JP2020088307A - Reactor and manufacturing method thereof - Google Patents

Abstract

To provide a reactor in which a lead wire and a bus bar resist vibration and are hard to be disconnected, and a manufacturing method thereof.SOLUTION: A reactor comprises a coil, a core, a lead wire 7b and a bus bar. The lead wire 7b is an end portion of a conductive wire constituting the coil and led out of the coil. The bus bar includes an end portion 42 extending toward the lead wire 7b and is connected with the lead wire 7b in the end portion 42. The end portion 42 of the bus bar and the lead wire 7b intersect obliquely, and the bus bar includes in the end portion 42 a flat surface 44 in non-parallel with a plane which is orthogonal to an extending direction of the lead wire 7b. The lead wire 7b includes an end face 71 which is tilted with respect to the extending direction of the lead wire 7b and spread in parallel with the flat surface 44. The lead wire 7b and the bus bar are then connected while continuously making the end face 71 flush with the flat surface 44.SELECTED DRAWING: Figure 3

Description

The present invention relates to a reactor and a manufacturing method thereof.

Conventionally, reactors have been used for various purposes. Even with a typical reactor alone, a boost reactor incorporated in the boost circuit of a hybrid vehicle or an electric vehicle, a series reactor that is connected in series to a motor circuit to limit the current at the time of a short circuit, a parallel reactor that stabilizes the current sharing between parallel circuits, Current limiting reactors and the like that limit the current when a short circuit occurs are known.

Generally, a rectangular wire is used as a conductive wire forming a coil in a reactor for a large current. There is a type of coil of a rectangular wire that is wound spirally while shifting the winding position for each turn along the winding axis, and a flatwise coil and an edgewise coil are known.

The spiral flatwise coil is formed by winding a conductive wire so that the wide surface of the conductive wire extends along the winding axis of the coil. The spiral edgewise coil is formed by winding a conductive wire so that the wide surface of the conductive wire extends in a direction orthogonal to the winding axis of the coil. Hereinafter, the flatwise coil wound in a spiral shape is simply referred to as a flatwise coil. An edgewise coil wound in a spiral shape is simply called an edgewise coil.

The flatwise coil and the edgewise coil are compared in terms of size. The flatwise coil is longer than the edgewise coil in the winding axis direction of the coil if the number of turns is the same. On the other hand, the flatwise coil can be miniaturized in the direction orthogonal to the winding axis of the coil. Further, since the flat-width coil can reduce the radius of curvature even in consideration of the stress on the enamel film covering the conductive wire, further miniaturization can be achieved in the direction orthogonal to the winding axis of the coil.

Further, in comparison with heat dissipation, the flatwise coil has good heat dissipation because the wide surface is exposed. Furthermore, when compared in terms of electrical characteristics, the flatwise coil has a shorter average current path length in a cross section along the direction orthogonal to the winding axis than the edgewise coil, so the direct current resistance can be kept low, Low loss.

When these comparison results are evaluated, it can be said that the flatwise coil is useful in a reactor having a small number of turns. For example, a reactor for removing noise requires only a few turns of the coil.

JP, 2013-016691, A

Here, the end portion of the conductive wire forming the coil is drawn out from the coil as a lead wire. It is conceivable to extend the lead wire along the winding axis of the coil (see Patent Document 1). When the lead wire is extended along the winding axis of the coil, the flatwise coil, which is likely to be elongated in the winding axis direction, is further lengthened. Further, not only the conductive wire is simply wound, but also the extension point change processing in the winding axis direction has to be performed, which increases the man-hours of the coil. Therefore, it is desirable that the leader line is drawn in a direction orthogonal to the winding axis direction.

However, since the spiral coil is produced by shifting the winding position of the conductive wire in the winding axis direction for each turn, the conductive wire is wound while being inclined in the direction in which the winding axis extends. In the flat wide coil, since the wide surface of the conductive wire expands along the winding axis, the tilt angle of the conductive wire becomes remarkable. As for the lead wire, at least at the end of winding, the lead wire is inclined and drawn out in the direction in which the winding shaft extends.

