JP2021125636A - Reactor - Google Patents

Abstract

To enhance heat dissipation of a coil in a reactor, while surely assembling a bobbin to which the coil is wound.SOLUTION: A bobbin 14 structuring a reactor 10, is formed by first and second holders 26 and 28 coating a coil 12 engaged in an axial direction along a center of winding of the coil 12. The first holder 26 comprises: an inner peripheral wall 30 arranged in an inner periphery of the coil 12; and first and second flanges 32 and 34 formed on one end and the other end to the axial direction of the inner peripheral wall 30. In the first flange 32, a first circular ring part 38 on an outer peripheral side is formed thickly to each first cross-linkage part 36 provided to an inner peripheral side. In the first circular ring part 38, a plurality of concave parts concaved to the axial direction is formed, and an engagement hole engaging with a claw part of the second holder 28 is formed on a bottom face of each concave part, and a plurality of first exposure holes 40 exposing a part of the coil 12 is provided between the first cross-linkage parts 36.SELECTED DRAWING: Figure 5

Description

The present invention relates to a reactor in which a coil is wound around a bobbin and housed inside a core.

Conventionally, a reactor in which a coil is wound on the outer peripheral side of the bobbin is known. For example, the reactor disclosed in Patent Document 1 is a first reactor in which the bobbin around which the coil is wound can be divided in the axial direction. It is composed of a split body and a second split body. The first divided body has a first tubular member having a rectangular cross section, a first flange formed at an axial end of the first tubular member, and a protrusion protruding from the first flange. It includes a first arm member extending along the first tubular member. On the other hand, the second divided body has a second tubular member having a rectangular cross section, a second flange formed at an axial end portion of the second tubular member, and a protrusion protruding from the second flange. It includes two second arm members extending along the second tubular member.

Then, after winding the coil around the first tubular member in the first divided body, the second tubular member in the second divided body is inserted into the inside of the first tubular member, and the first tubular member is inserted. The arm member is inserted between one second arm member and the other second arm member, and the protrusion is engaged with the protrusion of the second arm member, whereby the first arm member is first. The split body and the second split body are connected in the axial direction to form a bobbin.

JP-A-2017-103422

In the reactor described above, in the first and second divided bodies, the first and second arm members are provided on the outside of the tubular member, respectively, and are exposed to the outside. Therefore, when the bobbin is housed inside the core with the coil wound around the outside of the tubular member, the first and second arm members come into contact with the inner wall surface of the core, or the coil moves outward. There is a concern that the first and second divided bodies will be separated from each other due to the contact with the first and second arm members and the disengagement state due to the expansion.

The present invention has been made in consideration of the above problems, and an object of the present invention is to provide a reactor capable of reliably assembling a bobbin around which a coil is wound and improving heat dissipation of the coil.

In order to achieve the above object, an aspect of the present invention is a bobbin member comprising a coil wound with a conducting wire and first and second bobbins engaged in an axial direction along the winding center of the coil and covering the coil. And in a reactor with a core that covers the outside of the bobbin member, including the coil.
The first bobbin includes an inner peripheral cylindrical portion arranged on the inner circumference of the coil and a flange covering at least one of one end and the other end along the axial direction of the coil, and the second bobbin covers the outer surface of the coil. Equipped with a cylindrical part on the outer peripheral side,
The flange consists of an inner peripheral flange portion that is connected to the inner peripheral side cylindrical portion and extends outward, and an outer peripheral side flange portion that is thicker in the axial direction with respect to the inner peripheral side flange portion and is formed on the outer peripheral side. Prepare,
A plurality of concave portions recessed in the axial direction are formed on the outer peripheral side flange portion, an engaging hole is formed on the bottom surface of the concave portion to engage with the second bobbin, and the outer peripheral side cylindrical portion is engaged with the engaging hole. As well as forming an engaging protrusion
The inner peripheral flange portion is provided with at least one or more exposed holes for exposing a part of the coil.

