JP2019029594A - Reactor - Google Patents

Abstract

To provide a reactor which has less possibility of the generation of a noise, even when a core is vertically arranged to a case.SOLUTION: A reactor comprises: a core; a coil mounted to a leg part of the core; a reactor main body that includes a resin member for covering and insulating the core from the coil; and a case that houses the coil so that a winding axial direction of the coil becomes vertical to a bottom surface of the reactor main body. The reactor main body is horizontally divided into two of an upper side resin member covering the circumference of an upper core and a lower core and a lower side resin member covering a lower core and the circumference of the lower core with a surface orthogonal to the winding axial direction of the coil. Further, the reactor main body comprises: a core side fixing part extended to a vertical direction to the coil winding axial direction from the upper side resin member; and a gap part 6 that is positioned between a whole circumference of the lower part of the reactor main body and the case when housing the reactor main body into the case 4. The reactor main body is fixed to the case by the core side fixing part.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a reactor in which a core is accommodated in a case.

  Reactors are used in various applications including drive systems for hybrid vehicles and electric vehicles. For example, a reactor in which a coil is wound around a resin bobbin disposed around a core is often used as a reactor used in an in-vehicle booster circuit.

  This type of reactor has a core and a coil attached to a part of the core. The core and the coil are accommodated in a metal case, and a filler is filled and solidified in the case to constitute a reactor. That is, in the reactor, a core and a coil are arranged in the case, and a filler is filled and solidified in a gap in the accommodation space in the case.

  When the core and the case are not sufficiently fixed, when vibration is applied to the reactor, members come into contact with each other and noise is generated. Therefore, it is necessary to securely fix the core and the case, and the core is disposed horizontally with respect to the case so that the core can be easily fixed to the case. When the core is horizontally arranged with respect to the case, the core is arranged in the case so that the winding axis direction of the coil is horizontal, and fixed portions provided at the four corners of the core and four fixed portions provided at the bottom surface of the case And fix with screws. Since the case-side fixing portion is provided on the bottom surface of the case, the thickness of the side surface of the case is not increased, and the work can be performed from above the opened case, so that the core is easily fixed to the case.

JP2013-026420A

  In recent years, there has been an increasing demand for arranging the core vertically with respect to the case. When the core is arranged in the case so that the winding axis direction of the coil is vertical, and the core is arranged perpendicular to the case, the four fixing portions provided at the four corners of the core and the side surfaces of the case as in the conventional case It is possible to use a method in which the coil is fixed by four fixing portions provided on the core and fixed so that the coil is floating with respect to the core. In this fixing method, stress is applied to the bonded portion of the split core due to the stress due to the difference in linear expansion coefficient of each member. Therefore, the adhesion part of a division | segmentation core may peel off. When the bonded portion is peeled off, a gap is generated between the upper and lower cores. When vibration is applied to the reactor in this state, the core collides with the core, causing a problem that causes noise.

  The present invention has been made in order to solve the above-described problems. The purpose of the present invention is to provide an adhesive portion of a split core due to a difference in linear expansion coefficient of each member even when the core is arranged perpendicular to the case. An object of the present invention is to provide a reactor that reduces the stress applied to the hanger.

  The reactor of the present invention includes a coil, a core having a leg portion on which the coil is mounted, a reactor main body having a resin member that covers the core and is insulated from the coil, and a winding axis direction of the coil in the reactor main body is A reactor that accommodates the reactor main body so as to be perpendicular to the bottom surface of the case, wherein the reactor main body, the core, and the insulating resin are surfaces orthogonal to the winding axis direction of the coil, respectively. The core is composed of an upper core and a lower core, and an adhesive portion that bonds the upper core and the lower core, and the resin member is surrounded by the upper core and the lower core. An upper resin member and a lower resin member, and the reactor main body includes an upper reactor main body composed of the upper core and the upper resin member, and the lower core. And a reactor body lower portion made of a lower resin member, and a core-side fixing portion extending in a direction perpendicular to the winding axis direction of the coil from the upper resin member, and when the reactor body is accommodated in the case And a gap portion located between the entire periphery of the lower part of the reactor body and the case, and the reactor body is fixed to the case by the core-side fixing part.

  ADVANTAGE OF THE INVENTION According to this invention, the reactor which suppressed generation | occurrence | production of noise can be obtained, arrange | positioning a core vertically.

It is the whole reactor perspective view concerning a 1st embodiment. It is a disassembled perspective view of the reactor which concerns on 1st Embodiment. It is a disassembled perspective view of the reactor main body which concerns on 1st Embodiment. It is a perspective view which shows the structure of a core. It is a perspective view of the upper side resin member concerning a 1st embodiment. It is a perspective view of the lower resin member concerning a 1st embodiment. It is sectional drawing of the case which concerns on 1st Embodiment. It is sectional drawing in the surface parallel to the winding axis direction of a coil in the reactor which concerns on 1st Embodiment. It is a figure which shows the manufacturing process of the reactor which concerns on 1st Embodiment. It is a figure which shows the manufacturing process of the conventional reactor.