A bus bar is connected to the leader line. Since the lead wire is expected to be drawn out in the direction orthogonal to the winding axis, the bus bar extends parallel to the winding axis of the coil. Then, as shown in FIG. 7, the obliquely extending lead wire 70 and the bus bar 40 parallel to the winding axis cross each other at their connecting ends. It is conceivable to extend the bus bar 40 obliquely in accordance with the diagonally extending leader line 70, but this is not realistic because the positioning of the bus bar 40 becomes complicated.

When the reactor is used in an environment where vibration is severe, such as in a vehicle, it is desirable to join the lead wire 70 and the bus bar 40 by welding to increase the joining strength. In the process of welding, a torch is applied to the boundary between the lead wire 70 and the bus bar 40, and the torch is moved in parallel along the boundary. However, when the leader line 70 and the bus bar 40 cross each other obliquely, a region where the leader line 70 and the bus bar 40 are staggered occurs on most of the boundary line 810 between the leader line 80 and the bus bar 40. A step portion formed along the boundary line 810 becomes a physical obstacle, prevents the torch from reaching the boundary line 810, and performs a good welding process over the entire boundary line 810 between the leader line 70 and the bus bar 40. Make it difficult.

Should the welding process be incomplete, the joint strength will be weaker than expected, and there is a concern that the leader wire and the bus bar may be disconnected. In order to prevent the disconnection more reliably, the torch must be welded while changing the angle to various angles so as to avoid the stepped portion, which reduces the reactor production efficiency. Such difficulty of welding becomes apparent in the flatwise coil having a large inclination of the lead wire. However, inferring from the knowledge obtained by the flatwise coil, if the lead wire and the bus bar have a large oblique relationship due to various circumstances, the disconnection can occur regardless of the reactor using the flatwise coil.

The present invention has been proposed in order to solve the above-mentioned problems of the prior art, and an object of the present invention is to provide a reactor in which a lead wire and a bus bar do not easily come off against vibration and a method for manufacturing the reactor. ..

In order to achieve the above object, the reactor of the present invention is a coil formed by winding a conductive wire, a core inserted in the coil, and an end portion of the conductive wire forming the coil. A leader line that is drawn out; and a bus bar that has an end that extends toward the leader line and that is connected to the leader line at the end, and the end of the bus bar and the leader line are diagonal. The bus bar has a flat surface that is non-parallel to a plane orthogonal to the extension direction of the leader line at the end portion, the leader line is inclined with respect to the extension direction of the leader line, and is flat. It has an end face which spreads in parallel with a field, and the above-mentioned leader line and the above-mentioned bus bar are connected so that the end face and the above-mentioned flat surface are connected in the same plane.

The coil is formed by shifting the winding position of the conductive wire in the winding axis direction for each turn, and the lead wire is inclined and drawn out in the extending direction of the winding shaft by shifting the winding position. , The end portion of the bus bar extends parallel to the winding axis toward the lead wire side, and the end surface of the lead wire extends in the extension direction of the lead wire so as to spread in the same plane as the flat surface. You may make it incline with respect to it.

The coil may be a flatwise coil whose wide surface extends along the winding axis of the coil.

The lead line and the bus bar may be welded at a boundary line between the end surface and the flat surface.

Further, in order to achieve the above-mentioned object, the reactor manufacturing method of the present invention is configured such that a lead wire of a coil having a core inserted therein is connected to an end portion of a bus bar extending obliquely relative to the lead wire. A method of manufacturing a reactor comprising: a coil forming step of winding a conductive wire; and a lead wire forming step of forming the lead wire by pulling out an end of the conductive wire forming the coil from the coil. And a inserting step of inserting the core into the coil, and a connecting step of connecting the lead wire and the end portion of the bus bar while the end portion of the bus bar and the lead wire are obliquely crossed, The method further includes an end face processing step of forming an end face that is inclined with respect to the extending direction of the leader line and extends in the same plane as the flat surface of the end portion of the bus bar, in the connecting step, in the connecting step. While maintaining the orientation of the flat surface, the end surface of the leader line and the flat portion of the bus bar are flush with each other, and the leader line and the end portion of the bus bar are connected. To do.

In the coil forming step, the winding position of the conductive wire is shifted for each turn in the winding axis direction for winding, and in the leader wire forming step, the end portion of the conductive wire forming the coil is The end portion of the conductive wire is pulled out while being inclined toward the extending direction, the connecting step extends the end portion of the bus bar parallel to the winding axis, and the end surface processing step extends parallel to the winding axis. The end face may be formed on the leader line so as to extend in the same plane as the flat surface of the extended end portion.