According to the present invention, the bobbin members constituting the reactor are composed of first and second bobbins that are engaged in the axial direction along the winding center of the coil, and the first bobbin is located on the inner circumference of the coil. The inner peripheral side cylindrical portion to be arranged and the flange covering at least one of one end and the other end along the axial direction of the coil are provided, and the second bobbin is provided with an outer peripheral side cylindrical portion covering the outer surface of the coil. Further, the flanges are an inner peripheral side flange portion that is connected to the inner peripheral side cylindrical portion and extends outward, and an outer peripheral side flange portion that is thicker in the axial direction with respect to the inner peripheral side flange portion and is formed on the outer peripheral side. A plurality of concave portions recessed in the axial direction are formed on the outer peripheral side flange portion, and an engaging hole that engages with the engaging convex portion formed on the outer peripheral side cylindrical portion of the second bobbin is the bottom surface of the concave portion. At least one exposed hole for exposing a part of the coil is provided on the inner peripheral side flange portion.

Therefore, the first bobbin and the second bobbin constituting the bobbin member can be reliably connected in the axial direction in the wound state of the coil by engaging the engaging convex portion with the engaging hole. Moreover, since the engaging convex portion is engaged in the concave portion and does not protrude outward with respect to the flange, the bobbin member in which the coil is wound is engaged when the bobbin member is housed inside the core. It is prevented that the convex portion comes into contact with the core and the engaged state between the first bobbin and the second bobbin is released. Further, in the flange, only the outer peripheral side flange portion provided with the concave portion is formed thick, and the inner peripheral side flange portion facing the coil is formed thinly to prevent deterioration of heat dissipation, and the heat of the coil is externally generated by the exposed hole. Can be escaped to.

As a result, in the reactor, by engaging the engaging convex portion with the engaging hole provided in the concave portion, the first bobbin and the second bobbin can be securely assembled with the coil wound. At the same time, the heat dissipation of the coil can be improved by increasing the thickness of the flange only on the outer peripheral side flange portion, making the inner peripheral side flange portion facing the coil thin, and providing an exposed hole.

According to the present invention, the following effects can be obtained.

That is, in the bobbin member constituting the reactor, the engaging convex portion of the second bobbin is reliably engaged in the axial direction by engaging the engaging convex portion of the concave portion formed in the outer peripheral flange portion of the first bobbin. It can be connected, and since the engaging convex portion is engaged in the state of being housed in the concave portion, it does not protrude outward with respect to the flange. Further, in the flange, only the outer peripheral side flange portion provided with the concave portion is formed thick, and the inner peripheral side flange portion facing the coil is formed thinly to prevent deterioration of heat dissipation and to open to the inner peripheral side flange portion. The exposed holes allow the heat of the coil to escape to the outside.

As a result, in the reactor, when the coil is wound around the first and second bobbins and stored inside the core, the engaging convex portion comes into contact with the core and the engaged state is released. The first bobbin and the second bobbin can be securely assembled, and the thickness of the flange is increased only on the outer peripheral side flange portion, and the exposed holes opened in the inner peripheral side flange portion dissipate heat from the coil. It can enhance the sex.

It is external perspective view of the reactor which concerns on embodiment of this invention. FIG. 5 is an external perspective view of a coil assembly composed of a core, a coil, and a bobbin in the reactor of FIG. It is an exploded perspective view of the coil assembly shown in FIG. It is an exploded perspective view of the 1st and 2nd holders constituting the bobbin of FIG. It is an overall cross-sectional view of the reactor shown in FIG.

Suitable embodiments of the reactor according to the present invention will be given and will be described in detail below with reference to the accompanying drawings.

As shown in FIGS. 1 to 5, the reactor 10 includes a coil 12 whose both ends are pulled out from the outer peripheral side and wound by α winding, and a bobbin (bobbin member) 14 around which the coil 12 is wound. , The coil 12 and the core 16 in which the bobbin 14 is housed.

For the coil 12, for example, a flat conducting wire covered with an insulating film such as enamel and having conductivity is used, and the outer peripheral side of the bobbin 14 is wound α in two layers in the vertical direction so that the wide surface thereof is in the radial direction. It is wound around.

Specifically, as shown in FIGS. 3 and 5, the coil 12 is formed with an upper layer 18 and a lower layer 20 which are wound a plurality of times, respectively, and the first end portion 22 which is an end portion of the upper layer 18 and the said The second end 24, which is the end of the lower layer 20, is pulled out outward. Further, a portion connecting the upper layer 18 and the lower layer 20 is provided in the middle of the coil 12. The upper layer 18 and the lower layer 20 of the coil 12 are formed with the same number of turns, and the outermost peripheral diameters thereof are formed to be substantially the same.