  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 an overall perspective view of the reactor according to the first embodiment. FIG. 2 is an exploded perspective view of the reactor according to the first embodiment. FIG. 3 is an exploded perspective view of the reactor body according to the first embodiment. FIG. 4 is a perspective view of the upper resin member according to the first embodiment. FIG. 5 is a perspective view of the lower resin member according to the first embodiment.

  In FIG. 1, the reactor includes a plurality of reactor bodies. The number of reactor bodies included in the reactor can be any number including one. In the present embodiment, for the sake of explanation, it is assumed that three reactor bodies A to C are arranged in the reactor. A reactor is an electromagnetic component that converts electric energy into magnetic energy and stores and discharges it, and is used for voltage step-up / step-down and the like. 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 a main component of the booster circuit mounted on these automobiles.

  Moreover, as shown in FIGS. 1-6, the reactor which concerns on this embodiment is provided with reactor main body AC, the case 4, and the filling molding part 6. FIG. Reactor bodies A to C each include a core 1, a resin member 2, and a coil 5.

  The core 1 and the resin member 2 of the reactor bodies A to C are divided into a reactor body upper part 3A and a reactor body lower part 3B on a surface orthogonal to the winding axis direction of the coil 5. The core 1 includes an upper core 1A and a lower core 1B. The resin member 2 (hereinafter referred to as the cover 2) is a surface orthogonal to the winding axis direction of the coil 5, and is an upper resin member (hereinafter referred to as the upper cover 2A) and a lower resin member (hereinafter referred to as the lower cover 2B). ). The upper cover 2A covers the upper core 1A and becomes the reactor main body upper part 3A, and the lower cover 2B covers the lower core 1B and becomes the reactor main body lower part 3B. Reactor body upper part 3A and reactor body lower part 3B are bonded and fitted together, and reactor body AC is formed by fitting coil 5 into the middle leg part. Reactor main body AC is arrange | positioned in a case and a reactor is comprised by filling and solidifying a filler and comprising the filling molding part 6. FIG.

[1-2. Detailed configuration]
The detailed structure of each part of the reactor of this embodiment is demonstrated below. In this specification, the z-axis direction shown in FIG. 1 is the “upper” side, and the opposite direction is the “lower” side. In describing the configuration of each member, “lower” is also referred to as “bottom” or “back”. “Upper” and “lower” refer to the positional relationship between the components of the reactor, and do not refer to the positional relationship or direction when the reactor is mounted on an actual machine.

(Reactor body)
The core 1 that constitutes the reactor body is an annular core that includes a magnetic material. As the core 1, a ferrite core, a laminated steel plate, a dust core, or a metal composite core can be used. The metal composite core is a core formed by molding a magnetic material obtained by mixing magnetic powder and resin with a mold, and is a core that has not been annealed. Here, the core 1 is a dust core.

  As shown in FIG. 3, the reactor main body is constituted by a reactor main body upper part 3 </ b> A and a reactor main body lower part 3 </ b> B, and the reactor main body upper part 3 </ b> A and the reactor main body lower part 3 </ b> B are constituted by a core 1 and a cover 2.

  The core 1 is configured by joining an upper core 1A and a lower core 1B (see FIG. 4). A bonding portion for bonding the upper core 1A and the lower core 1B is provided at a joint portion between the upper core 1A and the lower core 1B. The upper core 1A and the lower core 1B are E-shaped cores having an E shape, and both the upper core 1A and the lower core 1B use E-shaped cores having the same dimensions. The E-shaped core includes a central middle leg 15, outer legs 16 and 17 provided on both sides of the middle leg 15 in parallel with the middle leg 15, and a yoke 18 that connects the legs 15 to 17. .

  In the upper core 1A and the lower core 1B, the middle leg 15 constitutes the middle leg part to which the coil 5 is attached, the outer legs 16 and 17 constitute the outer leg part, and the yoke 18 constitutes the yoke part. The outer legs 16 and 17 of the upper core 1A and the lower core 1B are in contact with each other by an adhesive or the like, and the middle legs 15 of the upper core 1A and the lower core 1B are separated from each other, and there is a gap. To do.

  That is, the core 1 has a substantially θ shape, a middle leg portion on which the coil 5 is mounted, a pair of outer leg portions extending in parallel with the middle leg portion on both sides of the middle leg portion, and the middle leg portion and the outer leg portion. And a yoke part connecting the two. When the coil 5 is energized, a magnetic flux is generated in the air core portion of the coil 5, and the generated magnetic flux returns from the middle leg portion to the middle leg portion via the yoke portion and the outer leg portion to form a closed magnetic path.

  The cover 2 covers the periphery of the core member to constitute the core 1, and the cover 2 is joined to the case 4. The cover 2 includes an upper cover 2A that covers at least a part around the upper core 1A and a lower cover 2B that covers at least a part around the lower core 1B. Each of the upper cover 2A and the lower cover 2B is made of resin. As the resin, for example, an epoxy resin, an unsaturated polyester resin, a urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), PBT (Polybutylene Terephthalate), or the like can be used.