Before the lead wire forming step, the conductive wire may be cut obliquely in the end face processing step.

In the connecting step, a boundary line between the end surface of the leader line and the flat surface of the bus bar may be welded.

In the coil forming step, the wide surface of the conductive wire may be wound so as to spread along the axis of the coil.

According to the reactor manufacturing method of the present invention, the lead wire and the bus bar can be simply and satisfactorily welded, and according to the reactor of the present invention, the vibration resistance is improved by the good welding of the lead wire and the bus bar.

It is an appearance perspective view of the reactor concerning this embodiment. It is an enlarged view of the flatwise coil concerning this embodiment. It is an enlarged view of the connection part of a leader line and a bus bar concerning this embodiment, (a) is an enlarged view of the wide side of a leader line, and (b) is an enlarged view of the end face side of a leader line. It is a transition diagram showing a manufacturing process of a coil of the present embodiment. It is a transition diagram which shows the assembly process of the reactor of this embodiment. It is a schematic diagram which shows the joining process of the leader line and bus bar of this embodiment. It is a schematic diagram which shows the diagonal relationship of the conventional leader line and a bus bar.

(Constitution)
FIG. 1 is an external perspective view of a reactor according to this embodiment. The reactor 1 roughly includes a reactor body 2, a case 3, and a bus bar 4. The reactor main body 2 is an electromagnetic component that converts electric energy into magnetic energy and stores and emits it, and is a reactor assembly having two coils 5 and 5. The reactor body 2 includes a core 6 having a substantially θ shape in addition to the two coils 5 and 5. The two coils 5 and 5 are fitted on the outer legs 62 and 62 of the core 6. The reactor body 2 is housed in the case 3. The case 3 is a metal box body having an opening on one surface, and serves as a magnetic shield that houses the reactor body 2 in the internal space and protects the heat dissipation path of the reactor body 2 and the reactor body 2 from an external magnetic field.

The bus bar 4 is a conductive member that electrically connects the external circuit and the reactor main body 2, has a fastening hole 45 for connecting to the external path outside the case 3, and extends above the opening of the case 3. It is connected to the reactor body 2. A total of four lead wires 7, 7... Are drawn from the two coils 5 and 5 and are connected in parallel by the bus bar 4. Two bus bars 4 are provided, and four lead wires 7, 7... Are selected from the coils 5 and 5 so as to be connected in parallel, and a pair is formed. 4 is connected.

Such a reactor 1 will be described in detail. The core 6 is formed by coating the outer circumference of a magnetic body with an insulating resin. The core 6 serves as a path for the magnetic flux generated by the coil 5 to form a magnetic circuit. The core 6 is formed in a substantially θ shape by one middle leg 61, two outer legs 62, and two yokes 64, 64. The middle leg 61 and the outer leg 62 have substantially the same length, and are aligned in parallel on the same plane with their directions aligned. The outer legs 62 are separately arranged on both sides of the middle leg 61. The yoke 64 extends orthogonally to the outer legs 62, 62 and the middle leg 61 from one outer leg 62 to the other outer leg 62 via the middle leg 61. The yoke 64 is arranged so as to sandwich the two outer legs 62 and the middle leg 61 from both end sides, and the respective yokes 64, 64 connect the ends of the middle leg 61 and the two outer legs 62, 62 facing in the same direction. ..

The coil 5 is formed by winding a conductive wire 51. The conductive wire 51 is a rectangular wire and has a rectangular cross section defined by a narrow surface 53 and a wide surface 52. The width of the narrow surface 53 is relatively narrower than that of the wide surface 52, and the width of the wide surface 52 is relatively wider than that of the narrow surface 53. The coil 5 has a spiral shape in which the winding position of the conductive wire 51 is shifted in the direction of the winding shaft 54 for each turn. The coil 5 is a flatwise coil and is wound so that the wide surface 52 extends along the winding shaft 54. The two coils 5 and 5 are inserted in the outer legs 62 and 62, and are arranged side by side on the same plane with the winding shafts 54 and 54 aligned in the same direction.

