JP2021108352A - Reactor - Google Patents

Abstract

To provide a reactor capable of achieving the miniaturization.SOLUTION: A reactor 100 of the present application, comprises: a coil 3 mounted to a core 1; a bus bar 71 connected with the coil 3; a coated part 73 coating the core or the bus bar 71 with a resin; and a sensor 6 detecting a state of the reactor 100. The sensor 6 includes: a detection part 61; and a lead wire 62 connected with the detection part. The coated part provides a concave part 74, and the lead wire 62 is distributed while passing through the concave part 74.SELECTED DRAWING: Figure 2

Description

The present invention relates to a reactor comprising a sensor having a lead wire.

Reactors are used in various applications such as office automation equipment, photovoltaic power generation systems, automobiles, and uninterruptible power supplies. In this type of reactor, the reactor body including the resin member that covers the circumference of the core and the coil wound around the resin member is housed in a metal case such as aluminum, and a filler is provided between the reactor body and the case. Is injected to solidify the filler.

In recent years, a sensor for detecting the state of the reactor is often attached to the reactor body. The sensor has a detection unit that detects the state of the reactor, a lead wire that transmits the information detected by the detection unit to the external device of the reactor, and a connector that connects to the external device. One end of the lead wire is connected to the detection unit and the other end is connected to the connector, and the lead wire is arranged from the detection unit toward the connector.

Japanese Unexamined Patent Publication No. 2019-021686

The reactor is used together with other electric parts and is installed in a state where the degree of integration with other electric parts is high. Therefore, if the lead wire is arranged through the outside of the reactor, the size of the reactor may be increased and the lead wire may interfere with other electric components to cause mechanical or electrical damage. In particular, in recent years, the degree of integration of the reactor and other electric components has further increased, and miniaturization of the reactor is strongly desired.

The present invention has been made to solve the above problems, and an object of the present invention is to provide a reactor capable of miniaturization.

The reactor of the present invention includes a coil mounted on the core, a bus bar connected to the coil, a coating portion covering the core or the bus bar with resin, and a sensor for detecting the state of the reactor. Has a detection unit and a lead wire connected to the detection unit, the covering portion is provided with a recess, and the lead wire is disposed through the recess. It is a feature.

According to the present invention, it is possible to obtain a reactor that can be miniaturized.

It is a perspective view which shows the whole structure of the reactor which concerns on embodiment. It is an exploded perspective view of the reactor which concerns on embodiment. It is a perspective view which shows the whole structure of a terminal block. It is an enlarged view which enlarged a part of a terminal block. It is a schematic diagram which shows the arrangement of the mold at the time of molding a terminal block. It is a schematic diagram which shows the arrangement of the lead wire.

(First Embodiment)
The reactor of the present embodiment will be described with reference to the drawings. FIG. 1 is a perspective view showing the overall configuration of the reactor of the present embodiment. FIG. 2 is an exploded perspective view of the reactor of the present embodiment. In some cases, the winding axis direction of the coil 3 is referred to as the Y-axis direction, the side-by-side direction of the coil 3 orthogonal to the Y-axis direction is referred to as the X-axis direction, and the direction orthogonal to the Y-axis direction and the X-axis direction is referred to as the Z-axis direction. Yes, the Z-axis direction may also be referred to as the height direction.

The reactor 100 is an electromagnetic component that converts electrical energy into magnetic energy and stores and releases it, and is used for raising and lowering voltage and the like. The reactor 100 of the present embodiment is a reactor used in, for example, a drive system for a hybrid vehicle or an electric vehicle.

The reactor 100 includes a reactor body 10, a case 4, a filling molding section 5, a sensor 6, and a terminal block 7. The reactor body 10 has an annular core 1, a resin member 2, and a coil 3. The reactor body 10 is housed in a case 4, to which a sensor 6 and a terminal block 7 are attached. Further, a filling molding portion 5 is formed in the gap between the reactor main body 10 and the case 4. The terminal block 7 has a bus bar 71, and the bus bar 71 is connected to the coil 3 by welding or the like.

In such a reactor 100, when a current is supplied to the coil 3 from an external power source, the coil 3 generates a magnetic flux. The magnetic flux generated by the coil 3 passes through the core 1 forming a closed magnetic circuit. As a result, electrical energy is converted into magnetic energy. The heat generated in the coil 3 by the current supply is transmitted to the case 4 via the filling molding section 5 and released to the outside.