  The upper cover 2A covers at least a part of the periphery of the upper core 1A. The upper cover 2A is provided with openings through which the end surfaces of the middle leg 15 and the outer legs 16 and 17 are exposed. The upper cover 2 </ b> A is provided with a core side fixing portion 21 for fixing the upper core 1 </ b> A to the case 4. The core side fixing portion 21 extends in a direction perpendicular to the winding axis direction of the coil 5. The core side fixing portion 21 is provided with a screw insertion hole 21 a extending in the winding axis direction of the coil 5. The upper core 1 </ b> A is fixed to the case 4 by inserting a screw 91 into the screw insertion hole 21 a and screwing it into a case-side fixing portion 44 described later.

  Further, end portions 51a and 51b of the coil 5 are drawn out from the upper surface of the reactor body. The end portions 51a and 51b are in contact with one end of the connection terminal 52a. The other end of the connection terminal 52a is fitted into the terminal fixing portion 22 and fixed. The upper cover 2A is provided with a terminal fixing portion 22 for fixing the connection terminal 52a connected to the end portions 51a and 51b. The terminal fixing portion 22 is erected so as to extend outward from the side surface of the reactor. In other words, in the reactor main body A of FIG. 1, the terminal fixing portion 22 extends in a direction substantially orthogonal to the side surface of the reactor so as to extend in the y-axis direction.

  FIG. 5 is an enlarged perspective view showing the configuration of the upper cover 2A, FIG. 5 (a) is a perspective view from above in the z-axis direction, and FIG. 5 (b) is a perspective view from below in the z-axis direction. It is. As shown in FIG. 5A, in the upper cover 2A, the leg portions are located on the lower side, and the yoke portions connecting the leg portions are located on the upper side. The upper cover 2A covers each leg portion and the yoke portion of the upper core 1A, but does not cover all, but provides an opening in a part of the upper cover 2A. That is, the upper cover 2A covers the periphery of the upper core 1A that is an E-shaped core. Openings X1 to X3 are provided at the ends of the legs of the upper cover 2A, and the upper core 1A inside is exposed. As shown in FIG. 5 (b), the opening provided at the end of the central middle leg 15 is defined as an opening X 1, and the openings provided at the ends of the outer legs 16, 17 provided parallel to the middle leg 15. Let the part be openings X2 and X3. When the upper cover 2A is covered with the upper core 1A, the upper core 1A is exposed from each opening, and this end face is a leg of the lower core 1B when the reactor main body upper part 3A and the main body lower part 3B are joined. Contact the end face of the part.

  In addition, two injection marks 23 are provided on the upper portion of the upper cover 2A. The upper cover 2A is configured by resin molding using the upper core 1A as an insert, and the upper cover 2A is made of the same resin. The injection trace 23 corresponds to the position of the gate G where the resin is injected during resin molding. The resin is injected from the direction perpendicular to the surface where the injection mark 23 is provided. That is, being provided on the upper surface of the upper cover 2A means that the resin has been injected from the direction perpendicular to the upper surface of the upper cover 2A, that is, from the winding axis direction of the coil 5.

  In resin molding, the gate G has a role of controlling the flow rate of the resin, sealing the gate G, controlling the resin temperature, and cutting the molded product. That is, when molding the upper cover 2A, the gate G portion is cured first, thereby preventing the back flow of the resin and adjusting the pressure. Further, since the gate G is thin, the upper cover 2A after molding is easily cut. That is, the molded product is taken out by separating the resin in the gate G portion after molding. The injection mark 23 can be obtained at this time. The injection mark 23 may be in a state of being separated or a state in which the separation part is subjected to a polishing process such as sanding. Further, by adjusting the amount of the resin and the method of injecting the resin, the resin that has come out of the gate G portion may not come into contact with the gate G and may not be separated. In this case, the injection mark 23 is in a state where the resin is raised or indented.

  The lower cover 2B covers at least a part of the periphery of the lower core 1B. 6 is an enlarged perspective view showing the configuration of the lower cover 2B, FIG. 6 (a) is a perspective view from above in the z-axis direction, and FIG. 6 (b) is a perspective view from below in the z-axis direction. It is. As shown in FIG. 6 (a), in the lower cover 2B, the leg portions are located on the upper side, and the yoke portion connecting the leg portions is located on the lower side. The lower cover 2B covers each leg portion and the yoke portion of the lower core 1B, but does not cover all, but provides an opening in a part of the yoke portion and the lower cover 2B. That is, the upper cover 2A covers the periphery of the upper core 1A that is an E-shaped core. Openings X4 to 6 are provided at the ends of the legs of the lower cover 2B, and an opening X7 is provided on the upper surface of the yoke portion to expose the internal lower core 1B. As shown in FIG. 6B, the opening provided at the end of the central middle leg 15 is defined as an opening X4, and the openings provided at the ends of the outer legs 16, 17 provided in parallel with the middle leg 15. The openings are X5 and X6, and the opening provided in the yoke is X7. When the lower cover 2B is covered with the lower core 1B, the lower core 1B is exposed from the openings X4 to X6, and this end face is formed when the reactor main body upper part 3A and the main body lower part 3B are joined. In contact with the end face of the leg. Similarly, the lower core 1B is exposed from the opening X7. The lower core 1B exposed from the opening X7 faces the bottom surface 47 of the case when the reactor body is fixed to the case 4.