The lead wire 7 is an end portion of the conductive wire 51 that constitutes the coil 5, and is drawn from the winding start and winding end of the coil 5, respectively. The lead wire 7 extends from the beginning and the end of the winding so as to draw a tangent line without being bent, removes the coil 5, and is drawn straight without bending. All the lead lines 7, 7,... Are drawn to the upper side on the side opposite to the bottom surface of the case 3, and extend so that the wide surface 52 rises vertically with respect to the same plane on which the coils 5 and 5 are arranged. Hereinafter, the same plane (XY plane) where the coils 5 and 5 are arranged is referred to as a reference plane.

The bus bar 4 includes a bus bar main body 41 having a fastening hole 45 and an end portion 42, and is formed, for example, by stamping and bending a single metal plate. The busbar body 41 is arranged outside the case 3. The busbar body 41 extends along any one of the sides of the case 3 that is orthogonal to the winding axis 54 of the coil 5. The two bus bar main bodies 41, 41 extend along the same side of the case 3. However, in order to ensure insulation, the two busbar main bodies 41, 41 are arranged at different positions in the height direction from the bottom surface of the case 3 toward the opening, the depth direction away from one side of the case 3, and the fastening holes 45 are provided. Except for being covered with insulating resin.

The end portions 42 extend from both ends of the bus bar body 41 and extend toward the leader line 7. The end portion 42 is erected from the bus bar main body 41 to the height of the leading end of the lead wire 7, then bent in a direction coinciding with the extending direction of the winding shaft 54, and extended in a direction coinciding with the extending direction of the winding shaft 54. The extension direction is adjacent to the wide surface 52 of the leader line 7 and is joined to the leader line 7 by welding. That is, the end portion 42 extends in the direction parallel to the reference plane and orthogonal to the winding axis 54 by the width of the narrow surface 53 of the leader wire 7 and displaced from the position of the leader wire 7.

The end portion 42 has a consistent rectangular cross section, and has a side surface 43 orthogonal to the reference plane and a flat surface 44 parallel to the reference plane. The end portion 42 is extended such that the side surface of the end portion 42 is parallel to the wide surface 52 of the leader wire 7, and the wide surface 52 of the leader wire 7 contacts the side surface 43. A surface farther from the coil 5, that is, a surface facing the outside of the reactor 1 is called a flat surface 44.

The shape of the coil 5 will be described in more detail. FIG. 2 is an enlarged view of the coil 5. FIG. 3 is an enlarged view of a connecting portion between the lead wire 7b and the bus bar 4 that is drawn out from the winding end, (a) is an enlarged view of the lead wire 7b on the wide surface 52 side, and (b) is a lead wire. It is the enlarged view which looked at the end face 71 side of 7b. As shown in FIG. 2, assuming that the width of the wide surface 52 of the conductive wire 51 is W and the height of the coil 5 in the direction orthogonal to the winding axis 54 is H, the conductive wire 51 extends in the extending direction of the winding axis 54. Is wound with an inclination angle θ=tan ⁻¹ (H/W) as a reference. However, the tilt angle θ of the conductive wire 51 also takes into consideration the mechanical characteristics of the winding device.

The lead wire 7a at the beginning of winding can be drawn straight out in a direction orthogonal to the winding shaft 54. The lead wire 7b at the end of winding can be maintained perpendicular to the wide surface 52 and the reference surface, but is drawn straight out in a direction inclined by the tilt angle θ from the reference surface in the extending direction of the winding shaft 54. On the other hand, the end portion 42 of the bus bar 4 extends in the direction corresponding to the extending direction of the winding shaft 54 and reaches the lead wire 7b. Therefore, the extending direction of the lead wire 7b at the end of winding and the extending direction of the end portion 42 of the bus bar 4 are not perpendicular but intersect obliquely.

The end surface 71 of the leader line 7a at the beginning of winding is cut off at right angles to the extending direction of the leader line 7a. In other words, the lead wire 7a at the beginning of winding is cut off orthogonally to both the wide surface 52 and the narrow surface 53. Since the lead wire 7a at the beginning of winding is drawn straight out in the direction orthogonal to the winding shaft 54, the end surface 71 of the lead wire 7a at the beginning of winding extends parallel to the reference plane. On the other hand, the end surface 71 of the leader line 7b at the end of winding is formed so as to be oblique to the extending direction of the leader line 7b, in other words, to be obliquely intersected with the narrow surface 53, while being perpendicular to the wide surface 52. Has been done. That is, the end surface 71 of the leader line 7b is an inclined surface that extends orthogonal to the wide surface 52 and is inclined with respect to the extending direction of the leader line 7b.