The sensor 6 detects the state of the reactor 100. The sensor 6 has a detection unit 61 and a lead wire 62 connected to the detection unit 61. The terminal block 7 is provided with a recess 74, and the lead wire 62 is arranged through the recess 74.

(Reactor body)
The reactor body 10 has a core 1, a resin member 2, and a coil 3. The core 1 is made of a magnetic material such as a dust core. The core 1 has an annular shape. Two coils 3 are provided, and each coil 3 is mounted on the core 1. The two coils 3 are provided side by side with a gap so that the winding axis directions are parallel to each other. The outer circumference of the core 1 is covered with a resin member 2 such as an epoxy resin. That is, the resin member 2 is interposed between the core 1 and the coil 3 to insulate the core 1 and the coil 3.

(Case)
The case 4 houses the reactor main body 10. The case 4 has a substantially rectangular bottom surface and four side walls, and has a box shape with an open upper surface. The case 4 is made of a lightweight metal having high thermal conductivity, such as an aluminum alloy, and has excellent heat dissipation. The case 4 has a fixing portion for fixing the reactor main body 10 and the terminal block 7.

(Filling molding part)
The filling molding unit 5 is a member formed by filling the gap between the reactor main body 10 and the case 4 with a filler and solidifying it. 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 100 and reducing the vibration propagation from the reactor body 10 to the case 4. Specific examples thereof include silicone resin, urethane resin, epoxy resin, and acrylic resin.

(Sensor)
The sensor 6 has a detection unit 61, a lead wire 62, and a connector 63. The detection unit 61 is, for example, a temperature detector such as a thermistor whose electrical resistance changes with respect to a temperature change, and detects the temperature of the reactor 100. The detection unit 61 is provided between the coils 3. The detection unit 61 is held by the holding unit of the resin member 2.

The lead wire 62 transmits the temperature information detected by the detection unit 61 to an external device installed outside the reactor 100. That is, the lead wire 62 is a wiring that electrically connects the detection unit 61 and other members. The lead wire 62 is composed of a metal wire and a coating material for coating the metal wire. The metal wire may include, for example, copper, nickel, aluminum, silver, gold, or two or more of these. As the metal wire, only one single wire or a stranded wire obtained by twisting a plurality of wires is used. The covering material is an insulating member such as vinyl, silicone rubber, or fluororubber. One end of the lead wire 62 is connected to the detection unit 61, and the other end is connected to the connector 63.

The connector 63 includes a metal member that conducts electricity and a resin member that covers a part of the metal member. The connector 63 is connected to a connector of a pair of external devices. By connecting the connector 63 to the connector of the paired external device, the detection unit 61 and the external device are electrically connected via the lead wire 62. Therefore, the temperature information of the reactor 100 detected by the detection unit 61 can be transmitted to the external device.

(Terminal block)
FIG. 3 is a perspective view showing the overall configuration of the terminal block 7. The terminal block 7 is a component for electrically connecting the reactor 100 and an external device. The terminal block 7 is separate from the reactor main body 10. The terminal block 7 is fixed to the fixed portion of the case 4. The terminal block 7 has a bus bar 71 and a covering portion 73. The bus bar 71 and the covering portion 73 are integrally formed by molding.

The bus bar 71 is, for example, a conductive member such as copper. One end of the bus bar 71 is connected to the coil 3, and the other end (also referred to as a terminal) is connected to the wiring of an external device. As a result, when the external device and the coil 3 are electrically connected and power is supplied from the external device, a current flows through the coil 3, a magnetic flux is generated, and a closed magnetic circuit is formed in the core 1.

The covering portion 73 is made of a resin such as PPS (Polyphenylene Sulfide) and covers the bus bar 71. The covering portion 73 is composed of a pedestal portion 73a and two extending portions 73b and 73c. The pedestal portion 73a supports a terminal on which the bus bar 71 is connected to an external device. The pedestal portion 73a has a rectangular parallelepiped shape extending parallel to the winding axis direction of the coil 3, and is provided on the outside of the case 4 along the side wall of the case 4.

The extending portions 73b and 73c extend from both ends of the pedestal portion 73a in a direction orthogonal to the winding axis direction, respectively. The extending portions 73b and 73c are provided on the upper surface of the core 1 to which the coil 3 is not mounted. The end of the bus bar 71 is exposed from the extending portions 73b and 73c, and the end of the bus bar 71 connects the coil 3 by welding or the like.