  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 attached to the middle leg 15 of the core 1. In this case, when the reactor main bodies A to C are arranged in the case 4, the winding axis of the coil 5 is in the z-axis direction shown in FIG. Further, both end portions 51 a and 51 b of the coil 5 are pulled out above the reactor, and are connected to wiring of an external device such as an external power source via a connection terminal 52 a fixed to the terminal fixing portion 22. The fixing screw 53 is used to fix the connection terminal 52a and the wiring of the external device.

(Reactor)
The reactor includes reactor main bodies A to C, a case 4, and a filling molding part 6. Case 4 is a container that houses reactor main bodies A to C. The case 4 is made of a metal excellent in heat dissipation and thermal conductivity, and has heat dissipation. The heat generated in the reactor main bodies A to C is dissipated to the outside of the case 4 by being transmitted to the case 4 via the filling molding part 6. The case 4 is made of a metal having high thermal conductivity and light weight, such as aluminum or an aluminum alloy, in order to obtain a good heat dissipation efficiency, and a part of the surface of the case 4 is roughened. It may be.

  As shown in FIG. 2, the case 4 has a substantially rectangular parallelepiped shape with an upper surface opened. The case 4 is a box-shaped member having one surface opened. The case 4 includes a bottom surface 47 provided at a position facing the opening 45, and a case side surface 46 connected to the bottom surface 47. The case 4 is provided with a space for arranging the reactor therein. An inner surface of the case 4 is defined as an inner surface of the case 4, that is, a surface facing the space where the reactor on the case side surface 46 is disposed.

  The opening 45 is an opening provided in the upper portion of the case 4. The dimensions of the opening are such that the reactor bodies A to C in which the axial direction of the coil 5 is perpendicular to the bottom surface 47 (in the direction of arrow B in FIG. 7) can be accommodated in the opening 45. A bottom surface 47 is located at the bottom portion of the case 4. The bottom surface 47 is a reference when the reactor main bodies A to C are arranged in the case 4. The case side surface 46 is erected vertically from the entire periphery of the bottom surface 47, but if the position of the opening 45 can be relatively fixed with respect to the bottom surface 47, the erected portion and angle are arbitrary. Can do. Further, the case side 46 does not need to rise vertically and may rise at an acute angle or an obtuse angle.

  The case 4 has a dent portion 48 in which the reactor main bodies A to C are arranged on the bottom surface 47 portion. The recessed portion 48 has a shape along the shape of the reactor main bodies A to C. By making the recessed part 48 into such a shape, the case 4 formed of a metal having good thermal conductivity can be brought close to the reactor bodies A to C. Thereby, since it becomes possible to transmit the heat which generate | occur | produced in reactor main body AC to the case 4, the heat dissipation of a reactor can be improved. When the reactor main bodies A to C are arranged in the recessed portion 48, the reactor main bodies A to C and the case 4 are provided with a predetermined clearance, but are 1.0 mm or more in consideration of ensuring insulation and the flow of the filler. It is desirable to arrange at a distance. The recessed portion 48 includes a case side surface 46, three projecting portions 41, 42, 43 projecting from the inside of the case side surface 46 toward the inside of the case 4, and a projecting portion 41 a erected from the reactor bottom surface 47.

  When the reactor main bodies A to C are arranged, the inner peripheral surface of the case 4 facing the side peripheral surfaces of the reactor main bodies A to C has a shape along the side peripheral surface of the reactor.

  The protrusion 41 separates the reactor main body B and the reactor main body C from each other. The protruding portion 41 is a wall that protrudes from the case side surface 46 in the y-axis direction while standing from the bottom surface 47 in the z-axis direction. When the reactor main body B and the reactor main body C are arranged in the case 4, the side surface in the x-axis direction of the protrusion 41 is the outer leg 17 of the reactor main body B among the side peripheral surfaces of the reactor main body B and the reactor main body C. It faces the outer leg 17 of the reactor body C. Moreover, the front-end | tip part of the protrusion part 41 extended in a y-axis direction opposes the coil 5 of the reactor main body B and the reactor main body C. As shown in FIG. The tip portion of the protruding portion 41 has a shape along the shape of each reactor. For example, the portion of the tip portion of the protruding portion 41 that faces the reactor main body B has an R according to the shape of the coil 5 of the reactor main body B.

  The projecting portions 42 and 43 are walls projecting in the x-axis direction from the case side surface 46 while standing from the bottom surface 47 in the z-axis direction. The projecting portion 42 separates the reactor main body A and the reactor main body B, and the projecting portion 43 separates the reactor main body A and the reactor main body C from each other. For example, when the reactor main body A and the reactor main body C are arranged in the case 4, the side surface of the protrusion 43 on the side of the reactor main body C in the y-axis direction faces the outer leg 16 of the reactor main body C. Further, the side surface of the protrusion 43 on the side of the reactor main body A in the y-axis direction faces the outer leg 16 of the reactor main body A. Further, the tip end portion of the projecting portion 43 extending in the x-axis direction has an R according to the shape of the coil 5 of the reactor main body A. The same applies to the projecting portion 42 disposed between the reactor main body A and the reactor main body B. Each protrusion 41-43 is made of a metal made of the same metal as that of the case 4, and surrounds the reactor main bodies A to C to form an accommodation space for the reactor main bodies A to C.

