JP2016122764A - Reactor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a reactor capable of reducing production cost and improving adhesive strength and resistance.SOLUTION: The reactor includes: an annular core to which a plurality of split cores, an I-shaped core 1b, an U-shaped core 1d are connected through an adhesive layer 1e; and an insulating coating part for coating an outer circumference of the annular core. A linear part 22b of the insulating coating part includes a projection 4 sandwiched between split cores.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a reactor in which cores are insulation-coated, and more particularly to a technique for ensuring a film thickness of an adhesive between cores.

  Reactors are used in various applications including drive systems for hybrid vehicles and electric vehicles. For example, as a reactor used in an in-vehicle booster circuit, after winding a coil around a resin bobbin placed around the core, place them in a metal case, and pour the filler into the case and harden it. Are often used.

  This kind of reactor is provided with the annular core which consists of magnetic materials, the resin coating part which covers the outer periphery of the said annular core, and the coil wound around a part of outer periphery of the annular core via the resin coating part. In general, a molding method is employed to form a resin coating portion by arranging a resin around the annular core.

  In this type of reactor, the annular core is configured by abutting a plurality of divided cores made of a magnetic material in an annular shape. When a current flows from the external power source to the coil, a magnetic flux is generated in a portion where the coil of the annular core is wound, and an annular magnetic circuit is formed by passing through the inside of the annular core. As the magnetic flux is generated, a magnetic attractive force acts on the split core. Therefore, if the divided cores are not fixed, the divided cores may collide with each other and noise may be generated. Therefore, conventionally, a method of fixing the divided cores with an adhesive has been adopted. As a result, even if a magnetic attractive force is applied to each of the divided cores, they do not collide with each other, so that the generation of a large noise can be suppressed.

  The thickness of the adhesive is important for fixing the divided cores with an adhesive. That is, when the adhesive is cured to fix these split cores, the adhesive is thinly spread on the adhesive surface because the pressure is applied in the direction sandwiching the adhesive surface of the split core, ensuring a sufficient film thickness. There are cases where it is not possible. For this reason, the adhesive strength between the divided cores is lowered, the durability is lowered, and noise may not be suppressed.

  As a technique for solving this problem, a technique is known in which a filler having a predetermined particle size is contained in an adhesive. In this technique, even when pressure is applied in the direction in which the adhesive surface is sandwiched, the film thickness corresponding to the particle diameter of the filler can be ensured by interposing the filler between the divided cores. Moreover, when providing a gap between division | segmentation cores, the technique which provides a processus | protrusion in the spacer arrange | positioned between them, and ensures the film thickness of the adhesive agent for the length of a processus | protrusion (for example, refer patent document 1) is known. .)

JP 2006-135018 A

  However, in the technique of including a filler in the adhesive, there is a problem that the manufacturing cost increases because the filler is expensive. On the other hand, the technique of providing a protrusion on the spacer cannot be applied when the spacer is not required. For this reason, the thickness of the adhesive becomes too thin at the time of adhesion pressurization, and the problems of decrease in adhesive strength and durability cannot be solved.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a reactor capable of reducing manufacturing costs and improving adhesive strength and durability.

The reactor of the present invention is a reactor including an annular core formed by connecting a plurality of divided cores to each other via an adhesive layer having a predetermined film thickness, and an insulating covering portion that covers the outer periphery of the annular core. And having the following configuration.
(1) The said insulation coating part has a projection part pinched | interposed between the said division | segmentation cores.

The present invention may have the following configuration.
(2) The said insulation coating part has an inner wall which covers between the said division | segmentation cores, and the said protrusion part protrudes in a row from the said inner wall.
(3) The protrusion is made of resin.
(4) The protrusion has a shape in which the proximal end side is wider than the distal end side.
(5) The split core includes an adhesive surface connected to another split core, the pair of sides facing the adhesive surface is chamfered, and the annular core is the pair of split cores. It is formed by connecting the divided cores so that sides are orthogonal to the pair of sides of the divided core to be bonded to the divided core.

A reactor according to the present invention includes a ring core formed by connecting a plurality of divided cores to each other via an adhesive layer having a predetermined film thickness, and an insulating covering that covers the outer periphery of the ring core. And having the following configuration.
(6) The annular core includes spacers disposed between the split cores on both sides with the adhesive layer interposed therebetween, and the insulating coating portion includes protrusions sandwiched between the split cores and the spacers. To prepare.

The present invention may have the following configuration.
(7) The insulating covering portion includes a first protrusion sandwiched between one of the divided cores connected to each other and the spacer, and the other of the divided cores connected to each other and the spacer. A second protrusion sandwiched therebetween.
(8) The said insulation coating part has an inner wall which covers between the said division | segmentation cores, and the said protrusion part protrudes in a row from the said inner wall.
(9) The protrusion is made of resin.
(10) The protrusion has a shape in which the proximal end side is wider than the distal end side.
(11) The split core includes an adhesive surface connected to another split core, the pair of sides facing the adhesive surface is chamfered, and the annular core is the pair of split cores. It is formed by connecting the divided cores so that sides are orthogonal to the pair of sides of the divided core to be bonded to the divided core.

