JP2022045275A - Reactor, converter, and power conversion device - Google Patents

Abstract

To provide a reactor capable of suppressing displacement of a combinational body in a case.SOLUTION: The reactor comprises a coil, a magnetic core, a resin member, a case, and a sealing resin part. The magnetic core has an inner core and an outer core. The case has a bottom plate, a side wall, and an opening. The side wall has a pair of short sides and a pair of long sides. The combinational body is housed in the case with a coil axial direction set along a Z direction. The outer core includes a first outer core and a second outer core. The resin member includes a first resin member ad a second resin member. The first resin member has a protruded part protruded toward one short side, and a fitting seat in an inner surface of one short side. When the combinational body housed in the case is seen from the X direction, one of the second resin member and the side wall has a projected part in a part of a fixed point diagonal to the fitting seat of the protruded part. The other has a recessed part. The combinational body is positioned at a space from the bottom plate through fitting of the projected part to the recessed part.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to reactors, converters, and power converters.

Patent Documents 1 and 2 disclose a reactor including a coil, a magnetic core, a case for accommodating a combination of the coil and the magnetic core, and a sealing resin portion filled in the case and covering the outer periphery of the combination. do. Patent Documents 1 and 2 describe that the union is fixed in a state of being pressed against the bottom plate portion of the case by two strip-shaped stays. Each stay is arranged on the upper surface of the outer core portion arranged outside the coil in the magnetic core. Both ends of each stay are fastened with bolts or screws to four stay mounting portions provided in the case.

Japanese Unexamined Patent Publication No. 2013-131567 Japanese Unexamined Patent Publication No. 2017-05509

In the above reactor, it is desired to suppress the change in the position of the union within the case. This change in position can occur with coil excitation or external vibration.

In the above-mentioned fixed structure with stays described in Patent Documents 1 and 2, the union is easily displaced in the case for the following reasons. There are a total of four fixed points between the union and the case. If there are many fixed points, vibration is likely to be transmitted between the union and the case. Therefore, the union is easily displaced in the case.

In particular, it is desired to suppress the displacement of the union in a plurality of directions such as the vertical direction and the horizontal direction in the case.

Therefore, one of the purposes of the present disclosure is to provide a reactor capable of suppressing the displacement of the union within the case. Another object of the present disclosure is to provide a converter having the above reactor. Further, one of the other purposes of the present disclosure is to provide a power conversion device including the above converter.

The reactor of this disclosure is
With the coil
A magnetic core having portions arranged inside and outside the coil,
A resin member that defines the mutual position between the coil and the magnetic core,
A case for accommodating the coil, the magnetic core, and the union including the resin member, and
It is provided with a sealing resin portion to be filled in the case.
The magnetic core is
The inner core portion arranged inside the coil and
It has an outer core portion arranged outside the coil and has an outer core portion.
The case is
The bottom plate on which the union is placed and
A square cylindrical side wall that surrounds the union and
It has an opening facing the bottom plate and has an opening.
The side wall portion has a pair of facing short sides and a pair of facing long sides.
The union is housed in the case so that the axial direction of the coil is along the Z direction.
The outer core portion includes a first outer core portion arranged on the opening side and a second outer core portion arranged on the bottom plate portion side.
The resin member includes a first resin member provided on the outer peripheral surface of the first outer core portion and a second resin member provided on the outer peripheral surface of the second outer core portion.
The first resin member has an overhanging portion that protrudes toward the short side portion of one of the pair of short side portions.
The inner surface of the one short side portion has a mounting seat on which the overhanging portion is fixed.
When the union housed in the case is viewed from the X direction,
At the diagonal portion of the fixing point of the overhanging portion to the mounting seat,
One of the second resin member and the side wall portion has a convex portion extending in the Z direction.
The other of the second resin member and the side wall portion has a concave portion that fits with the convex portion.
The union is positioned with a gap between the bottom plate portion by fitting the convex portion and the concave portion.
The X direction is a direction along the short side portion.
The Z direction is a direction orthogonal to both the X direction and the Y direction.
The Y direction is a direction along the long side portion.