Then, in the coil 12, the first end portion 22 which is one end along the winding direction is pulled out radially outward from the outermost outer peripheral portion which is the outermost peripheral side in the winding portion of the upper layer 18 of the two layers. The second end portion 24, which is the other end, is pulled out radially outward from the outermost outer peripheral portion, which is the outermost peripheral side in the winding portion of the lower layer 20 of the two layers, and the first end portion 22 and the second end portion 22 are provided. It is provided so as to be substantially parallel to the end portion 24 and offset in the vertical direction.

As shown in FIGS. 2 to 5, the bobbin 14 is formed of a resin material and covers the first holder (first bobbin) 26 that covers the upper and lower parts of the coil 12 and the outer peripheral side of the coil 12. It includes a second holder (second bobbin) 28 connected to the first holder 26.

The first holder 26 has an inner peripheral wall (inner peripheral side cylindrical portion) 30 having a circular cross section and extending in the axial direction (arrows A1 and A2 directions), and is formed at the upper end of the inner peripheral wall 30 and extends outward in the radial direction. The existing first flange 32 and the second flange 34 formed at the lower end of the inner peripheral wall 30 and extending radially outward are provided.

The inner peripheral wall 30 is formed in a cylindrical shape having the same diameter and extending in the axial direction (arrows A1 and A2 directions), and the coil 12 is wound on the outer peripheral side thereof so as to have two layers in the vertical direction (axial direction). (See FIG. 5).

The first flange 32 connects a plurality of first cross-linked portions (inner peripheral side flange portions) 36 extending radially outward with respect to the upper end of the inner peripheral wall 30 and an outer edge portion of the first cross-linked portion 36 to each other. A plurality of first exposed holes surrounded by an annular first annular portion (outer peripheral flange portion) 38, an upper end of the inner peripheral wall 30, the first crosslinked portion 36, and the first annular portion 38. It is provided with an exposed hole) 40. The first crosslinked portions 36 are formed at equal intervals from each other along the circumferential direction of the inner peripheral wall 30.

The first annular portion 38 is formed thicker in the axial direction (arrow A1 direction) with respect to the first crosslinked portion 36, is formed radially outward by a predetermined distance from the inner peripheral wall 30, and is formed at a distance of a predetermined distance. A recess 42 recessed by a predetermined thickness toward the second flange 34 side (arrow A2 direction) is formed at a portion on the outer side in the radial direction of the crosslinked portion 36. Then, at the bottom of the recess 42 on the side of the second flange 34, an engaging hole 44 that is long along the circumferential direction of the first annulus 38 is formed. A plurality of engaging holes 44 are provided so as to penetrate the bobbin 14 in the axial direction (arrows A1 and A2 directions) and correspond to the first crosslinked portion 36.

Further, in the first annular portion 38, a cover portion 46 projecting outward in the radial direction is formed at a position between two adjacent first bridging portions 36. The cover portion 46 is formed, for example, having a substantially rectangular cross section, and protrudes outward by a predetermined length in the radial direction with respect to the outer circumference of the first annulus portion 38.

The first exposed hole 40 is formed in an elongated hole shape adjacent to the first crosslinked portion 36 in the circumferential direction and at equal intervals along the circumferential direction of the first flange 32 in the axial direction (arrow A1). , A2 direction).

The second flange 34 connects a plurality of second cross-linking portions (inner peripheral side flange portions) 48 formed at the lower end of the inner peripheral wall 30 and extending outward in the radial direction to each other and the outer edge portion of the second cross-linking portion 48. A plurality of second exposed holes surrounded by an annular second annular portion (outer peripheral flange portion) 50, a lower end of the inner peripheral wall 30, the second cross-linked portion 48, and the second annular portion 50. It is provided with an exposed hole) 52.

The second cross-linked portion 48 is formed so as to be equidistant from each other along the circumferential direction of the inner peripheral wall 30, and the second annular portion 50 is a predetermined distance outward in the radial direction with respect to the inner peripheral wall 30. Formed only apart.