  ADVANTAGE OF THE INVENTION According to this invention, a manufacturing cost can be reduced and the reactor which can improve adhesive strength and durability can be obtained.

It is a perspective view which shows the whole structure of the reactor which concerns on 1st Embodiment. It is a disassembled perspective view which shows the whole structure of the reactor which concerns on 1st Embodiment. It is sectional drawing which concerns on sectional drawing of the reactor which concerns on 1st Embodiment, and cut | disconnected the orthogonal | vertical direction of the adhesive surface of a split core. It is a partial expanded sectional perspective view of the adhesion part periphery of a split core. It is an enlarged view of A part of FIG. It is a schematic diagram when the I-shaped core side is seen from the U-shaped core side in the BB cross section of FIG. It is a partial expanded sectional view of the periphery of the projection part which concerns on 2nd Embodiment. It is a schematic diagram which shows the installation position of the projection part which concerns on other embodiment. It is a schematic diagram which shows the form of the projection part which concerns on other embodiment. It is a partial expanded sectional view of the periphery of the projection part which concerns on other embodiment. It is a partial expanded sectional view of the periphery of the projection part which concerns on other embodiment.

  Hereinafter, a reactor according to an embodiment of the present invention will be described with reference to the drawings.

[1. First Embodiment]
[1-1. Schematic configuration]
FIG. 1 is a perspective view showing the overall configuration of the reactor according to the present embodiment, and FIG. 2 is an exploded perspective view thereof. The reactor according to the present embodiment is a large-capacity reactor used in, for example, a drive system for a hybrid vehicle or an electric vehicle. The reactor is the main component of the electric circuit mounted on these automobiles. This electric circuit includes a semiconductor switching element such as an IGBT in addition to a reactor. The reactor converts the electrical energy supplied from the external power source into magnetic energy by turning on and off the semiconductor switching element at high speed, repeatedly stores and releases the energy, and suppresses current and voltage.

  As shown in FIGS. 1 and 2, the reactor includes an annular core 1, a coil 5 wound around a part of the outer periphery of the annular core 1, an outer periphery of the annular core 1, and the annular core 1 and the coil 5. It has the insulation coating | coated part 2 which insulates.

  The annular core 1 is an annular magnetic body, and has a pair of parallel straight portions and a U-shaped connecting portion that connects these straight portions to a portion of the annular shape. In the annular core 1, the straight portion around which the coil 5 is wound is a leg portion where magnetic flux is generated. The legs of the annular core 1 of this embodiment are a pair of linear portions wound around a pair of parallel coils 51a and 51b shown in FIG. The reason why the magnetic flux is generated in the leg portion is that when a current flows through the coil 5, a magnetic flux interlinking the coil 5 is generated. The U-shaped connecting portion around which the coil 5 is not wound is a yoke portion through which the magnetic flux generated at the leg portion passes. That is, the yoke portion connects the pair of straight portions. An annular closed magnetic circuit is formed in the annular core 1 by the magnetic flux generated at the leg portion passing through the yoke portion.

  The insulating cover 2 covers the outer periphery of the annular core 1 and has an annular shape as the entire annular core 1.

  Such a reactor is fixed in a heat dissipation case (not shown) having a substantially rectangular parallelepiped housing space formed of a metal having high thermal conductivity and light weight such as an aluminum alloy. For this fixing, fixing portions 23a, 23b, 24a, and 24b are provided in the connecting portions 21c and 22d of the insulating coating portion 2, and a screw is fastened to the fixing portions 23a, 23b, 24a, and 24b so that the reactor is connected. Fixed to the heat dissipation case. The reason why the heat radiating case has thermal conductivity is to release heat generated by energization of the coil 5.

  A filler is filled and solidified in the gap between the reactor and the heat radiating case to form a filled resin portion (not shown). As the filler, a resin that is relatively soft and has high thermal conductivity is suitable for ensuring the heat dissipation performance of the reactor and reducing the propagation of vibration from the reactor to the heat dissipation case.

[1-2. Detailed configuration]
Next, each structure of the reactor of this embodiment is demonstrated in detail. The annular core 1 is a magnetic body such as a dust core, a ferrite core, or a laminated steel plate. The annular core 1 has a plurality of divided cores, and the divided cores are connected so as to be annular via the adhesive layer 1e. The split cores of the present embodiment are I-shaped cores 1a and 1b that constitute the left and right leg portions, and two U-shaped cores 1c and 1d that constitute the yoke portion.

  The I-shaped cores 1a and 1b and the U-shaped cores 1c and 1d have bonding surfaces to which other divided cores are bonded at both ends. The I-shaped cores 1a and 1b and the U-shaped cores 1c and 1d are connected and fixed in an annular shape by an adhesive layer 1e interposed between the adhesive surfaces. In this embodiment, as shown in FIG. 2, the I-shaped cores 1 a and 1 b and the U-shaped cores 1 c and 1 d are rounded by chamfering a pair of opposite sides of a substantially rectangular bonding surface. They are R-shaped and are connected orthogonally so as not to overlap each other. In other words, in FIG. 2, the R-shaped sides of the I-shaped cores 1a and 1b extend in the horizontal direction, and the R-shaped sides of the U-shaped cores 1c and 1d extend in the vertical direction. Therefore, in the bonded portion of the split core, at least one of the two opposing sides of the split core is a side that is not R-shaped.