  In the region where the reactor main bodies A to C face each other, a protruding portion 41a is provided to stand from the bottom surface 47 in the z-axis direction. The shape of the protrusion 41a is a shape along the shape of the side surfaces of the opposing reactor main bodies A to C. The protrusion 41a has a pentagonal shape and faces the leg portions of the reactor main body B and the reactor main body C on the side surface in the x-axis direction. Further, one side surface in the y-axis direction faces the coil 5 of the reactor body A, and two surfaces projecting in the y-axis direction face the reactor body B and the coil 5 in the reactor body C. The shape of the two surfaces protruding in the y-axis direction is a shape along the shape of the coil 5 of the reactor main body B and the reactor main body C.

  The filling molding unit 6 is formed by filling and solidifying a filling material in a space in the accommodation space of the reactor body surrounded by the case 4. 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 vibration propagation from the reactor to the case 4. Moreover, it is preferable that a filler has insulation.

(Cross section of reactor)
FIG. 8 is a cross-sectional view of the reactor. As shown in FIG. 8, the reactor is arranged in a direction perpendicular to the case 4. The reactor body is fixed to the case 4 by fixing the core-side fixing portion 21 and the case-side fixing portion 44 with a rod-like fixing member (hereinafter referred to as a screw 91). A case side surface 46 extends from the case bottom surface 47 in the vertical direction. The case side surface 46 has an upper surface parallel to the bottom surface 47 of the case, and the surface parallel to the bottom surface 47 of the case serves as the case-side fixing portion 44. The size of the surface provided on the upper portion of the case side surface 46 that becomes the case side fixing portion 44 is such that the case side fixing portion 44 and the core side fixing portion 21 are located when the reactor body is inserted into the case 4 from the Z-axis direction. The size is such that contact is possible. Further, the case-side fixing portion 44 is the upper surface of the case side surface 46, but if there is no obstacle above the Z-axis direction, the reactor body can be inserted into the case 4 from the Z-axis direction. Therefore, the position of the case side fixing portion 44 is not limited to the upper portion of the case side surface 46.

  The core side fixing portion 21 is provided with a screw insertion hole 21a. The screw insertion hole 21 a communicates with a screw insertion hole 44 a provided in the case side fixing portion 44 when the reactor main body is disposed at an appropriate position of the case 4. Here, the screw insertion hole 21a is a hole that communicates from the front surface to the back surface of the core-side fixing portion 21, and the screw insertion hole 44a is a hole having a bottom.

  In the case-side fixing portion 44, a screw 91 is inserted into the screw insertion hole 21a and the screw insertion hole 44a that are in communication with each other while the surface parallel to the bottom surface 47 is in contact with the core-side fixing portion 21, and is fastened with screws. The screw 91 includes a threaded round bar and a flange portion larger in diameter than the round bar portion. The screw insertion hole 44a is provided with a screw thread corresponding to the screw thread cut in the round bar portion of the screw 91. The screw 91 fixes the reactor body and the case 4 by sandwiching the core-side fixing portion 21 between the flange portion and the case-side fixing portion 44 and screwing them. The depth direction of the screw insertion hole 21 a and the screw insertion hole 44 a and the insertion direction of the screw 91 with respect to the screw insertion hole 21 a and the screw insertion hole 44 a coincide with the winding axis direction of the coil 5. The winding axis direction of the coil 5 coincides with the direction perpendicular to the bottom surface 47.

  The thickness of the cover 2 covering the periphery of the upper and lower cores is about 1.5 mm. The cover 2 has an annular shape, that is, a torus shape. The upper and lower cores and the resin member are in close contact. On the other hand, a gap of 1.0 mm or more is provided between the cover 2 and the case 4. This gap is a gap in the claims. In the present embodiment, the gap is set to 1.0 mm or more, but may be less than 1.0 mm as long as the cover 2 and the case 4 are separated. That is, if the gap between the cover 2 and the case 4 is small, it is possible to prevent the stress from the case 4 from being applied to the connection portion of the reactor body. The gap is set to 1.0 mm or more in consideration of the flowability and insulation of the filler.

[1-3. Reactor manufacturing method]
Next, the manufacturing method of the reactor of this embodiment is demonstrated. The manufacturing method of this reactor has (a) resin molding process, (b) assembly process, (c) reactor arrangement process, and (d) filling process.

(a) Resin molding process The resin molding process includes a reactor body upper molding process for molding the upper cover 2A around the upper core 1A and a reactor body lower molding process for molding the lower cover 2B around the lower core 1B. Since the upper core 1A and the lower core 1B perform basically the same process, the upper core 1A will be described below as an example. FIG. 9 is a diagram showing a state of setting in the mold of the upper core 1A of the resin molding step and a position where the resin is filled.