The second exposed hole 52 is formed in an elongated hole shape at equal intervals along the circumferential direction of the second flange 34, penetrates in the axial direction (arrows A1 and A2 direction), and is the first in the axial direction. It is arranged so as to face the exposed hole 40.

The first and second crosslinked portions 36, 48 and the first and second annular portions 38, 50 are formed in parallel with each other at predetermined intervals in the axial direction (arrows A1 and A2 directions) of the inner peripheral wall 30. In addition, the first and second flanges 32 and 34 of the first holder 26 cover the upper and lower parts of the coil 12 wound around the inner peripheral wall 30.

The second holder 28 has an outer peripheral wall (cylindrical portion on the outer peripheral side) 54 formed in an annular shape, and a guide portion 56 projecting radially outward with respect to the outer peripheral wall 54. It is formed in a circular shape in cross section with substantially the same diameter as the first annular portion 38 of the first holder 26, and extends at a predetermined height along the axial direction (arrows A1 and A2 directions).

Further, a plurality of engaging pieces 58 extending upward (in the direction of arrow A1) from the lower end thereof are formed on the outer peripheral wall 54. The engaging pieces 58 are formed at positions and quantities corresponding to the engaging holes 44 of the first flange 32, are provided at equal intervals from each other along the circumferential direction of the outer peripheral wall 54, and are provided with respect to the outer peripheral wall 54. It is independently provided so as to be tiltable in the radial direction. At the upper end of the engaging piece 58, a claw portion 60 having a triangular cross section is formed so as to gradually project outward in the radial direction from the upper end downward (in the direction of arrow A2).

Then, in a state where the coil 12 is wound around the inner peripheral wall 30 of the first holder 26, the upper end of the outer peripheral wall 54 of the second holder 28 is brought into contact with the first annular portion 38, and a plurality of engagements are made. While tilting the coal piece 58 inward in the radial direction, the claw portion 60 is inserted into and engaged with each engagement hole 44 of the first annular portion 38.

As a result, as shown in FIG. 2, the first holder 26 and the second holder 28 are placed between the coil 12 and the second holder 28 under the engaging action of the claw portion 60 of the engaging piece 58 and the engaging hole 44. It is connected in the axial direction (arrows A1 and A2 directions) in a state of being positioned in the circumferential direction, and the claw portion 60 is housed in the recess 42. That is, the claw portion 60 does not protrude outward in the axial direction (arrow A1 direction) and the radial direction with respect to the first flange 32.

In other words, the engaging hole 44 of the first holder 26, the engaging piece 58 and the claw portion 60 of the second holder 28 rotate the first holder 26 and the second holder 28 in the axial direction (vertical direction, arrow A1). , A2 direction) functions as a snap-fit mechanism that can be connected.

Further, the guide portion 56 of the second holder 28 is formed in a U-shaped cross section that opens toward the first holder 26 side (arrow A1 direction), and protrudes outward in the radial direction from the outer peripheral wall 54 while maintaining the same cross-sectional shape. Inside, a separation portion 62 is provided which divides the opening portion into two when viewed from the axial direction of the second holder 28. Then, when the first holder 26 is connected so as to cover the upper portion of the second holder 28, the upper portion of the guide portion 56 is covered by the cover portion 46 of the first holder 26.

Then, in the coil 12 wound around the inner peripheral wall 30 of the first holder 26, the first and second end portions 22, 24 thereof pass through the inside of the guide portion 56 and the cover portion 46, respectively, and are external from the lead groove 72 of the core 16. It is taken out (outward in the radial direction), connected to a mating member (not shown), and passed through a first exposed hole 40 opened in the first flange 32 and a second exposed hole 52 opened in the second flange 34. The upper surface of the upper layer 18 and the lower surface of the lower layer 20 are exposed in the axial directions (arrows A1 and A2, respectively).

As shown in FIGS. 1, 3 and 5, for example, the core 16 is formed in a cylindrical shape that can be divided vertically (in the directions of arrows A1 and A2) from the magnetic material, and has a base core portion 64 provided at the bottom. A cover core portion 66 provided so as to cover the upper portion of the base core portion 64, and a columnar core shaft portion 68 formed at the center of the base core portion 64 are included. Inside the core 16, there is a storage space 70 in which the bobbin 14 around which the coil 12 is wound is inserted and stored on the outer peripheral side of the core shaft portion 68.