  The adhesive layer 1e is made of an adhesive. Although it does not specifically limit as an adhesive agent, A thermosetting type adhesive agent can be used, For example, an epoxy-type, a silicone type, and an acrylic adhesive are mentioned. Epoxy adhesives are preferred because of their high strength. In the case of a thermosetting adhesive, since high heat resistance is required, an adhesive having a glass transition point of 160 ° C. or higher is preferable. Further, the adhesive preferably has thixotropy, which is a low viscosity during stirring and a high viscosity property in a normal state. When a one-component thermosetting adhesive is used as the adhesive, it is easy to handle because it does not cure until heated after application of the adhesive. Further, two types of adhesives may be mixed and cured using a two-component adhesive.

  In addition, the leg part of the annular core 1 is a part around which the coil 5 is wound as described above. In this embodiment, in addition to the I-shaped cores 1a and 1b, end parts of the U-shaped cores 1c and 1d. Is included. The yoke portion of the annular core 1 is a curved portion of the U-shaped cores 1c and 1d where the coil 5 is not wound. However, depending on the number of turns of the coil 5, only the I-shaped cores 1a and 1b can be used as the leg portions, and the U-shaped cores 1c and 1d can be used as the yoke portions. It can be appropriately changed depending on the design.

  The insulation coating portion 2 is a member that covers the outer periphery of the annular core 1 with an insulating material. Therefore, the insulating coating portion 2 is formed in an annular shape following the shape of the annular core 1. That is, the insulation coating portion 2 includes a pair of straight portions and a connecting portion that connects the pair of straight portions. A coil 5 is wound around a part of the outer periphery of the insulating covering portion 2, and the insulating covering portion 2 insulates the annular core 1 from the coil 5.

  Resin is mentioned as a material which has insulation. Examples of the resin include an epoxy resin, an unsaturated polyester resin, a urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulphide), and PBT (Polybutylene Terephthalate). These resins have a strength that does not break due to the pressure between the split cores applied when the annular core 1 is assembled. In the present embodiment, the insulating coating portion 2 will be described as a member made of resin. However, the insulating material is not limited to resin, and other materials may be used as long as they have insulating properties.

  The insulation coating part 2 is divided into two. That is, the insulation coating portion 2 is formed by separately molding a substantially U-shaped first separator 21 and a substantially C-shaped second separator 22 and abutting each other's ends. Composed. The reason why the first separator 21 and the second separator 22 are separately formed is to accommodate the I-shaped cores 1a and 1b and to fit the coil 5 therein.

  Specifically, the first separator 21 includes a pair of cylindrical straight portions 21a and 21b and a connecting portion 21c that connects these straight portions 21a and 21b. The second separator 22 includes a pair of cylindrical straight portions 22a and 22b and a connecting portion 22d that connects these straight portions 22a and 22b. The straight portions 21 a and 21 b of the first separator 21 are longer than the straight portions 22 a and 22 b of the second separator 22.

  U-shaped cores 1c and 1d are embedded in the connecting portions 21c and 22d by a molding method. In other words, the outer peripheral portions of the U-shaped cores 1c and 1d covered with the connecting portions 21c and 22d are fitted with the inner periphery of the connecting portions 21c and 22d.

  I-shaped cores 1a and 1b are arranged inside the straight portions 21a, 21b, 22a and 22b. Openings are provided at the ends of the straight portions 21a, 21b, 22a, 22b, respectively. At the time of reactor assembly, one ends of the I-shaped cores 1a and 1b are inserted from the openings of the straight portions 21a and 21b, and the other ends of the I-shaped cores 1a and 1b are inserted into the openings of the straight portions 22a and 22b. The insulation coating portion 2 that covers the annular core 1 is configured by abutting the openings of the first separator 21 and the second separator 22 with each other.

  FIG. 3 is a cross-sectional view of the reactor according to the present embodiment cut in a direction perpendicular to the bonding surface of the split core. FIG. 4 is a partial enlarged cross-sectional perspective view of the periphery of the bonded portion between the I-shaped core 1b and the U-shaped core 1d. However, the U-shaped core 1d is omitted. FIG. 5 is an enlarged view of a round dotted line A portion of FIG. FIG. 6 is a schematic view when the I-shaped core 1b side is viewed from the U-shaped core 1d side in the BB cross section of FIG.

  As shown in FIGS. 3 to 6, the insulating covering portion 2 has a protruding portion 4 sandwiched between divided cores. The protrusion 4 has a predetermined thickness in a direction perpendicular to the bonding surface of the split core, and the split cores are separated by the thickness. That is, the protrusions 4 are in contact with the adhesive surfaces of the split cores, and prevent the thickness of the adhesive layer 1e between the split cores from becoming thinner than the thickness of the protrusions 4. The thickness of the protrusion 4 is appropriately designed according to a predetermined film thickness that the adhesive layer 1e is desired to secure.