The converters of the present disclosure include the reactors of the present disclosure.

The power converter of the present disclosure comprises the converter of the present disclosure.

The reactors of the present disclosure can suppress the displacement of the union within the case. Further, the converter and the power converter of the present disclosure are highly reliable.

FIG. 1 is a schematic partial cross-sectional view of the reactor according to the first embodiment as viewed from the X direction. FIG. 2 is a schematic plan view of the reactor according to the first embodiment as viewed from the Z direction. FIG. 3 is a schematic partial cross-sectional view of the reactor according to the first embodiment as viewed from the Y direction. FIG. 4 is a schematic exploded perspective view of the reactor according to the first embodiment. FIG. 5 is a schematic exploded view of the union body provided for the reactor according to the first embodiment. FIG. 6 is a schematic cross-sectional view cut along the VI-VI line of FIG. FIG. 7 is an enlarged view of a main part in which the portion surrounded by the alternate long and short dash line in FIG. 6 is enlarged. FIG. 8 is an enlarged view of a main part in which the portion surrounded by the alternate long and short dash line in FIG. 1 is enlarged. FIG. 9 is a diagram illustrating a fixed point and a diagonal portion in the reactor shown in FIG. FIG. 10 is a diagram illustrating a convex portion and a concave portion in the reactor according to the modified example 1-1. FIG. 11 is a diagram illustrating a convex portion and a concave portion in the reactor according to the modified example 1-2. FIG. 12 is a configuration diagram schematically showing a power supply system of a hybrid vehicle. FIG. 13 is a circuit diagram illustrating an outline of an example of a power conversion device including a converter.

[Explanation of Embodiments of the present disclosure]
First, embodiments of the present disclosure will be listed and described.

(1) The reactor according to the embodiment of the present disclosure is
With the coil
A magnetic core having portions arranged inside and outside the coil,
A resin member that defines the mutual position between the coil and the magnetic core,
A case for accommodating the coil, the magnetic core, and the union including the resin member, and
It is provided with a sealing resin portion to be filled in the case.
The magnetic core is
The inner core portion arranged inside the coil and
It has an outer core portion arranged outside the coil and has an outer core portion.
The case is
The bottom plate on which the union is placed and
A square cylindrical side wall that surrounds the union and
It has an opening facing the bottom plate and has an opening.
The side wall portion has a pair of facing short sides and a pair of facing long sides.
The union is housed in the case so that the axial direction of the coil is along the Z direction.
The outer core portion includes a first outer core portion arranged on the opening side and a second outer core portion arranged on the bottom plate portion side.
The resin member includes a first resin member provided on the outer peripheral surface of the first outer core portion and a second resin member provided on the outer peripheral surface of the second outer core portion.
The first resin member has an overhanging portion that protrudes toward the short side portion of one of the pair of short side portions.
The inner surface of the one short side portion has a mounting seat on which the overhanging portion is fixed.
When the union housed in the case is viewed from the X direction,
At the diagonal portion of the fixing point of the overhanging portion to the mounting seat,
One of the second resin member and the side wall portion has a convex portion extending in the Z direction.
The other of the second resin member and the side wall portion has a concave portion that fits with the convex portion.
The union is positioned with a gap between the bottom plate portion by fitting the convex portion and the concave portion.
The X direction is a direction along the short side portion.
The Z direction is a direction orthogonal to both the X direction and the Y direction.
The Y direction is a direction along the long side portion.

The reactor can suppress the displacement of the union in the case. The reasons for this are as follows.

There is only one fixing point between the union and the case. In the reactor, the overhanging portion of the first resin member in the union is fixed to the mounting seat of the case, so that there is only one fixing point. Since there are few fixed points, it is difficult for vibration to be transmitted between the union and the case. Therefore, the displacement of the union is unlikely to occur.