Assuming that the lead wire 7b at the end of winding is inclined toward the bus bar main body 41 side, among the angles formed by the narrow surface 53 and the end surface 71, the angle close to the bus bar main body 41 is the same as the tilt angle θ. Is cut off. When the lead-out line 7b at the end of winding is inclined away from the busbar main body 41, among the angles formed by the narrow surface 53 and the end surface 71, the angle farther from the busbar main body 41 is the same as the inclination angle θ. It has been cut off to become. Therefore, the end surface 71 of the lead wire 7b at the end of winding extends in parallel with the reference surface.

As shown in FIG. 3, the end portion 42 of the bus bar 4 has the side surface 43 in contact with the wide surface 52. That is, the end portion 42 is bent so that the flat surface 44 is flush with the end surface 71 of the leader line 7b, and extends toward the leader line 7b. Therefore, the flat surface 44 of the bus bar 4 and the end surface 71 of the lead wire 7b are flush with each other, and the welding region where the boundary line 81 extends is flat, including the areas along the boundary line 81. The bus bar 4 and the lead wire 7b are joined to each other with a welded portion 82 provided along the boundary line 81.

(Production method)
A method of manufacturing such a reactor 1 will be described with reference to FIGS. 4 to 6. FIG. 4 is a transition diagram showing a method for manufacturing the coil 5, and FIG. 5 is a transition diagram showing assembly of the reactor body 2. FIG. 6 is a perspective view showing the joining of the lead wire 7 and the bus bar 4.

First, as shown in FIG. 4A, a conductive wire 51 for forming the coil 5 is prepared. As the conductive wire 51, for example, an enameled copper wire is selected. The blade 100 is inserted and cut so as to be orthogonal to the wide surface 52 and the narrow surface 53 of the conductive wire 51, and the end surface 71 of the lead wire 7a at the beginning of winding is formed. Then, as shown in FIG. 4B, the conductive wire 51 continuing from the cut surface is erected perpendicularly to the reference surface, and the conductive wire 51 is spirally wound along the winding shaft 54 (coil Forming step). At this time, the lead wire 7a at the start of winding extends orthogonal to the winding shaft 54, and the end surface 71 of the lead wire 7a is parallel to the reference plane.

As shown in (b) of FIG. 4, when the winding is advanced, the blade 100 is put into the conductive wire 51 which has not been wound yet, and the conductive wire 51 forming the coil 5 is prepared. Disconnect from. The blade 100 is inserted so as to be perpendicular to the wide surface 52 with respect to the end of the conductive wire 51, but obliquely intersect with the narrow surface 53, and the end surface 71 of the lead wire 7b at the end of winding is inserted. Form (end face processing step). At this time, among the angles formed by the narrow surface 53 and the end surface 71, the blade 100 is inserted and cut so that the angle that is located on the outermost side of the coil 5 becomes the tilt angle θ. The cutting angle is preferably determined by experiment, simulation, or calculation.

Then, as shown in FIG. 4C, the lead wire 7b is extended so as to draw the tangent line of the coil 5 without bending from the winding end of the conductive wire 51 (lead wire forming step). Then, the lead wire 7b at the end of winding is inclined by the tilt angle θ in the direction in which the winding shaft 54 extends, but the end surface 71 of the lead wire 7b becomes parallel to the reference plane.

As shown in FIG. 5A, a core 6 is formed separately from the coil 5 (core forming step). First, two E-shaped magnetic bodies 64 are prepared. The E-shaped magnetic body 64 is formed in an E-shape by a dust core, a ferrite core, a laminated steel plate, or the like. With the E-shaped magnetic body 64 set in the mold, resin is injected into the mold and solidified, so that the insulating resin molded product 65 covers the outer periphery of the E-shaped magnetic body 64. Examples of the resin to be injected include epoxy resin, unsaturated polyester resin, urethane resin, BMC (Bulk Molding Compound), PPS (Polyphenylene Sulfide), and PBT (Polybutylene Terephthalate). However, avoid coating the three leg end faces of the E-shaped magnetic body 64 with resin.