  As shown in FIG. 3, such a protruding portion 4 is provided on the inner wall that covers between the split cores of the insulating coating portion 2. In the present embodiment, between the divided cores, the annular core 1 is provided on the inner peripheral side and the outer peripheral side, respectively. Specifically, in this embodiment, there are four divided cores, and the protrusions 4 are between the U-shaped core 1c and the I-shaped cores 1a and 1b, and between the U-shaped core 1d and the I-shaped core. A total of eight places are provided so as to be sandwiched between 1a and 1b. Since the structure of the protrusion 4 is the same between the divided cores, FIG. 4 shows the periphery of the bonded portion between the I-shaped core 1b and the U-shaped core 1d as a representative.

  The protrusion 4 will be described in more detail with reference to FIGS. The protruding portion 4 is integrally formed with a portion covering the outer periphery of the split core of the insulating coating portion 2. That is, the protrusion 4 is made of a resin when molding the U-shaped cores 1c and 1d, and the linear portions 21a, 21b, 22a, which are portions covering the outer periphery of the split core, of the insulating coating portion 2. From the inner wall of 22b, it protrudes so that the internal dimension of the width direction of linear part 21a, 21b, 22a, 22b may be narrowed. In other words, the protrusion 4 has no joints with the straight portions 21a, 21b, 22a, 22b, and is formed continuously.

  Further, as shown in FIGS. 4 and 6, the protrusion 4 is vertically long in the direction parallel to the bonding surfaces of the I-shaped core 1b and the U-shaped core 1d, that is, in the direction perpendicular to the width direction of the divided cores 1b and 1d. Is growing. In FIG. 6, there is a gap between the protrusion 4 and the adhesive layer 1e. However, the protrusions 4 on both sides between the divided cores may be connected without a gap by the adhesive layer 1e.

  Further, the protrusion 4 has a shape in which the proximal end side is wider than the distal end side. In other words, the protrusion 4 is narrowed from the proximal end side to the distal end side. Thereby, when resin is filled in the mold for molding the insulating coating portion 2, the resin is easily filled in the portion in the mold where the protrusion 4 is formed. In the present embodiment, as shown in FIGS. 3 to 5, one surface of the protrusion 4 has a shape having the curvature of the corner portion of the U-shaped core 1 d, and the corner portion of the U-shaped core 1 d is, for example, 2 mm. The radius of curvature is about.

  As shown in FIG. 2, the connecting portions 21c and 22d are provided with fixing portions 23a, 23b, 24a, and 24b for fixing the annular core 1 to the heat radiating case. The fixing portions 23a, 23b, 24a, and 24b protrude from the surfaces of the connecting portions 21c and 22d, and screw insertion holes 25a, 25b, 26a, and 26b for fixing the reactor to the heat radiating case are provided at the tips. Nuts 28a and 28b are fitted in the screw insertion holes 26a and 26b. The reactor is fixed to the heat radiating case by inserting screws into the screw insertion holes 25a, 25b, 26a, and 26b and fastening them to the screw holes of the heat radiating case.

  The fixing portions 23a and 23b of the connecting portion 21c are metal fittings, and one end portions are embedded in the connecting portion 21c by the molding method together with the U-shaped core 1c so that the screw insertion holes 24a and 24b are exposed. On the other hand, the fixing portions 24a and 24b of the connecting portion 22d are made of resin. In the present embodiment, the fixing portions 24a and 24b are formed by pouring resin into a mold for forming the second separator 22, and there is no joint between the fixing portions 24a and 24b and the connecting portion 22d. Therefore, the second separator 22 is a single member in which the straight portions 22a and 22b, the connecting portion 22d, the fixing portions 24a and 24b, and the protruding portion 4 are continuously formed of the same resin. In addition, the first separator 21 is composed of a single member in which the straight portions 21a and 21b, the connecting portion 21c, and the protruding portion 4 are continuously formed of the same resin, and fixing portions 23a and 23b made of metal fittings. It is a configured member.

  On the surface of the connecting portion 21c, a connector 8 that can connect other members is provided. In the present embodiment, a temperature sensor 9 is attached. The temperature sensor 9 includes a temperature detection unit 9a and a lead wire 9b connected to the temperature detection unit 9a. The temperature detection part 9a is arrange | positioned between the coils 51a and 51b mentioned later, for example, and detects the temperature inside a reactor. The lead wire 9b is attached to the connector 8, and transmits temperature information detected by the temperature detection unit 9a to the outside of the reactor. As the temperature sensor 9, for example, a thermistor whose electric resistance changes with respect to a temperature change can be used, but is not limited thereto.

  The coil 5 is a conducting wire having an insulating coating. In the present embodiment, the coil 5 is a flat wire edgewise coil. However, the wire material and winding method of the coil 5 are not limited to the rectangular wire edgewise coil, and may be in other forms. The coil 5 is wound around the outer periphery of the split core that constitutes the leg portion of the annular core 1. More specifically, in the present embodiment, the coil 5 includes left and right coils 51a and 51b. These coils 51a and 51b are wound around the outer periphery of a pair of linear portions 21a, 21b, 22a and 22b of the insulating coating portion 2.