One of the second resin member in the union and the side wall portion of the case has a convex portion, and the other has a concave portion that fits into the convex portion, so that the displacement range of the union body is restricted in the case. Specifically, by fixing the overhanging portion to the mounting seat and fitting the convex portion and the concave portion, it is possible to suppress the union body from being displaced in each of the X direction, the Y direction, and the Z direction. In particular, in the reactor, the convex portion and the concave portion are located diagonally to the fixing point of the overhanging portion to the mounting seat. That is, the overhanging portion and the mounting seat, and the convex portion and the concave portion are provided at positions separated from each other. In the above reactor, since the overhanging portion is fixed to the mounting seat, the union body is displaced with the overhanging portion as a fulcrum. Therefore, the farther the position is from the overhanging portion, the larger the displacement amount of the union body. Displacement of the union can be effectively suppressed by fitting the convex portion and the concave portion at the diagonal portion of the fixing point of the overhanging portion to the mounting seat. Therefore, the displacement amount of the union can be reduced.

Further, in the reactor, vibration is less likely to be transmitted between the union body and the case in that the union body is arranged at a distance from the bottom plate portion due to the fitting between the convex portion and the concave portion.

Since the reactor can suppress the displacement of the union in the case, it can suppress the cracking of the sealing resin portion. The reason for this is that since the displacement of the union is small, it is difficult for excessive stress or strain to be applied to the sealing resin portion filled between the union and the case. The reactor is highly reliable because the sealing resin portion is unlikely to crack.

(2) As one form of the above reactor,
The overhanging portion is a line that bisects the union in the Z direction on one side of the line that bisects the union in the Y direction when the union is viewed from the X direction. Located on the side of the opening,
The diagonal portion is located on the opposite side of the line that bisects the union in the Y direction and on the bottom plate side of the line that bisects the union in the Z direction. Can be mentioned.

In the above embodiment, the displacement of the union can be effectively suppressed by locating the convex portion and the concave portion at the specific diagonal portion.

(3) As one form of the above reactor,
The convex portion is arranged on one of the inner surfaces of each of the pair of long side portions and each surface of the second resin member facing each of the pair of long side portions.
The recess may be arranged on the inner surface of each of the pair of long side portions and on the other side of each surface of the second resin member facing each of the pair of long side portions.

The above embodiment can suppress the displacement of the union in each of the X direction, the Y direction, and the Z direction in the case.

(4) As one form of the above reactor,
The distance between the convex portion and the concave portion may be 0.5 mm or less.

The above-mentioned form can effectively suppress the displacement of the union in the X direction and the Y direction.

(5) As one form of the above reactor,
The length of the portion where the convex portion and the concave portion are fitted along the Z direction may be 10% or more of the length of the union body along the Z direction.

The above-mentioned form can effectively suppress the displacement of the union in the Z direction.

(6) As one form of the above reactor,
The distance between the end surface on the bottom plate portion side and the inner bottom surface of the bottom plate portion in the union is 0.5 mm or more and 1.0 mm or less.

In the above form, the heat dissipation of the union is improved. When the distance between the union body and the bottom plate portion is 0.5 mm or more, the sealing resin portion is easily filled between the union body and the bottom plate portion. Therefore, the heat of the union can be transferred to the case via the sealing resin portion. Further, since the distance between the union body and the bottom plate portion is 1.0 mm or less, the distance between the union body and the bottom plate portion is short. Therefore, it is easy to transfer the heat of the union to the case.

(7) As one form of the above reactor,
The second resin member may have the concave portion, and the side wall portion may have the convex portion.

The above form makes it easy to manufacture a case having a convex portion. The length of the concave portion along the Z direction is shorter when the convex portion is provided on the side wall portion than when the concave portion is provided on the side wall portion. In particular, when the case is manufactured by die-casting, it is easier to remove the molded case from the mold by integrally molding the convex portion on the side wall portion than by integrally molding the concave portion on the side wall portion.

(8) As one form of the above reactor,
The cross-sectional shape of the convex portion orthogonal to the Z direction may be a quadrangular shape.

The above-mentioned form tends to effectively suppress the displacement of the union.