Then, the outer legs of the one E-shaped magnetic body 64 covered with the insulating resin molded product 65 are inserted into the coil 5 (insertion step). After inserting the coil 5 into the coil 5, the two E-shaped magnetic bodies 64 and 64 covered with the insulating resin molded product 65 are joined to each other in a substantially θ shape by abutting the legs. At this time, the two E-shaped magnetic bodies 64, 64 may be abutted by interposing an adhesive, or may be directly abutted without using an adhesive, or a magnetic gap may be provided. Good. The magnetic gap may be formed by interposing a spacer or may be formed by a void. As a result, the reactor body 2 is completed.

As shown in FIG. 5B, the reactor body 2 is housed in the case 3 and screwed, and then filled with a filler to be solidified. As the filler, a resin that is relatively soft and has high thermal conductivity is suitable in order to secure the heat dissipation performance of the reactor body 2 and reduce the vibration propagation from the reactor body 2 to the case 3. Then, the bus bar 4 is attached.

The end 42 of the bus bar 4 is run parallel to the winding shaft 54 toward the leader lines 7a and 7b. At this time, the flat surface 44 of the bus bar 4 becomes parallel to the reference surface. Then, the side surface 43 of the end portion 42 is adjacent to the wide surface 52 of the leader lines 7a and 7b. The lead wire 7b at the end of winding is tilted by a tilt angle θ along the direction in which the winding shaft 54 extends, and the end surface 71 of the lead wire 7b has a tilt angle θ between the narrow surface 53 and the end surface 71. Since it is inclined with respect to the extending direction of the leader line 7b, it extends in parallel with the reference plane. Therefore, the flat surface 44 of the end portion 42 of the bus bar 4 and the end surface 71 of the lead wire 7b are flush with each other.

As shown in FIG. 6, by moving the torch 200 parallel to the boundary line 81 between the flat surface 44 and the end surface 71 that are continuous in the same plane, the torch 200 is moved in parallel along the boundary line 81, so that the entire area of the boundary line 81. A welded portion 82 is formed over the area, and the lead wire 7 and the bus bar 4 are joined by welding (connection step).

(Effect)
As described above, in the reactor 1, the coil 5 is formed by shifting the winding position of the conductive wire 51 in the direction of the winding shaft 54 for each turn, and the lead wire 7b is formed by shifting the winding position. It is pulled out while being inclined in the extending direction of 54. On the other hand, the end portion 42 of the bus bar 4 has a flat surface 44 that extends in parallel to the winding shaft 54 and faces the lead wire 7b side and is non-parallel to a plane orthogonal to the extending direction of the lead wire 7b. At this time, the end face 71 of the leader line 7b is inclined with respect to the extending direction of the leader line 7b so as to spread in the same plane as the flat surface 44. Then, the lead wire 7b and the bus bar 4 are connected with the end surface 71 and the flat surface 44 being flush with each other.

As a result, the end surface 71 of the leader line 7b and the flat surface 44 of the bus bar 4 do not have a step difference, and the torch 200 can easily move in parallel along the boundary line 81, so that the leader line 7b and the bus bar 4 are firmly joined by welding. it can. Therefore, even if the reactor 1 is used in an environment where vibrations are severe, the leader line 7b and the bus bar 4 do not easily come off from the vibration resistance. That is, when the end surface 71 of the leader line 7b and the flat surface 44 of the bus bar 4 are flush with each other, aligned in the same plane, or parallel to each other, the boundary line 81 is obtained only by the parallel movement without changing the orientation of the torch 200. It only needs to be flat enough to weld the entire area, and includes some deviation.

In the present embodiment, the flatwise coil is described as an example of the coil 5. This is because in the flatwise coil, the inclination of the lead wire 7b becomes remarkable. According to the knowledge obtained by this flatwise coil, it is because the lead wire 7b and the end portion 42 of the bus bar 4 obliquely intersect each other. Therefore, the lead wire 7b and the bus bar do not depend on the flatwise coil. The present invention can be applied to any reactor 1 as long as it is obliquely intersecting with the end portion 42 of No. 4.