  The coils 51a and 51b are each composed of a single enamel-coated copper wire. The coil 51a has end portions 52a and 53a, and the coil 51b has end portions 52b and 53b. One end 52a, 52b is drawn out to the first separator 21 side, and the other end 53a, 53b is drawn out to the second separator side. The ends 52a, 52b, 53a, 53b are joined to a bus bar (not shown) and connected to an external power source (not shown) via the bus bar. When power is supplied from the external power source, a current flows through the coils 51a and 51b to generate a magnetic flux penetrating the coils 51a and 51b, and a closed magnetic circuit is formed in the annular core 1.

  In the present embodiment, both end portions 52a, 52b, 53a, and 53b of the coils 51a and 51b are pulled out, respectively, but may be connected to the end portion of one coil 51a and the end portion of the other coil 51b. . For example, the end portions 52a and 52b may be connected to each other, receive power from one of the end portions 53a and 53b, and allow current to flow from the other end portions 53a and 53b to the outside.

[1-3. Effect]
(1) The reactor according to the present embodiment includes an annular core 1 in which a plurality of divided cores 1a to 1d are connected to each other via an adhesive layer 1e having a predetermined film thickness, and an insulating covering portion 2 that covers the outer periphery of the annular core 1. The insulation coating portion 2 has a protrusion 4 sandwiched between the split cores 1a to 1d. Thereby, the film thickness of the adhesive that bonds the divided cores by the thickness of the protrusion 4, that is, the thickness of the adhesive layer 1 e can be ensured. Therefore, the protrusion 4 can control the thickness of the adhesive to a desired thickness, and an adhesive layer 1e having a predetermined thickness can be obtained. Moreover, since the protrusion part 4 is made into the structure of the insulation coating part 2, it is not necessary to make an adhesive agent contain a filler, and can reduce manufacturing cost.

(2) The insulation coating portion 2 has an inner wall that covers between the split cores, and the protrusion 4 protrudes continuously from the inner wall of the insulation coating portion 2. Thereby, compared with the case where the projection part 4 is produced separately and attached to the inner periphery of the insulation coating part 2, the number of manufacturing steps and the manufacturing cost can be reduced.

(3) The protrusion 4 is made of resin. Thereby, since resin has intensity | strength, it can suppress that the distance between division | segmentation cores becomes smaller than the thickness of the projection part 4, even if adhesion | attachment pressurization of division | segmentation cores is carried out. Therefore, the film thickness of the adhesive 1e can be ensured.

(4) The protrusion 4 has a shape in which the proximal end side is wider than the distal end side. Thereby, in the case where the projection 4 is molded together with the mold for molding the insulating coating 2, the material of the insulating coating 2 such as resin can easily flow into the portion where the projection 4 of the mold is formed, Compared to the case where the protrusion 4 is separately manufactured and attached, the number of manufacturing steps and the manufacturing cost can be reduced.

(5) The split core is provided with an adhesive surface connected to another split core, and a pair of sides facing the adhesive surface is chamfered, and the annular core 1 has a pair of sides of the split core. The split cores are connected and formed so as to be orthogonal to a pair of chamfered sides of another split core to be bonded to the split core. Thereby, in the connection part of split cores, the chamfered side of one split core and the non-chamfered side of the other split core face each other. That is, at least one of the two opposing sides of the split cores is a non-chamfered side that is a portion where the corners of the split core are perpendicular. For this reason, it becomes easy to pinch not only the front-end | tip part but the base end side, and it becomes easy to control the film thickness of the contact bonding layer 1e.

[2. Second Embodiment]
[2-1. Constitution]
A second embodiment will be described with reference to FIG. The basic configuration of the second embodiment is the same as that of the first embodiment. Therefore, only a different point from 1st Embodiment is demonstrated, the same code | symbol is attached | subjected about the same part as 1st Embodiment, and detailed description is abbreviate | omitted.

  FIG. 7 is a partially enlarged cross-sectional view of the periphery of the bonded portion between the I-shaped core 1b and the U-shaped core 1d. The other bonded portions are the same as the bonded portions of the I-shaped core 1b and the U-shaped core 1d, and thus the description thereof will be omitted as appropriate.

  In the second embodiment, the annular core 1 is configured with a spacer 1f sandwiched between divided cores. In other words, the spacer 1f is disposed between the split cores on both sides of the spacer 1f via the adhesive layer 1e. The spacer 1f is made of, for example, ceramic, and gives a magnetic gap having a predetermined width between the divided cores.

  Specifically, the spacer 1f of the present embodiment is a flat plate having a predetermined thickness. The plate-like spacer 1f is disposed between the bonding surfaces of the U-shaped core 1c and the I-shaped cores 1a and 1b and between the bonding surfaces of the U-shaped core 1d and the I-shaped cores 1a and 1b. Yes. The spacer 1f provides a magnetic gap having a predetermined width between the U-shaped core 1c and the I-shaped cores 1a and 1b and between the U-shaped core 1d and the I-shaped cores 1a and 1b. Prevents inductance drop. For example, it is effective in reducing inductance when a high current is passed.