  In the resin molding step, as shown in FIG. 9A, the upper core 1A is set in the lower mold B1. The upper core 1A is configured such that an end surface of the upper core 1A that is a contact surface with respect to the lower core 1B is in contact with the lower part of the mold (see (a)). When the upper core 1A is set, each part of the upper core 1A may be pressed with a jig or the like (not shown). At this time, the end face of the upper core 1A is in close contact with the mold. After completing the lower mold B1 set of the upper core 1A, the upper mold B2 is lowered (see (b)). A gap for forming the core side fixing portion 21 is provided at a contact portion between the lower mold B1 and the upper mold B2. In FIG. 9, although provided on the upper mold B2 side, it may be provided on the lower mold B1. Moreover, although not shown in the figure, in the gap for forming the core side fixing portion 21, a protrusion extending downward from the upper mold B2 is provided.

  Thereafter, the mold is filled with resin from the gate G and solidified (see (c) and (d)). The resin is filled by injecting the resin from the gate G. The resin is filled between the upper core 1A, the lower mold B1, and the upper mold B2 including a gap for forming the core-side fixing portion 21. At this time, due to the momentum of the resin filled from the gate G, a downward force is applied to the upper core 1A. By this force, the end surface of the upper core 1A is pressed against and closely contacts the lower mold B1. Therefore, resin does not flow between the end surface of the upper core 1A and the lower mold B1, and the end surface of the upper core 1A is not molded. In addition, the resin fills the gap for forming the core-side fixing portion 21.

  Thereafter, the resin is cured by passing a certain time, and the upper cover 2A is formed. The upper cover 2A is in close contact with the upper core 1A. In the upper cover 2A, a trace when the resin is injected from the gate G remains. In other words, in the cover 2A, the resin injection trace 23 of the upper cover 2A is a group indicating the direction of the gate G into which the resin was injected during molding. That is, two injection marks 23 are provided on the upper portion of the upper cover 2A, which indicates that the resin is injected from the upper two portions of the upper cover 2A. When the end surface of the upper core 1A that is in close contact with the lower mold B1 is used as a reference, an injection mark 23 indicating the resin injection direction is attached to the surface opposite to the end surface of the upper core 1A. The resin filled in the contact portion between the lower mold B1 and the upper mold B2 becomes the core-side fixing portion 21 by curing. Further, the protruding portion provided in the gap for forming the core-side fixing portion 21 is not filled with resin, and that portion becomes the screw insertion hole 21a.

  After the resin is cured, the upper mold B2 is raised and the upper core 1A is taken out (see (e)). Since the protruding portion provided in the gap for forming the core side fixing portion 21 extends in the vertical direction, there is no obstacle when the upper mold B2 is raised or when the upper core 1A is taken out from the lower mold B1. Without removing the upper core 1A.

(b) Assembling process The assembling process is a process of assembling the reactor with the upper core 1A on which the upper cover 2A is formed and the lower core 1B on which the lower cover 2B is formed with the coil 5 interposed. That is, the coil 5 is attached to the middle leg of the lower core 1B, and the legs of the upper core 1A and the lower core 1B are assembled to face each other. At that time, an adhesive is applied to each leg of the upper core 1A and the lower core 1B and the opposing surfaces of the upper cover 2A and the lower cover 2B to bond the upper core 1A and the lower core 1B.

(c) Reactor arrangement process The reactor arrangement process is a process of arranging the assembled reactor body in the case 4. The reactor body is fixed to the case 4 using screws 91. As a fixing method, the case-side fixing portion 44 and the core-side fixing portion 21 are previously brought into contact with each other, and the screw insertion hole 21a and the screw insertion hole 44a are communicated with each other. Then, the screw 91 is inserted into the screw insertion hole 21a and the screw insertion hole 44a that are communicated with each other, and is screwed.

(c) Filling step The filling step is a step of filling the case 4 with a filler and solidifying it. At that time, the case 4 is filled with a filler from the upper part of the case 4.

[1-3. Action / Effect]
(1) A reactor according to the present embodiment includes a coil 5, a core 1 having a leg portion to which the coil 5 is attached, a reactor body having a resin member 2 that covers the core 1 and is insulated from the coil 5, and a coil in the reactor body And a case 4 that accommodates the reactor main body so that the winding axis direction of 5 is perpendicular to the bottom surface 47 of the case 4. The reactor body is fixed to the case 4 by a core side fixing portion 21 provided on the upper cover 2A.

  In the reactor having the above-described configuration, when the reactor is arranged vertically, the reactor main body is fixed to the case 4 only by the upper part of the reactor. In other words, a gap is present between the reactor main body lower part 3B and the case 4, and the lower part of the reactor has a floating structure. Thereby, even when the stress by the linear expansion coefficient difference of each member generate | occur | produces, it becomes difficult to apply a stress to the adhesion part of a division | segmentation core. Therefore, it becomes possible to prevent peeling of the bonded portion of the split core. As a result, it is possible to provide a reactor in which noise due to separation of the split core is prevented.

(2) The case 4 has a case side surface 46 extending in a direction perpendicular to the bottom surface 47. A surface parallel to the bottom surface 47 on the case side surface 46 is a part of the case side fixing portion 44. And the case side fixing | fixed part 44 and the core side fixing | fixed part 21 are made to contact, and a reactor main body is fixed with respect to the case 4. FIG. That is, the core side fixing portion 21 extending perpendicularly to the winding axis direction of the coil 5 is brought into contact with the case side fixing portion 44 so as to be placed thereon. In other words, the reactor main body is positioned with respect to the case 4 with a predetermined gap even before the fixing with the screw 91. Thereby, it is possible to easily perform the screwing operation with the screw 91.