As shown in FIG. 4, the covering portion 73 has a recess 74. The recess 74 is a recess in which the upper surface of the extending portion 73b is recessed. The recess 74 reaches the bus bar 71 embedded in the extending portion 73b, and a part of the bus bar 71 is exposed. In other words, the bus bar 71 has an exposed surface 72 exposed from the extending portion 73b (covered portion 73). That is, the bottom surface of the recess 74 becomes the exposed surface 72. The lead wire 62 is arranged so as to pass through the recess 74. The recess of the recess 74 does not reach the bus bar 71, and the bus bar 71 does not have to have the exposed surface 72. However, the depth of the recess 74 is preferably about the outer diameter of the lead wire 62. With this configuration, the lead wire 62 can be arranged without protruding from the recess 74.

As shown in FIG. 4, the covering portion 73 has a locking portion 75. The locking portion 75 is provided above the extension portion 73b so as to face the extension portion 73b. More specifically, the locking portion 75 is provided so as to face the recess 74. The fact that the locking portion 75 is provided facing the extending portion 73b or the recess 74 includes the case where only the opening portion 76 of the locking portion 75, which will be described later, faces the locking portion 75.

The locking portion 75 extends in the same direction as the extending portion 73b, that is, in a direction orthogonal to the winding axis direction of the coil 3. The locking portion 75 is provided between the lower surface of the locking portion 75 and the bottom surface (exposed surface 72) of the recess 74 with a gap. The gap may be wide enough to allow the lead wire 62 to pass through. The lower surface of the locking portion 75 is the end surface of the locking portion 75 facing the recess 74.

In this embodiment, the locking portion 75 has an opening 76 cut out in a substantially rectangular shape. The opening 76 is provided so as to face the exposed surface 72. Since the locking portion 75 has the opening 76, the locking portion 75 has a substantially U-shape when viewed in a plan view. By having the opening 76, the bus bar 71 can be directly pressed by the mold when the bus bar 71 is molded.

When the terminal block 7 obtained by molding the bus bar 71 is manufactured, the bus bar 71 may be deformed or misaligned due to the injection pressure of the resin. If the bus bar 71 is deformed or misaligned, there is a risk that the required insulation distance from other members cannot be secured. Therefore, in order to prevent the bus bar 71 from being deformed or misaligned, there is a method of arranging a jig such as a pin inside the mold. However, the method of arranging the jig inside the mold complicates the configuration of the mold, such as arranging the jig so that the jig does not get in the way when taking out the molded product from the mold.

However, in the present embodiment, since the locking portion 75 has the opening 76, the bus bar 71 can be directly pressed by the mold A as shown in FIG. Specifically, the mold A has a protruding convex portion B. The mold A is arranged on the upper surface of the locking portion 75. At this time, the convex portion B passes through the portion where the opening 76 of the locking portion 75 is formed, and the tip of the convex portion B is attached to the bus bar 71. Contact. That is, the convex portion B of the mold A serves as a jig. Note that FIG. 5 also shows the exposed surface 72 of the bus bar 71.

In this state, the resin is filled. Therefore, the convex portion B can suppress the deformation and misalignment of the bus bar 71. Therefore, the convex portion B comes into contact with the bus bar 71 without complicating the structure of the mold, so that the resin does not flow into the portion and the concave portion 74 is formed in the covering portion 73. That is, the surface with which the convex portion B is in contact becomes the exposed surface 72. Therefore, the convex portion B serves as a jig and also contributes to the formation of the concave portion 74.

The surface of the bus bar 71 on the opposite side of the exposed surface 72 may be in contact with a mold different from the mold A, or may be in contact with a jig. That is, the bus bar 71 may be gripped by a mold different from the convex portion B and the mold A, or may be gripped by the convex portion B and the jig.

(Arrangement of lead wires)
Next, the arrangement of the lead wire 62 will be described with reference to FIGS. 1 and 6. The lead wire 62 extends from the detection unit 61 toward the recess 74. The lead wire 62 extends toward the connector 63 through a gap between the lower surface of the locking portion 75 and the bottom surface of the recess 74, that is, the exposed surface 72 of the bus bar 71. In the present embodiment, this gap is slightly smaller than the outer diameter of the lead wire 62.