  The insulation coating portion 2 of the present embodiment includes a protruding portion 4 sandwiched between the split core and the spacer 1f. As shown in FIG. 7, the protrusions 4 secure the thickness of the adhesive layer 1e located on both sides of the spacer 1f. Specifically, the insulating cover 2 is one of the divided cores connected to each other. And a first protrusion 4a sandwiched between the spacer 1f and a second protrusion 4b sandwiched between the other of the divided cores connected to each other and the spacer 1f. The divided cores connected to each other are the U-shaped core 1c and the I-shaped core 1a or I-shaped core 1b, or the U-shaped core 1d and the I-shaped core 1a or I-shaped core 1b. .

  The first protrusion 4a protrudes continuously from the inner wall of the insulating cover 2 so as to cover a part of the bonding surface of the U-shaped cores 1c and 1d. A spacer 1f is disposed on the back surface of the first protrusion 4a so as to come into contact therewith. An adhesive layer 1e is interposed between the spacer 1f and the U-shaped cores 1c and 1d, and the film thickness can be secured by the thickness of the first protrusion 4a. On the spacer 1f, the 2nd protrusion part 4b protrudes in a row from the inner wall of the insulation coating part 2, and it arrange | positions so that the said 2nd protrusion part 4b may contact | connect, I-shaped core 1a, 1b and spacer The thickness of the adhesive layer 1e interposed between the first protrusion 1f and the second protrusion 4b can be secured.

  The first protrusion 4 a is provided in a portion of the insulating cover 2 that covers the U-shaped cores 1 c and 1 d, and the second protrusion 4 b of the insulating cover 2 is the I-shaped core 1 a. 1b is provided on the portion covering 1b. How to provide the 1st projection part 4a and the 2nd projection part 4b can be suitably changed by design.

  For example, when the configuration of the insulating coating portion 2 is configured by the first separator 21 and the second separator 22 as in the first embodiment, the first separator 21 and the second separator 22 is further subdivided and molded. That is, the connecting portion 21c and the straight portions 21a and 21b, and the connecting portion 22d and the straight portions 22a and 22b are separately formed. In this case, the second separator 22 will be described as an example. The connecting portion 22d and the first protrusion 4a are continuously formed by resin molding, and the straight portions 22a and 22b and the second protrusion 4b are formed. Are formed in a row. And the edge part of straight part 22a, 22b and the edge part of the connection part 22d are faced | matched, and the 2nd separation body 22 is comprised. You may make it provide attachment parts, such as a level | step difference, so that the edge part of the linear parts 22a and 22b and the edge part of the connection part 22d may fit one side in the other.

  Alternatively, in the first embodiment, the first insulating member 21 and the second separating member 22 obtained by dividing the insulating coating portion 2 into two parts are used. However, as shown in FIGS. The pair of straight portions 20a, 20b covering the character-shaped cores 1a, 1b and the ends of the pair of straight portions 20a, 20b on the U-shaped core 1c side are connected by a connecting portion 21c, and a pair of straight portions The respective ends of 20a and 20b on the U-shaped core 1d side may be connected by a connecting portion 22d.

  In other words, the linear portion 21a and the linear portion 21b which are separated in the first embodiment may be a single linear portion 20a, and similarly, the linear portion 22a and the linear portion 22b may be a single linear portion 20b. In this case, the U-shaped cores 1c and 1d are resin-molded to form the connecting portions 21c and 22d, and the first projecting portion 4a covers a part of the bonding surface of the U-shaped cores 1c and 1d. Provided. Further, by linearly molding the I-shaped cores 1a and 1b, the straight portions 20a and 20b are formed, and the second protruding portions 4b are covered with a part of the bonding surface of the I-shaped cores 1a and 1b. Provide.

  When the reactor is assembled, the first protrusion 4a or the second protrusion 4b functions as a pressing jig for pressing the spacer 1f against the other protrusions 4a and 4b.

  In FIG. 7, the two opposite sides of the split cores 1 b and 1 d are R-shaped sides that are chamfered. However, as in the first embodiment, a pair of opposing face surfaces of the split cores are opposed to each other. The annular core 1 is formed by connecting the split cores so that the pair of sides of the split core is orthogonal to the pair of sides of the split core to be bonded to the split core. It may be formed.

[2-2. Effect]
The reactor of the present embodiment includes an annular core 1 formed by connecting a plurality of divided cores to each other via an adhesive layer 1e having a predetermined film thickness, and an insulating covering portion 2 that covers the outer periphery of the annular core 1. The annular core 1 includes spacers 1f disposed between the split cores on both sides via the adhesive layer 1e, and the insulating cover 2 includes a protrusion 4 sandwiched between the split cores and the spacer 1f. I did it. Thereby, since the thickness separation of the protrusion 4 can be performed between the split core and the spacer 1f, the thickness of the adhesive layer 1e interposed between the split core and the spacer 1f is equal to the thickness of the protrusion 4. Can be secured.

  In particular, the insulating coating 2 is sandwiched between the first protrusion 4a sandwiched between one of the split cores connected to each other and the spacer 1f, and the other of the split cores connected to each other and the spacer 1f. Since the second protrusion 4b is provided, the thickness of the adhesive layer 1e located on both sides of the spacer can be set to a predetermined thickness.

