in the combined body 1 is configured by combining a substantially E-shaped first divided core 3C and a second divided core 3D with a gap member 33 interposed therebetween. In this case, the E-shaped middle projecting portion is the inner core portion 31, and the other portion is the outer core portion 32. Also in this example, the core side engaging portions 3f and 3f are formed on the upper surface of the portion which becomes the outer core portion 32 in both split cores 3C and 3D.

  On the other hand, the columnar fixing portion 91 formed on the mounting plate 9 is formed in a prismatic shape. When the combined body 1 is placed on the placement plate 9, the columnar fixing portion 91 can be used as a heat dissipation path if the columnar fixing portion 91 is brought into surface contact with the outer core portion 32.

  As shown in FIG. 5, the assembly 1 having the above configuration is placed on the mounting plate 9 from above the mounting plate 9, and is screwed to the mounting plate 9 by the stay 7. At that time, the stay side engaging portion 7f of the stay 7 and the core side engaging portion 3f of the outer core portion 32 are engaged with each other. As shown in FIG. A firmly fixed reactor 1β is formed.

<Modification 1>
In Embodiments 1 and 2, the magnetic core is configured by combining two split cores, but the magnetic core may be configured by combining three or more split cores. For example, in the reactor 1α of the first embodiment, the magnetic core 3 may be configured by a pair of columnar core pieces that are the inner core portions 31 and a pair of block core pieces that are the outer core portions 32 ( The number of division is four). Further, in the reactor 1β of the second embodiment, the magnetic core 3 may be configured by a columnar core piece that becomes the inner core portion 31 and a pair of C-shaped core pieces that become the outer core portions 32 (number of divisions). Is three). In any case, the core-side engaging portion 3f is formed in the core piece that becomes the outer core portion 32.

<Modification 2>
In the first and second embodiments, the concave core side engaging portion 3 f is formed in the outer core portion 32, and the convex stay side engaging portion 7 f is formed in the stay 7. On the other hand, the convex core side engaging portion 3 f may be formed on the outer core portion 32, and the concave stay side engaging portion 7 f may be formed on the stay 7.

<Modification 3>
In the first and second embodiments, the height of the columnar fixing portion 91 is adjusted so that the height of the upper end surface of the columnar fixing portion 91 is the same as the height of the upper surface of the outer core portion 32. On the other hand, the height of the upper end surface of the columnar fixing portion 91 may be higher or lower than the height of the upper surface of the outer core portion 32. In that case, both ends of the stay 7 are bent so that both ends of the stay 7 are arranged on the upper end surface of the columnar fixing portion 91.

<Modification 4>
In the first and second embodiments, the reactors 1α and 1β formed by placing the combined body 1 on the flat placing plate 9 have been described. On the other hand, although illustration is abbreviate | omitted, it can also be set as the reactor which accommodates the assembly 1 demonstrated in Embodiment 1 in a case.

  A case is a bottomed cylindrical member provided with a baseplate part and a side wall part. In this case, the bottom plate portion of the case also serves as a mounting plate for mounting the combination. A converter case can also be used as a case for storing the combination. A fixing portion corresponding to the columnar fixing portion 91 may be formed inside the case.

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

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

1α, 1β Reactor 1 Assembly 2 Coil 2A, 2B, 2C Winding part 2R Connection part 2a, 2b End part 3 Magnetic core 3f Core side engagement part 3A, 3C First split core 3B, 3D Second split core 31 Inside Core part 32 Outer core part 33 Gap material 7 Stay 7f Stay side engaging part 7h Screw hole 7B Screw 8 Joining layer 9 Mounting plate 91 Columnar fixing part 9h Screw hole

According to the reactor, the reactor can be firmly fixed to the mounting plate.

The composite material can easily adjust its magnetic properties by adjusting the amount of soft magnetic powder relative to the resin. Therefore, according to the composite material, it is possible to easily produce the outer side core part having a desired magnetic properties. Outer side core part composed of a composite material to be formed in such cast molding or injection molding, it is easy to form the core-side engaging portion to the outer core portion.

Fixing the reactor 1α for installation target such as a cooling base, for example mounting plate 9 into the mounting hole (not shown) such as to form, it can be carried out by fixing the mounting plate 9 each reactor 1α to the installation target .

Claims (7)

A reactor comprising a combined body having a coil having a winding part and a magnetic core, and a mounting plate on which the combined body is mounted,
Of the magnetic core, comprising a stay for pressing the upper surface of the outer core portion arranged outside the winding portion, and fixing the position of the combined body with respect to the mounting plate,
The outer core part includes a core side engaging part formed on the upper surface thereof,
The said stay is a reactor provided with the stay side engaging part engaged with the said core side engaging part. The core side engaging portion is formed in a concave shape,
The reactor according to claim 1, wherein the stay side engaging portion is formed in a convex shape that matches a concave shape of the core side engaging portion.   The reactor according to claim 1, wherein the mounting plate includes a columnar fixing portion that is disposed so as to surround the combined body and to which the stay is fixed.   The reactor according to claim 3, wherein an upper end surface of the columnar fixing portion and an upper surface of the outer core portion are on the same plane.   The reactor of any one of Claims 1-4 provided with the joining layer which joins the said assembly to the said mounting plate between the said combined body and the said mounting plate.   The reactor according to any one of claims 1 to 5, wherein the outer core portion is made of a composite material including soft magnetic powder and a resin. The outer core portion includes a magnetic body, and an outer resin mold portion formed on the surface of the magnetic body,
The reactor of any one of Claims 1-5 in which the said core side engaging part is formed in the said outer side resin mold part.

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