Therefore, as shown in FIG. 6, the lead wire 62 is in contact with the exposed surface 72. Further, the lead wire 62 is in contact with the lower surface of the locking portion 75 and is suppressed by the lower surface of the locking portion 75. That is, the lead wire 62 is gripped and fixed by the exposed surface 72 and the locking portion 75.

Since the lead wire 62 is arranged through the recess 74 in this way, the dimension of the reactor in the height direction can be reduced. Further, since the lead wire 62 is gripped by the exposed surface 72 and the locking portion 75, the misalignment of the lead wire 62 can be suppressed, and the lead wire 62 is prevented from loosening and interfering with other electric components. can.

In the present embodiment, the lead wire 62 is gripped and fixed by the exposed surface 72 and the locking portion 75, but the present invention is not limited to this. For example, the length (length L shown in FIG. 4) orthogonal to the winding axis direction of the coil 3 of the recess 74 is slightly shorter than the outer diameter of the lead wire 62, and is fitted into the recess 74 to fix the lead wire 62. May be good. Alternatively, the lead wire 62 may not be fixed in the recess 74, and for example, a grip portion for fixing the lead wire 62 may be provided in the resin member 2 so that the lead wire 62 passes through the recess 74. In such a case, the lower surface of the locking portion 75 does not have to be in contact with the lead wire 62.

However, even when the lead wire 62 is not in contact with the lead wire 62, the gap between the lower surface of the locking portion 75 and the bottom surface of the recess 74 is formed in the locking portion 75 when the lead wire 62 is loosened. It is preferable that the lower surface is in contact with the lead wire 62. With this configuration, even if the lead wire 62 is loosened, the locking portion 75 can prevent the lead wire 62 from protruding from the recess 74.

(Action effect)
The reactor 100 of the present embodiment includes a coil 3 mounted on the core 1, a bus bar 71 connected to the coil 3, a covering portion 73 covering the bus bar 71 with resin, a sensor 6 for detecting the state of the reactor 100, and the like. To be equipped. The sensor 6 has a detection unit 61 and a lead wire 62 connected to the detection unit 61. The covering portion 73 is provided with a recess 74, and the lead wire 62 is disposed through the recess 74.

By arranging the lead wire 62 through the recess 74 in this way, the height at which the lead wire 62 is arranged can be lowered. Therefore, the size of the reactor 100 can be reduced by passing through the recess 74.

The bottom surface of the recess 74 reaches the bus bar 71 covered by the covering portion 73, and the bus bar 71 has an exposed surface 72 exposed from the covering portion 73. As a result, the recess of the recess 74 can be maximized, and the reactor 100 can be further miniaturized. Further, since the concave portion 74 can be formed by the convex portion B, the concave portion 74 can be easily formed. In other words, the mold A does not require an internal configuration for forming the recess 74, and the mold configuration can be simplified. Further, the bus bar 71 can be brought into contact with the convex portion B to prevent the bus bar 71 from being deformed or displaced due to the injection pressure of the resin.

The covering portion 73 has a locking portion 75 arranged to face the recess 74, and the lead wire 62 is disposed below the locking portion 75. As a result, it is possible to prevent the lead wire 62 from protruding above the reactor 100, and even if the lead wire 62 is loosened, it is possible to prevent it from interfering with other electrical components, and the reliability of the reactor 100 can be improved. Can be improved.

In particular, in the present embodiment, the lead wire 62 is gripped and fixed by the lower surface of the locking portion 75 and the exposed surface 72. As a result, the effect of miniaturization of the reactor 100 can be obtained to the maximum, and the position of the lead wire 62 can be fixed by the locking portion 75 and the exposed surface 72, and the lead wire 62 can be prevented from coming out of the recess 74.

Further, in the present embodiment, the locking portion 75 has an opening 76 at a position facing the exposed surface 72. If the locking portion 75 does not have the opening 76, the mold must have a configuration for forming the recess 74 in addition to the configuration for forming the locking portion 75, and the mold must have a configuration for forming the recess 74. The internal structure of is quite complicated. However, in the present embodiment, since the convex portion B of the mold A can be inserted from the opening 76, the concave portion 74 can be formed by the convex portion B. That is, the mold A does not require a configuration for forming the recess 74, and the configuration of the mold can be simplified. Further, since the convex portion B can be brought into contact with the bus bar 71, it is possible to prevent the bus bar 71 from being deformed or displaced due to the injection pressure of the resin. By providing the opening 76 in this way, even when the locking portion 75 is formed, deformation and misalignment of the bus bar 71 are suppressed, and a mold having a complicated structure is not required, which improves production efficiency. do.