(9) As one form of the above reactor,
The resin constituting the sealing resin portion may be a silicone resin.

In the above form, the heat dissipation of the union is improved. This is because the silicone resin has a higher thermal conductivity than a resin such as an epoxy resin. Therefore, it is easy to transfer the heat of the union to the case through the sealing resin portion.

(10) The converter according to the embodiment of the present disclosure is
The reactor according to any one of (1) to (9) above is provided.

Since the converter of the present disclosure includes the above reactor, it is highly reliable.

(11) The power conversion device according to the embodiment of the present disclosure is
The converter according to (10) above is provided.

Since the power conversion device of the present disclosure includes the above converter, it is highly reliable.

[Details of Embodiments of the present disclosure]
Specific examples of the reactor according to the embodiment of the present disclosure will be described below with reference to the drawings. The same reference numerals in the figure indicate the same names. In each drawing, for convenience of explanation, a part of the configuration may be exaggerated or simplified. The dimensional ratio of each part in the drawing may also differ from the actual one. It should be noted that the present invention is not limited to these examples, and is indicated by the scope of claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

[Embodiment 1]
<Overview>
The reactor 1 according to the first embodiment will be described with reference to FIGS. 1 to 9. As shown in FIG. 1, the reactor 1 includes a coil 2, a magnetic core 3, a resin member 4, a case 5, and a sealing resin portion 6. In this embodiment, the coil 2 has two winding portions 21 and 22. The magnetic core 3 has portions arranged inside and outside the coil 2. Specifically, the magnetic core 3 has inner core portions 31 and 32 arranged inside the coil 2 and outer core portions 33 and 34 arranged outside the coil 2. The resin member 4 defines the mutual position between the coil 2 and the magnetic core 3. The case 5 houses the union body 10 including the coil 2, the magnetic core 3, and the resin member 4. The sealing resin portion 6 is filled in the case 5. The case 5 has a bottom plate portion 51, a side wall portion 52, and an opening portion 55. As shown in FIG. 2, the side wall portion 52 has a pair of facing short side portions 531 and 532, and a pair of facing long side portions 541 and 542.

In the reactor 1, as shown in FIG. 4, the X direction is the direction along the short side portions 531 and 532 of the side wall portion 52. The Y direction is a direction along the long side portions 541 and 542. The Z direction is a direction orthogonal to both the X direction and the Y direction.
1 and 9 are partial cross-sectional views of the case 5 and the sealing resin portion 6 cut along a plane parallel to the Y direction.
FIG. 3 is a partial cross-sectional view of the case 5 and the sealing resin portion 6 cut along a plane parallel to the X direction.
In FIGS. 1, 3, and 9, the union body 10 shows an appearance rather than a cross section.
The cross-sectional view of FIG. 1 corresponds to the cross-sectional view cut along the line I-I of FIG.
The cross-sectional view of FIG. 3 corresponds to the cross-sectional view cut along the line III-III of FIG.
FIG. 2 is a plan view seen from the opening 55 side of the case 5 in the Z direction.
In FIGS. 2, 6 and 7, the sealing resin portion 6 is omitted.
FIG. 4 shows a state before the union body 10 is stored in the case 5.
FIG. 5 shows the union body 10 in a state in which it does not have the mold resin portion 8 described later in an exploded manner.
In FIG. 8, the convex portion 91 is virtually shown by a two-dot chain line.

In the following description, the bottom plate portion 51 side of the case 5 is on the bottom, and the side opposite to the bottom plate portion 51 side, that is, the opening 55 side is on the top. The vertical direction corresponds to the Z direction. The Z direction corresponds to the height direction of the union body 10 and the depth direction of the case 5. The X direction corresponds to the width direction of the union body 10 and the case 5. The Y direction corresponds to the length direction of the union body 10 and the case 5.