[3. Other Embodiments]
The present invention is not limited to the first and second embodiments, and includes other embodiments described below. In addition, the present invention also includes a combination of the following other embodiments.

(1) In the first and second embodiments, the protrusions 4 are provided between the divided cores at two locations on the inner and outer portions of the closed magnetic path of the annular core 1. Or only an outer peripheral part may be sufficient. Further, as a modification of the second embodiment, as shown in FIG. 8A, only the linear portions 20a and 20b formed by resin molding the I-shaped cores 1a and 1b, the protrusions 4, that is, the first 2 projections 4b may be provided, and as shown in FIG. 8 (b), the first projection 4a and the second projection 4b may be either straight portions 20a, 20b or connecting portions 21c, 22d. It may be provided to complement each other. Moreover, it is not limited to these, The protrusion part 4 is sectional drawing between the division | segmentation cores of the insulation coating part 2, Comprising: The form like FIG. 9 which shows the installation aspect of the protrusion part 4 may be sufficient. That is, as shown in FIG. 9A, it may be provided annularly on the inner periphery of the insulating coating portion 2 so as to be in contact with the entire periphery of the adhesive surface of the split core, or as shown in FIG. 9B. In addition, the insulating coating portion 2 may be provided in a dot shape so that a part thereof is in contact with each side of the adhesive surface of the split core. Further, as shown in FIGS. 9C and 9D, the insulating coating portion 2 may be provided in the shape of a tens (plus) or X in the inner periphery. In addition, the dotted line part of Fig.9 (a)-(d) has shown the outline of the location in which the protrusion part 4 is not provided among the inner walls of the insulation coating part 2. FIG.

(2) In the first and second embodiments, the protrusion 4 is provided inside the straight portions 21a, 21b, 22a, 22b, but is not limited thereto. The installation location is not limited as long as it can be sandwiched between the divided cores and the inner periphery of the insulating coating 2 covers the outer periphery of the annular core 1. For example, you may provide in the inner periphery of the connection parts 21c and 22d.

(3) As a modification of the second embodiment in which the spacer 1f is arranged between the divided cores, the protrusion may be a protrusion 40a as shown in FIG. The protrusion 40a ensures the thickness of the adhesive layer 1e located on both surfaces of the spacer 1f, and includes a first protrusion 41 and a second protrusion 42. The first protrusion 41 and the first protrusion 42 are similar to the protrusion 4 of the first embodiment from the inner walls of the straight portions 21a, 21b, 22a, and 22b of the insulating coating portion 2 to the straight portions 21a, 21b, and 22a. , 22b protrudes to narrow the left and right width directions.

  The first protrusion 41 is sandwiched between the U-shaped core 1d and the spacer 1f, and ensures the thickness of the adhesive layer 1e between them. In other words, the first protrusion 41 overlaps the end of the spacer 1f.

  The second protrusion 42 is provided adjacent to the first protrusion 41 and protrudes from the inner wall of the insulating coating portion 2, but does not protrude from the first protrusion 41. In other words, the protrusion 40a has a staircase shape, and as shown in FIG. 10, the second protrusion 42 is adjacent to the bonding surface direction of the spacer 1f and the split cores 1b and 1d. The length of the second protrusion 42 protruding from the first protrusion 41 in this way is short because the spacer 1 f is inserted from the straight portions 21 a, 21 b, 22 a, 22 b and arranged so as to overlap the first protrusion 41. This is to make it easier.

  The thickness of the second protrusion 42 is larger than the thickness of the spacer 1f, and the second protrusion 42 is in contact with the bonding surface of the I-shaped core 1b. Accordingly, the thickness of the adhesive layer 1e between the I-shaped core 1b and the spacer 1f is equal to the thickness of the second protrusion 42 minus the thickness of the spacer 1f. The thickness of the adhesive layer 1e can be ensured.

(4) As a modification of the second embodiment in which the spacer 1f is arranged between the divided cores, the protrusion may be a protrusion 40b as shown in FIG. The basic configuration is the same as that of the modified example (3), and only the differences from the modified example (3) will be described. The same parts are denoted by the same reference numerals, and detailed description thereof will be omitted. Since the configuration of the protruding portion 40b is the same between the divided cores, the bonding portion between the I-shaped core 1b and the U-shaped core 1d will be described as an example with reference to FIG.

  The protrusion 40b has a first protrusion 41 and a second protrusion 42b. The first protrusion 41 has the same configuration as that of the protrusion 40a, and is sandwiched between one U-shaped core 1d of the split cores connected to each other and the spacer 1f. As shown in FIG. 11, the second protrusion 42b protrudes from the inner wall of the insulating coating portion 2 by the same length as the first protrusion 41, and the other split core, i-shaped core 1b and spacer 1f. It is sandwiched between. The second protrusion 42b is provided apart from the first protrusion 41, and the distance is the same as the plate thickness of the spacer 1f. That is, the spacer 1f is positioned so as to be sandwiched between the first protrusion 41 and the second protrusion 42b.