Further, a drawer groove 72 extending outward from the storage space 70 is formed in the base core portion 64 and the cover core portion 66 constituting the core 16, and the guide portion 56 of the bobbin 14 is formed in the drawer groove 72. And the cover portion 46 is inserted, and the first and second end portions 22 and 24 of the coil 12 are pulled out to the outside through the guide portion 56, respectively.

As shown in FIGS. 3 and 5, the core shaft portion 68 includes, for example, a plurality of split magnetic bodies 74 formed in a disk shape and laminated in the axial directions (arrows A1 and A2 directions), and adjacent split magnetic bodies. A plurality of ceramic plates 76 provided between 74 are included, and bobbins 14 are provided on the outer peripheral side of the core shaft portion 68 at predetermined intervals in the radial direction.

Further, the split magnetic body 74 is formed of a magnetic material, the ceramic plate 76 is formed of a ceramic which is a non-magnetic material, and there are gaps between adjacent sets of split magnetic bodies 74 at predetermined intervals in the axial direction. Is provided.

Further, as shown in FIG. 5, in the storage space 70 of the core 16, the heat radiating material 78 is provided at a portion of the bobbin 14 facing the first and second flanges 32 and 34. The heat radiating material 78 is made of, for example, a silicone-based material having high heat dissipation, and is provided so as to fill the first exposed hole 40 of the first flange 32 and the second exposed hole 52 of the second flange 34. The heat radiating material 78 is in contact with the upper surface of the upper layer 18 and the lower surface of the lower layer 20 of the coil 12 by being provided so as to satisfy the above conditions. The heat radiating material 78 is provided so as to fill the space between the inner wall surface of the cover core portion 66 and the first flange 32.

Then, the wound bobbin 14 of the coil 12 is in a state in which the inner peripheral wall 30 is inserted so as to be on the outer peripheral side of the core shaft portion 68 in the base core portion 64, and the upper portion of the base core portion 64 is covered with the cover core portion. The coil assembly S shown in FIG. 2 is formed by covering with 66 and filling the upper portion of the first flange 32 and the lower portion of the second flange 34 with the heat radiating material 78.

In the coil assembly S, as shown in FIG. 5, the upper and lower ends of the coil 12 are axially exposed through the first and second exposed holes 40 and 52, and the first and second exposed holes 40 are exposed. , 52, the coil 12 is in contact with the heat radiating material 78, and the heat radiating material 78 is in contact with the upper wall of the base core portion 64 and the lower wall of the cover core portion 66.

As described above, in the present embodiment, the bobbin 14 constituting the reactor 10 is composed of the first and second holders 26 and 28 that can be divided in the axial direction, with respect to the inner peripheral wall 30 of the first holder 26. The coil 12 is wound around the coil 12 and the outer peripheral side of the coil 12 is covered with the second holder 28. The first flange 32 of the first holder 26 is formed thick in the axial direction with respect to the first cross-linked portion 36 extending radially outward from the inner peripheral wall 30 and the first cross-linked portion 36, and is formed radially outward. A plurality of engaging holes 44 are formed in the first annular portion 38 to be provided with the connected first annular portion 38, and the claw portion 60 of the engaging piece 58 in the second holder 28 is engaged in the recess 42. It can be engaged with the joint hole 44.

Therefore, by engaging the first holder 26 and the second holder 28 constituting the bobbin 14 with the claw portion 60 of the engaging piece 58 into the engaging hole 44, the shaft in the wound state of the coil 12 It can be reliably connected in the directions (arrows A1 and A2), and the claw portion 60 of the engaging piece 58 projects axially and radially outward with respect to the first flange 32 of the first holder 26. It is stored in the recess 42 without any trouble.

Therefore, when the coil assembly S in which the coil 12 is wound around the bobbin 14 including the first holder 26 is stored in the storage space 70 of the core 16, the engaging piece 58 comes into contact with the core 16. The disengagement of the engaged state is prevented.

As a result, in the reactor 10, it is possible to reliably maintain the axially connected state of the first holder 26 and the second holder 28 in a state where the coil 12 is wound around the bobbin 14.