In the reactor 1 of the first embodiment, as shown in FIG. 1, the combined body 10 is housed in the case 5 so that the axial direction of the coil 2 is along the Z direction. Hereinafter, this arrangement form is referred to as an upright type. Further, among the outer core portions 33 and 34 constituting the magnetic core 3, the outer core portion 33 arranged on the opening 55 side of the case 5 is called the first outer core portion, and the outer side arranged on the bottom plate portion 51 side. The core portion 34 is referred to as a second outer core portion. The resin member 4 includes a first resin member 4a provided on the outer peripheral surface of the first outer core portion 33 and a second resin member 4b provided on the outer peripheral surface of the second outer core portion 34.
One of the features of the reactor 1 is that it includes a partnership 10 having a specific structure and a case 5 having a specific structure that hold each other's positions. Specifically, as shown in FIGS. 1 and 2, the first resin member 4a has an overhanging portion 7, and the case 5 has a mounting seat 56 to which the overhanging portion 7 is fixed. Further, as shown in FIG. 4, the case 5 has a convex portion 91, and the second resin member 4b has a concave portion 92 that fits into the convex portion. In the reactor 1, the overhanging portion 7 and the mounting seat 56, and the convex portion 91 and the concave portion 92 are provided at positions separated from each other.
Hereinafter, the configuration of the reactor 1 will be described in detail.

(coil)
As shown in FIG. 1, the coil 2 has two winding portions 21 and 22. The winding portions 21 and 22 are formed by winding windings in a spiral shape. The winding portions 21 and 22 are arranged in parallel so that their axial directions are parallel to each other. In the state where the combined body 10 is housed in the case 5, the axial direction of the coil 2, that is, the axial direction of the winding portions 21 and 22 coincides with the Z direction.

In the coil 2, both winding portions 21 and 22 may be formed by winding one continuous winding, or each winding portion 21 and 22 may be formed by winding separate windings. When both winding portions 21 and 22 are composed of one continuous winding, for example, after forming one winding portion 21, the winding is bent and folded on the other end side, and the other winding portion is wound. The formation of the portion 22 is mentioned. When the winding portions 21 and 22 are composed of separate windings, after the winding portions 21 and 22 are formed of separate windings, the ends of the windings are connected to each other on the other end side of the winding portions 21 and 22. Can be mentioned. Joining methods such as welding, crimping, soldering, and brazing can be used for this connection.

The end of the winding on one end side of the winding portions 21 and 22 is pulled out from the opening 55 side of the case 5. Terminal fittings (not shown) are attached to the ends of the drawn windings. An external device such as a power supply (not shown) is connected to the terminal fitting. Note that FIG. 1 and the like show only the winding portions 21 and 22, and the end portions of the windings and the like are omitted.

Examples of the winding include a conductor wire and a covered wire having an insulating coating. Examples of the constituent material of the conductor wire include copper and the like. Examples of the constituent material of the insulating coating include resins such as polyamide-imide. Examples of the covered wire include a covered flat wire having a rectangular cross-sectional shape, a covered round wire having a circular cross-sectional shape, and the like.

In the present embodiment, both winding portions 21 and 22 are made of windings having the same specifications, and have the same shape, size, winding direction, and number of turns. Further, the winding portions 21 and 22 are square cylinder-shaped edgewise coils in which the covering flat wire is wound edgewise. In the present embodiment, the winding portions 21 and 22 have a rectangular tubular shape. The shapes of the winding portions 21 and 22 are not particularly limited, and may be, for example, a cylindrical shape, an elliptical cylinder shape, a long cylindrical shape, or the like. Further, the specifications of the windings forming the both winding portions 21 and 22 and the shapes of the both winding portions 21 and 22 may be different.

In the present embodiment, the end face shape of the wound portions 21 and 22 viewed from the axial direction, that is, the Z direction is rectangular. That is, the winding portions 21 and 22 have four planes and four corner portions. The corners of the winding portions 21 and 22 are rounded. The outer peripheral surfaces of the winding portions 21 and 22 are substantially formed of a flat surface. Therefore, the outer peripheral surfaces of the wound portions 21 and 22 and the inner peripheral surface of the side wall portion 52 in the case 5 face each other in planes (see FIGS. 1 and 3). Therefore, it is easy to secure a large area where the outer peripheral surfaces of the wound portions 21 and 22 and the inner peripheral surface of the side wall portions 52 face each other. Further, the distance between the outer peripheral surfaces of the wound portions 21 and 22 and the inner peripheral surface of the side wall portion 52 tends to be small.