For example, the end portion 42 of the bus bar 4 may be extended non-parallel to the winding shaft 54 due to various circumstances when the end portion 42 of the bus bar 4 is arranged. Even in this case, if the end surface 71 of the lead wire 7b is inclined according to the inclination of the flat surface 44 of the bus bar 4, good welding processing can be performed and the vibration resistance of the reactor 1 is improved. To do.

That is, according to the present invention, the end portion 42 of the bus bar 4 and the lead wire 7b intersect obliquely, and the bus bar 4 has a flat surface 44, which is not parallel to a plane orthogonal to the extending direction of the lead wire 7b, at the end portion 42. The leader line 7b is inclined with respect to the extending direction of the leader line 7b and has an end face 71 that extends in parallel with the flat surface 44. The leader line 7b and the bus bar 4 are flat with the end face 71. The surface 44 and the surface 44 may be connected so as to be flush with each other.

In addition, in the present embodiment, since the end portion 42 of the bus bar 4 has a rectangular cross section, the entire one surface of the end portion 42 is the flat surface 44, but if the region continuous with the end surface 71 of the leader wire 7 is flat. It suffices that the flat region is wide enough to allow the torch 200 to move, and it is not necessary that the entire surface of the end portion 42 is flat.

In addition, the method for manufacturing the reactor 1 has a connecting step of connecting the lead wire 7b and the end portion 42 of the bus bar 4 while the end portion 42 of the bus bar 4 and the lead wire 7b are obliquely crossed. Before this connecting step, an end face processing step of forming an end face 71, which is inclined with respect to the extension direction of the lead wire 7b and extends in the same plane as the flat surface 44 of the end portion 42 of the bus bar 4 on the lead wire 7b, is further performed. I have included it.

Accordingly, in the connecting step, the end surface 71 of the lead wire 7b and the flat portion 44 of the bus bar 4 can be flush with each other while maintaining the orientation of the flat surface 44 of the bus bar 4. Therefore, the leader line 7b and the bus bar 4 can be joined to each other only by bringing the torch 200 into contact with the boundary line 81 and moving in parallel, and the manufacturing process of the reactor 1 is simplified.

Here, the manufacturing method of the reactor 1 includes a leader wire forming step of forming the leader wire 7b by drawing the end portion of the conductive wire 51 from the coil 5, but the end face processing step may be performed before the connection step. For example, it may be before or after the leader line forming step. However, it is preferable to perform the end face processing step before the leader line forming step because the end face processing step becomes easy. Before the leader line forming step, the conductive wire 51 and the blade 100 for cutting the conductor wire 51 may be positioned, but after the leader line forming step, the leader wire 7b extending from the reactor body 2 may be positioned. Since it is necessary to position the lead wire 7b, the handling of the lead wire 7b becomes complicated.

The end surface processing step before the leader line forming step may be performed after the coil forming step and before the leader line forming step or before the coil forming step. In the end face processing step before the coil forming step, before winding the conductive wire 51, one conductive wire 51 serving as the coil 5, the lead wire 7a at the start of winding, and the lead wire 7b at the end of winding is separated in advance. That is, by inserting the blade 100 at the start end of the conductive wire 51, the end surface 71 of the lead wire 7a at the start of winding is formed, and by further inserting the blade 100 at the end end of the conductive wire 51, the end surface of the lead wire 7b at the end of winding. After forming 71 and cutting the both ends, the conductive wire 51 is wound.

(Other embodiments)
The present invention is not limited to the above-mentioned embodiment, and includes other embodiments described below. Further, the present invention also includes a form in which the above-described embodiment and the following other embodiments are all or any combination thereof. Further, various omissions, replacements, and changes can be made to these embodiments without departing from the scope of the invention, and modifications thereof are also included in the present invention.

For example, the number of coils 5 included in the reactor 1 may be one, or may be three or more. The shape of the core 6 may be a substantially O shape as well as a substantially θ shape. When manufacturing the core 6 having a substantially θ shape, E-shaped and I-shaped magnetic bodies may be combined. When the lead wire 7b and the end portion 42 of the bus bar 4 cross obliquely to the extent that welding difficulty occurs, the present invention can be applied to an edgewise coil.