The lead wire 62 is gripped and fixed by the locking portion 75 and the bottom surface of the recess 74. As a result, it is possible to more reliably prevent the lead wire 62 arranged in the recess 74 from coming out of the recess 74, and it is possible to maintain the miniaturization of the reactor 100 even when vibration or the like is large. Further, the recess 74 and the locking portion 75 can function as a fixing portion of the lead wire 62.

(Other embodiments)
Although the embodiment according to the present invention has been described in the present specification, this embodiment is presented as an example and is not intended to limit the scope of the invention. The above-described embodiment can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. The embodiments and modifications thereof are included in the scope and gist of the invention as well as in the scope of the invention described in the claims and the equivalent scope thereof.

In the present embodiment, the locking portion 75 is provided, but the locking portion 75 may not be provided. Even when the locking portion 75 is not provided, if the lead wire 62 is fixed and arranged so as to pass through the recess 74, the size of the reactor 100 can be reduced by the amount of passing through the recess 74.

In the present embodiment, the recess 74 is provided in the covering portion 73 that covers the bus bar 71, but the recess 74 may be provided in the resin member 2 that covers the core 1. That is, the resin member 2 may be regarded as the covering portion 73. In this way, if the resin member 2 that covers the core 1 is provided with the recess 74 and the lead wire 62 is provided in the recess 74, the size of the reactor 100 can be reduced. The recess formed by the recess 74 may reach the core 1 and the core 1 may be exposed, or may not reach the core 1 and the core 1 may not be exposed.

In the present embodiment, the recess 74 is provided in the extending portion 73b (covered portion 73) extending from the upper surface of the core 1, but the arrangement of the recess 74 is not limited to this. For example, the extension portion 73b may be provided on the side surface of the core 1. That is, the extension portion 73b may extend from the end portion of the pedestal portion 73a in parallel with the winding axis direction of the coil 3 and may be provided along the side wall of the case 4 in the same manner as the pedestal portion 73a. In this case, the recesses 74 are recessed in the side-by-side direction of the coils 3. Then, the lead wire 62 is arranged through the recess 74. Even in such a configuration, the dimensions of the coils 3 of the reactor 100 in the side-by-side direction can be suppressed, and the reactor 100 can be miniaturized.

In the present embodiment, the opening 76 of the locking portion 75 has a substantially rectangular shape, but the shape of the opening 76 is not limited to this. As long as the convex portion B of the mold A can come into contact with the bus bar 71, it may have a round shape, for example.

100 Reactor 10 Reactor body 1 Core 2 Resin member 3 Coil 4 Case 5 Fill molding part 6 Sensor 61 Detection part 62 Lead wire 63 Connector 7 Terminal block 71 Bus bar 72 Exposed surface 73 Covering part 73a Pedestal part 73b Extension part 73c Extension part 74 Recessed 75 Locking part 76 Opening A Mold B Convex part

Claims (5)

The coil mounted on the core and
The bus bar connected to the coil and
A coating portion that coats the core or the bus bar with a resin, and
A sensor that detects the state of the reactor and
With
The sensor is
With the detector
The lead wire connected to the detection unit and
Have,
The covering portion is provided with a recess, and the covering portion is provided with a recess.
The lead wire is arranged through the recess.
Reactor featuring. The bottom surface of the recess reaches the core or the bus bar covered by the covering.
The core or the bus bar has an exposed surface exposed from the covering portion.
The reactor according to claim 1. The covering portion has a locking portion arranged so as to face the recess.
The lead wire is disposed so as to pass between the locking portion and the bottom surface of the recess.
The reactor according to claim 1 or 2. The covering portion has a locking portion arranged so as to face the recess.
The locking portion has an opening at a position facing the exposed surface.
The lead wire is disposed so as to pass between the locking portion and the bottom surface of the recess.
2. The reactor according to claim 2. The lead wire is gripped and fixed by the locking portion and the bottom surface of the recess.
The reactor according to claim 3 or 4.

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