As shown in FIG. 1, in the coil 2, the axial direction of each of the two winding portions 21 and 22 is orthogonal to the bottom plate portion 51 of the case 5, and the parallel direction of the two winding portions 21 and 22 is the case 5. It is arranged along the long side portions 541 and 542 of the side wall portion 52. That is, both winding portions 21 and 22 are arranged so as to be arranged in the Y direction. In the present embodiment, one winding portion 21 is arranged on one short side portion 531 side of the side wall portion 52, and the other winding portion 22 is arranged on the other short side portion 532 side.

(Magnetic core)
As shown in FIG. 1, the magnetic core 3 has two inner core portions 31, 32 and two outer core portions 33, 34. The inner core portions 31 and 32 are portions arranged inside the coil 2, that is, inside the winding portions 21 and 22. The outer core portions 33 and 34 are portions arranged outside the both winding portions 21 and 22. In the present embodiment, the outer core portions 33 and 34 are arranged so as to sandwich the inner core portions 31 and 32 from both ends (see also FIG. 5). The magnetic core 3 is formed in an annular shape by connecting the end faces of the inner core portions 31 and 32 and the inner end faces 33e of the outer core portions 33 and 34 (see also FIG. 5). A closed magnetic path through which magnetic flux flows when the coil 2 is excited is formed in the magnetic core 3.

(Inner core part)
The inner core portions 31 and 32 are arranged in parallel so that their axial directions are parallel to each other. In the state where the union body 10 is housed in the case 5, the axial directions of the inner core portions 31 and 32 coincide with the Z direction. The shapes of the inner core portions 31 and 32 substantially correspond to the inner peripheral shapes of the wound portions 21 and 22. There is a gap between the inner peripheral surfaces of the winding portions 21 and 22 and the outer peripheral surfaces of the inner core portions 31 and 32. This gap is filled with the resin constituting the mold resin portion 8 described later. In the present embodiment, the inner core portions 31 and 32 have a square columnar shape, more specifically a rectangular parallelepiped shape. The end face shape of the inner core portions 31 and 32 when viewed from the axial direction, that is, the Z direction is rectangular. The corners of the inner cores 31 and 32 are rounded along the corners of the windings 21 and 22. The sizes of both inner core portions 31 and 32 are the same. The axial ends of the inner core portions 31 and 32 slightly protrude from the end faces of the coil 2, that is, the end faces of the winding portions 21 and 22. Both ends of the inner core portions 31 and 32 protruding from the end faces of the winding portions 21 and 22 are inserted into the through holes 43 of the holding members 40a and 40b described later (see also FIG. 5).

In the present embodiment, the inner core portions 31 and 32 are each composed of one columnar core piece. The length of each core piece constituting the inner core portions 31 and 32 along the Z direction is substantially equal to the length of the winding portions 21 and 22 along the Z direction. That is, the inner core portions 31 and 32 are not provided with the magnetic gap material. Unlike the present embodiment, the inner core portions 31 and 32 may be composed of a plurality of core pieces and a magnetic gap material interposed between adjacent core pieces. As the magnetic gap material, a plate material made of a non-magnetic material such as resin or ceramics can be used.

(Outer core part)
The outer core portions 33 and 34 are arranged so as to connect the ends of both inner core portions 31 and 32 to each other. The outer core portions 33 and 34 have inner end surfaces 33e facing each end surface of both inner core portions 31 and 32 (see also FIG. 5). The shape of the outer core portions 33 and 34 is not particularly limited as long as it is a shape that connects the ends of both inner core portions 31 and 32. In the present embodiment, the outer core portions 33 and 34 have a rectangular parallelepiped shape. The sizes of both outer core portions 33 and 34 are substantially the same. The outer core portions 33 and 34 are each composed of one columnar core piece.