  In order to insert the spacer 1f through the openings of the straight portions 21a, 21b, 22a, and 22b and insert it between the first protrusion 41 and the second protrusion 42b, for example, the protrusion 40b is inserted into the annular core 1. It suffices to provide it only on one of the inner peripheral side and the outer peripheral side and not on the other. By doing in this way, the spacer 1f can be placed on the first protrusion 41 without the second protrusion 42b becoming a barrier.

  As described above, the first protrusion 41 and the second protrusion 42b of the protrusion 40b control the film thickness of the adhesive layer 1e on both surfaces of the spacer 1f even when the spacer 1f is disposed between the divided cores. In addition, the first protrusion 41 and the second protrusion 42b also function as positioning members for the spacer 1f, and the arrangement of the spacers between the divided cores becomes accurate, and variations between products can be reduced. .

(5) In the first and second embodiments, the I-shaped cores 1a and 1b constituting the legs of the annular core 1 are formed of a single core, but two or more small I-shaped cores are used. The legs may be configured by abutting each other. In this case, the protrusions 4 sandwiched between the small I-shaped cores may be provided at a plurality of locations inside the insulating coating portion 2.

(6) In the first and second embodiments, the protrusion 4 is provided by the resin molding of the U-shaped cores 1c and 1d so as to be seamless with the straight portions 21a, 21b, 22a, and 22b. 4 may be prepared separately and attached to the inside of the straight portions 21a, 21b, 22a, 22b with an adhesive or the like.

(7) In the first and second embodiments, the protrusion 4 has a rounded shape that is narrowed from the proximal end to the distal end. However, the rounded portion is straightened to be angular. It may be a staircase.

(8) In the first and second embodiments, the U-shaped core and the I-shaped core or the E-shaped core are used as the split cores in order to form the annular core 1, but the present invention is not limited to this. That is, the annular core 1 only needs to be configured by abutting a plurality of divided cores. In addition to these, a shape capable of configuring an E-shaped core, a T-shaped core, and other annular cores 1 as the divided cores. A core having can be used.

(9) In the first and second embodiments, one reactor has been described. However, the present invention may be applied to a configuration in which a plurality of reactors are arranged in parallel so that each leg portion is parallel.

DESCRIPTION OF SYMBOLS 1 cyclic | annular core 1a, 1b I-shaped core 1c, 1d U-shaped core 1e Adhesive layer 1f Spacer 2 Insulation coating | cover part 20a, 20b Linear part 21 1st isolation | separation body 21a, 21b Linear part 21c Connection part 23a, 23b Fixing part 25a, 25b Screw insertion hole 22 Second separator 22a, 22b Linear portion 22d Connecting portion 24a, 24b Fixing portion 26a, 26b Screw insertion hole 28a, 28b Nut 4 Protrusion 4a First protrusion 4b Second protrusion 40a protrusion 41 first protrusion 42 second protrusion 40b protrusion 42b second protrusion 5 coil 51a, 51b coil 52a, 52b end 53a, 53b end 8 connector 9 temperature sensor 9a temperature detector 9b lead wire

Claims (11)

An annular core formed by connecting a plurality of divided cores to each other through an adhesive layer having a predetermined film thickness;
An insulating coating covering the outer periphery of the annular core;
With
The insulating coating has a protrusion sandwiched between the divided cores;
Reactor characterized by. The insulating covering portion has an inner wall that covers between the divided cores,
The protrusion protrudes continuously from the inner wall;
The reactor according to claim 1. The protrusion is made of resin;
The reactor according to claim 1 or 2, characterized in that. The protruding portion has a shape in which the proximal end side is wider than the distal end side,
The reactor of any one of Claims 1-3 characterized by these. The split core includes an adhesive surface connected to another split core,
A pair of sides facing the adhesive surface is a chamfered side,
The annular core is
The pair of sides of the split core are formed by connecting the split cores so as to be orthogonal to the pair of sides of the split core bonded to the split core;
The reactor of any one of Claims 1-4 characterized by these. An annular core formed by connecting a plurality of divided cores to each other through an adhesive layer having a predetermined film thickness;
An insulating coating covering the outer periphery of the annular core;
With
The annular core includes spacers disposed between the split cores on both sides via the adhesive layer,
The insulating coating portion includes a protrusion sandwiched between the split core and the spacer;
Reactor characterized by. The insulating covering portion is
A first protrusion sandwiched between one of the divided cores connected to each other and the spacer;
A second protrusion sandwiched between the spacer and the other of the split cores connected to each other;
Providing
The reactor according to claim 6. The insulating covering portion has an inner wall that covers between the divided cores,
The protrusion protrudes continuously from the inner wall;
The reactor of Claim 6 or Claim 7 characterized by these. The protrusion is made of resin;
The reactor of any one of Claims 6-8 characterized by these. The protruding portion has a shape in which the proximal end side is wider than the distal end side,
The reactor of any one of Claims 6-9 characterized by these. The split core includes an adhesive surface connected to another split core,
A pair of sides facing the adhesive surface is a chamfered side,
The annular core is
The pair of sides of the split core are formed by connecting the split cores so as to be orthogonal to the pair of sides of the split core bonded to the split core;
The reactor of any one of Claims 6-10 characterized by these.

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