Further, the plurality of engaging pieces 58 are provided so as to be tiltable in the radial direction with respect to the outer peripheral wall 54 of the second holder 28, and have a triangular cross section protruding outward in the radial direction at the upper end of the engaging pieces 58. The claw portion 60 is provided. Therefore, when the first holder 26 and the second holder 28 are connected in the axial direction (arrows A1 and A2 directions) via the engaging piece 58, the coil 12 expands radially outward by springback. Since the engaging piece 58 is pressed radially outward together with the outer peripheral wall 54, the engaging piece 58 moves further radially outward in the engaging hole 44.

As a result, the engaged state between the claw portion 60 of the engaging piece 58 and the engaging hole 44 is more reliably maintained, and the first holder 26 having the engaging hole 44 and the second holder having the engaging piece 58 are provided. It becomes possible to connect the holder 28 more firmly. In other words, the coil 12 has a coil 12 as compared with a conventional reactor that has been urged in a direction in which the coil 12 expands outward to disengage the engagement between the first arm member and the second arm member. It is possible to maintain a strong connection by using springback.

Further, in the first flange 32, the first crosslinked portion 36 provided with the first exposed hole 40 is formed thinner in the axial direction (arrows A1 and A2 directions) with respect to the first annular portion 38. Therefore, by forming the first crosslinked portion 36 facing the coil 12 thinly, it is possible to avoid hindering the heat dissipation of the coil 12 and promote heat dissipation. Further, by providing the first crosslinked portion 36, it is possible to prevent the overall axial thickness of the first flange 32 from increasing, and the weight can be reduced, and the first exposed hole 40 can be easily formed. be able to.

Furthermore, the first and second flanges 32 and 34 are provided with first and second exposed holes 40 and 52 for exposing the upper surface and the lower surface of the coil 12 along the axial direction, thereby dissipating heat from the coil 12. The sex can be further enhanced.

Further, by providing the heat radiating material 78 for the first and second exposed holes 40 and 52, respectively, it is possible to easily secure a space for installing the heat radiating material 78, and further, the heat radiating material 78 can be easily secured. With 78, it is possible to further improve the heat dissipation of the coil 12.

It should be noted that the reactor according to the present invention is not limited to the above-described embodiment, and of course, various configurations can be adopted without departing from the gist of the present invention.

10 ... Reactor 12 ... Coil 14 ... Bobbin 16 ... Core 26 ... 1st holder 28 ... 2nd holder 30 ... Inner peripheral wall 32 ... 1st flange 34 ... 2nd flange 36 ... 1st crosslinked part 38 ... 1st ring part 40 ... 1st exposed hole 42 ... Recessed hole 44 ... Engagement hole 48 ... 2nd cross-linked portion 50 ... 2nd ring portion 52 ... 2nd exposed hole 54 ... Outer wall 58 ... Engagement piece 60 ... Claw portion 78 ... Heat dissipation material

Claims (2)

A bobbin member composed of a coil around which a conducting wire is wound, first and second bobbins that are engaged in an axial direction along the winding center of the coil and cover the coil, and the outside of the bobbin member including the coil. In a reactor with a core
The first bobbin includes an inner peripheral side cylindrical portion arranged on the inner circumference of the coil, and a flange covering at least one of one end and the other end of the coil along the axial direction. A cylindrical portion on the outer peripheral side that covers the outer surface of the coil is provided.
The flange has an inner peripheral side flange portion that is connected to the inner peripheral side cylindrical portion and extends outward, and an outer peripheral side that is thicker in the axial direction and is formed on the outer peripheral side with respect to the inner peripheral side flange portion. Equipped with a flange
A plurality of recesses recessed in the axial direction are formed in the outer peripheral flange portion, an engagement hole for engaging with the second bobbin is formed on the bottom surface of the recess, and the outer peripheral cylindrical portion is engaged. An engaging protrusion that engages with the perimeter is formed, and at the same time,
A reactor having at least one or more exposed holes for exposing a part of the coil on the inner peripheral side flange portion. In the reactor according to claim 1,
A reactor provided with a heat radiating material capable of dissipating the heat of the coil inside the exposed hole.

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