Further, when the lead wire 7a at the beginning of winding is produced, it can be erected vertically to the winding shaft 54. However, due to the inclined springback formed when the coil is shifted to the second turn from the winding start, the lead wire 7a at the winding start may be inclined along the extending direction of the winding shaft 54 so as to be expanded to the outside of the coil 5. There is. That is, the lead wire 7a at the beginning of winding and the end portion 42 of the bus bar 42 may cross at an angle. Even in this case, if the end face 71 of the lead wire 7a is inclined so as to be parallel to the flat surface 44, a good welding process can be ensured. Therefore, the present invention can be applied to the lead wire 7a at the beginning of winding.

1 Reactor 2 Reactor main body 3 Case 4 Busbar 41 Busbar main body 42 End portion 43 Side surface 44 Flat surface 45 Fastening hole 5 Coil 51 Conductive wire 52 Wide surface 53 Narrow surface 54 Winding shaft 6 Core 61 Middle leg 62 Outer leg 63 Yoke 64 E Character-shaped magnetic body 65 Insulating resin molded product 7 Leader wire 7a Leader wire 7b Leader wire 71 End face 81 Boundary line 82 Welded portion

Claims (9)

A coil formed by winding a conductive wire,
A core inserted in the coil,
An end portion of the conductive wire forming the coil, and a lead wire drawn from the coil,
A bus bar having an end portion extended toward the leader line and connected to the leader line at the end portion;
Equipped with
The end portion of the bus bar and the leader line intersect obliquely,
The bus bar has a flat surface non-parallel to a plane orthogonal to the extending direction of the leader line at the end portion,
The leader line has an end face that is inclined with respect to the extending direction of the leader line and extends in parallel with the flat surface,
The lead wire and the bus bar are connected such that the end surface and the flat surface are flush with each other.
Reactor characterized by. The coil is formed by shifting the winding position of the conductive wire in the winding axis direction for each turn,
The lead wire is pulled out by tilting in the extending direction of the winding shaft by shifting the winding position,
The end portion of the bus bar extends in parallel with the winding shaft toward the lead wire side,
The end surface of the leader line is inclined with respect to the extending direction of the leader line so as to spread in the same plane as the flat surface.
The reactor according to claim 1, wherein: The coil is a flatwise coil whose wide surface extends along the winding axis of the coil,
The reactor according to claim 2, wherein The leader line and the bus bar, the boundary line between the end surface and the flat surface is welded,
The reactor according to any one of claims 1 to 3, characterized in that. A method for manufacturing a reactor, wherein a lead wire of a coil having a core inserted therein is connected to an end portion of a bus bar extended obliquely relative to the lead wire,
A coil forming step of winding a conductive wire,
A leader line forming step of forming the leader line by pulling out an end portion of the conductive wire forming the coil from the coil,
A step of inserting the core into the coil;
While connecting the end portion of the bus bar and the lead wire obliquely, a connecting step of connecting the lead wire and the end portion of the bus bar,
Including,
Further including an end face processing step of forming an end face that is inclined with respect to the extension direction of the leader line and extends in the same plane as the flat surface of the end portion of the bus bar on the leader line,
In the connecting step, while maintaining the orientation of the flat surface of the bus bar, the end surface of the lead wire and the flat portion of the bus bar are connected in a plane, and the lead wire and the end portion of the bus bar are connected. Connecting
A method for manufacturing a reactor. In the coil forming step, the conductive wire is wound by shifting the winding position of each turn in the winding axis direction,
In the lead wire forming step, the end portion of the conductive wire forming the coil is pulled out while the end portion of the conductive wire is inclined toward the extending direction of the winding shaft,
In the connecting step, the end portion of the bus bar is extended in parallel with the winding shaft,
In the end face processing step, forming the end face in the leader line so as to spread in the same plane as a flat surface provided in the end portion extended in parallel with the winding axis,
The method for producing a reactor according to claim 5, wherein Before the lead wire forming step, cutting the conductive wire obliquely in the end face processing step,
7. The method for manufacturing a reactor according to claim 5 or 6. In the connecting step, welding the boundary line between the end surface of the leader line and the flat surface of the bus bar,
The method for manufacturing a reactor according to claim 5, wherein In the coil forming step, winding the wide surface of the conductive wire so as to spread along the axis of the coil,
9. The method for manufacturing a reactor according to claim 5, wherein:

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