(3) The case side fixing portion 44 and the core side fixing portion 21 are provided with a screw insertion hole 21a and a screw insertion hole 44a. The depth direction of the screw insertion hole 21 a and the screw insertion hole 44 a extends in a direction perpendicular to the bottom surface 47. When the reactor main body is fixed to the case 4, after inserting the reactor main body into the case 4, the screw insertion hole 21 a and the screw insertion hole 44 a are communicated with each other, and a rod-like screw is fixed with the screw 91. At this time, the insertion direction of the reactor main body with respect to the case 4 and the tightening direction of the screw 91 are the same. For this reason, since the flow line of the insertion operation of the reactor main body when the reactor main body is assembled to the case 4 and the tightening operation of the screw 91 are in the same direction, the assemblability when the reactor main body is fixed to the case 4 is improved. . The depth direction of the screw insertion hole 21 a and the screw insertion hole 44 a extends in the direction perpendicular to the bottom surface 47.

(4) The screw insertion hole 21a is a through-hole, and the screw insertion hole 44a is a hole having a bottom. The environment where the reactor is used includes an environment where fine dust is floating. When the screw insertion hole 44a is a hole, dust that has risen from the entrance on the opposite side where the screw 91 is inserted may enter the screw insertion hole. There is also a possibility that the screw 91 is fixed due to dust entering the inside. That is, by using the screw insertion hole 44a as a hole, it is possible to facilitate maintenance work and reassembly of the reactor body to the case 4.

(5) The screw 91 includes a threaded round bar and a flange portion having a large diameter of the round bar portion. The reactor main body can be fixed to the case 4 with a simple configuration in which the core-side fixing portion 21 is sandwiched between the flange portion of the screw 91 and the case-side fixing portion 44.

(6) The core-side fixing portion 21 is formed continuously with the same resin as the cover 2. Further, the upper cover 2A has a resin injection mark 23 at the time of molding. This injection trace 23 is a trace when the resin is injected from the direction opposite to the end face of the upper core. The coil 5 is attached to the leg portion of the core. FIG. 10 is a diagram showing the order of a conventional resin molding process. (A) is an upper view, (b) is a side view. Conventionally, the core 1A is set to the base B1 that stands vertically (see [1]). In the setting method, after fixing the core 1A to the fixing position of the base B1, the base B2 is lowered from above (see [2]). A predetermined gap is provided between the core 1A and the base B1. Thereafter, the slide S is slid, and the core 1A is sandwiched and fixed between the base B1 and the base B2. (See [3]). Thereafter, the resin is filled from the side surface direction of the core 1A (see [4]). The filling direction at this time is 90 ° different from the filling direction of the present embodiment. The upper cover 2A is formed by filling the resin between the upper core 1A and the mold and solidifying the resin. After the filler is solidified, the slide S is moved away from the core 1A to release the core 1A (see [5]). The contact portion between the core 1A and the slide S is not covered with the resin because the slide S is disposed when the resin is filled. That is, the core remains exposed, and if left as it is, problems such as rusting occur. Therefore, it is necessary to newly mold.

  On the other hand, in this embodiment, it is not necessary to provide the slide S in the mold when filling the resin. Conventionally, since the core 1A is arranged in the mold without the slide S in the direction of FIG. 10, there is a possibility that the position of the core 1A is shifted by the momentum of the resin injected from the gate. In addition, in the reactor main body upper part 3A created by the manufacturing method of FIG. 10, it is possible to expose the core 1A from the end surface of the leg portion of the core 1A. This is realized by bringing the core 1A into close contact with the base B1 and the base 2B. On the other hand, in this embodiment, since the gate G is arranged on the upper part of the core without arranging the slide, the weight of the core 1A is less likely to be displaced due to the weight of the resin injected from the gate. . The core 1A is pressed against the base B1 by the momentum of the resin injected from the gate (FIG. 9). At this time, since the resin does not flow between the core 1A and the base B1, the end surfaces of the leg portions of the core 1A and the base B1 are in close contact without providing the slide S of FIG. Thereby, the core 1A can be exposed from the end surface of the leg portion of the core 1A. As described above, even if the slide S is not provided in the mold, the cover in which the core 1A is exposed from the end surface of the leg portion of the core 1A is formed by injecting resin from the direction opposite to the end surface of the upper core. Therefore, it is possible to simplify the work process and reduce the cost. Moreover, when the injection trace 23 exists in the leg part of a core, the injection trace 23 may interfere with the coil 5 and may prevent smooth installation of the coil 5. On the other hand, since it is easy to secure a certain space in the upper part of the reactor body, even if there is an injection mark 23, it does not interfere with the wiring drawn out from the reactor or other members. By providing the injection mark 23 of the resin at the time of molding on the upper part of the upper cover 2A, the assembly work of the coil 5 can be made smooth. Furthermore, the screw insertion hole 22a of the core-side fixing portion 21 formed in the resin molding process of the upper core 1A is the same as the insertion direction of the reactor body with respect to the case 4. Thereby, the flow line of the insertion operation | movement of a reactor main body and the tightening operation | work of a screw becomes the same direction, and the assembly property of a reactor improves.

[3. Other Embodiments]
The present invention is not limited to the first embodiment, and includes other embodiments described below. Moreover, the present invention also includes a form in which the first embodiment and the following other embodiments are all or any combination thereof. Furthermore, various omissions, replacements, and modifications can be made to these embodiments without departing from the scope of the invention, and modifications thereof are also included in the present invention.

(1) For example, in the present embodiment, the shape of the core is an E shape, but the shape of the upper core 1A and the lower core 1B is not particularly limited as long as it is annular, and if an annular core can be formed. . For example, the upper core 1A and the lower core 1B may be I-shaped, C-shaped, U-shaped, E-shaped, J-shaped, or the like.

(2) In the present embodiment, two injection traces 23 are provided on the upper portion of the upper cover 2A, but the number of injection traces 23 is not limited to this. If the upper cover 2A can be molded, the injection mark 23 may be one place. Moreover, the injection trace 23 can also be made into three or more places.

(3) As the resin molding process, the reactor main body lower molding process is the same as the reactor main body upper molding process, but the reactor main body lower molding process can be fixed as in the conventional process. In this case, the portion where the slide S that fixes the core contacts the core is the opening X7.

DESCRIPTION OF SYMBOLS 1 ... Core 1A ... Upper core 1B ... Lower core 2 ... Cover 2B ... Lower cover 2A ... Upper cover 3A ... Main body upper part 3B ... Main body lower part 4 ... Case 5 ... Coil 6 ... Filling molding part 15 ... Middle leg 16 ... Outer leg 17 ... outer leg 18 ... yoke 21 ... core side fixing part 21a ... screw insertion hole 22 ... terminal fixing part 23 ... injection trace 44 ... case side fixing part 44a ... screw insertion hole 47 ... bottom surface 52a ... connection terminal 53 ... fixing screw 91 …screw

Claims (11)

A reactor body having a coil, a core having legs for mounting the coil, and a resin member covering the core and insulating from the coil;
A case housing the reactor main body such that the winding axis direction of the coil in the reactor main body is perpendicular to the bottom surface of the case;
A reactor comprising a housing case,
The reactor main body, the core, and the insulating resin are each divided into two vertically on a plane orthogonal to the winding axis direction of the coil,
The core is composed of an upper core and a lower core, and an adhesive portion that bonds the upper core and the lower core,
The resin member is composed of an upper resin member and a lower resin member that cover the periphery of the upper core and the lower core,
The reactor body is composed of a reactor body upper part composed of the upper core and an upper resin member, and a reactor body lower part composed of the lower core and a lower resin member,
A core-side fixing portion extending in a direction perpendicular to the winding axis direction of the coil from the upper resin member;
When the reactor main body is accommodated in the case, a gap portion located between the entire periphery of the lower part of the reactor main body and the case,
With
The reactor main body is fixed to the case by the core side fixing portion. The case is
A side surface extending in a direction perpendicular to the bottom surface of the case;
2. The reactor main body is fixed to the case by bringing a case-side fixing portion and a core-side fixing portion, which are parallel to the bottom surface of the case, into contact with each other on the wall surface. Reactor. A rod-shaped fixing member that fixes the case-side fixing portion and the core-side fixing portion;
In the case side fixing portion and the core side fixing portion, an insertion portion extending in a direction perpendicular to the bottom surface of the case into which the fixing member is inserted, and
The reactor according to claim 2, comprising: The insertion part provided in the case side fixing part is a hole having a bottom,
The reactor according to claim 3, wherein the insertion portion provided in the core-side fixing portion is a through-hole. The fixing member includes a threaded round bar and a flange portion having a large diameter of the round bar portion,
The insertion part provided in the case side fixing part is provided with a screw thread corresponding to the screw thread cut in the round bar part,
The fixing member sandwiches the core-side fixing portion between the flange portion and the case-side fixing portion,
Screw the round bar part against the insertion part provided in the case side fixing part,
The reactor according to claim 4, wherein the reactor main body is fixed to the case. The core side fixing portion is formed continuously with the same resin as the upper resin member,
The reactor according to any one of claims 1 to 5, wherein the upper resin member has an injection mark of the resin at the time of molding.   The reactor according to claim 6, wherein the injection trace is a trace when resin is injected from a direction opposite to an end surface of a leg portion of the upper core. In the gap part, a filling molded part having heat dissipation and insulating properties is formed,
It is only the filling molding part that is interposed between the inner peripheral surface of the case and the lower resin member,
The reactor according to claim 1, wherein: The bonding portion bonds the end portions of the upper core and the lower core,
The reactor according to any one of claims 1 to 8, wherein the end surface is not covered with the resin member, and the upper core and the lower core are exposed. The upper core and the lower core are E-shaped cores;
The reactor according to any one of claims 1 to 9, wherein:   The reactor according to any one of claims 1 to 10, wherein the joint surfaces of the upper resin member and the lower resin member are flush with the joint surfaces of the upper core and the lower core, respectively.

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