One outer core portion 33 arranged on the opening 55 side of the case 5 is a first outer core portion. The other outer core portion 34 arranged on the bottom plate portion 51 side of the case 5 is a second outer core portion. The outer end surface of the second outer core portion 34 opposite to the inner core portions 31 and 32 sides faces the inner bottom surface 510 of the bottom plate portion 51.

The inner core portions 31, 32 and the outer core portions 33, 34 are made of a molded body containing a soft magnetic material. Examples of the soft magnetic material include metals such as iron and iron alloys and non-metals such as ferrite. Examples of the iron alloy include Fe—Si alloy and Fe—Ni alloy. Typical examples of the molded body containing the soft magnetic material include a dust compact molded body and a molded body made of a composite material.

The compaction compact is formed by compression molding a powder made of a soft magnetic material. Hereinafter, the powder made of a soft magnetic material is referred to as "soft magnetic powder". The powder compact has a high content of soft magnetic powder as compared with the composite material. Therefore, the powder compact tends to improve the magnetic characteristics. Typical examples of the magnetic characteristics include relative permeability and saturation magnetic flux density. The content of the soft magnetic powder in the powder compact is, for example, 85% by volume or more and 99.99% by volume or less when the powder compact is 100% by volume.

The molded body of the composite material is formed by dispersing the soft magnetic powder in the resin. A molded product of a composite material is obtained by filling a mold with a raw material in which soft magnetic powder is mixed and dispersed in an unsolidified resin, and the resin is solidified. The composite material can easily adjust its magnetic properties by adjusting the content of the soft magnetic powder. The content of the soft magnetic powder in the composite material is, for example, 20% by volume or more and 80% by volume or less when the composite material is 100% by volume.

The soft magnetic powder is an aggregate of soft magnetic particles. The soft magnetic particles may be coated particles having an insulating coating on the surface thereof. Examples of the insulating coating include phosphate coating, silica coating, resin coating and the like. Examples of the constituent material of the resin coating include epoxy resin, phenol resin, silicone resin, polyamide resin, and polyimide resin.

Examples of the resin of the composite material include a thermosetting resin and a thermoplastic resin. Examples of the thermosetting resin include epoxy resin, phenol resin, silicone resin, urethane resin and the like. Examples of the thermoplastic resin include polyphenylene sulfide (PPS) resin, polyamide (PA) resin, polyimide (PI) resin, liquid crystal polymer (LCP), and fluororesin. Specific examples of the PA resin include nylon 6, nylon 66, and nylon 9T. The composite material may contain a filler in addition to the resin. By containing the filler, the heat dissipation of the composite material can be improved. As the filler, for example, a powder made of a non-magnetic material such as ceramics or carbon nanotubes can be used. Examples of ceramics include metal or non-metal oxides, nitrides, carbides and the like. Examples of oxides include alumina, silica, magnesium oxide and the like. Examples of the nitride include silicon nitride, aluminum nitride, and boron nitride. As an example of the carbide, silicon carbide and the like can be mentioned.

The constituent materials of the inner core portions 31 and 32 and the constituent materials of the outer core portions 33 and 34 may be the same or different. In the present embodiment, the inner core portions 31 and 32 are made of a molded body of a composite material, and the outer core portions 33 and 34 are made of a dust compact. Further, the magnetic core 3 of this example does not have a magnetic gap material.

(Resin member)
The resin member 4 defines the mutual position between the coil 2 and the magnetic core 3. As shown in FIGS. 1 and 3, the resin member 4 includes a first resin member 4a and a second resin member 4b. The first resin member 4a is provided on the outer peripheral surface of the first outer core portion 33. The second resin member 4b is provided on the outer peripheral surface of the second outer core portion 34. In addition to the holding members 40a and 40b described below, the resin member 4 also includes a mold resin portion 8 described later.

(Holding member)
In the present embodiment, as the resin member 4, as shown in FIGS. 1 and 3, two holding members 40a and 40b are provided (see also FIG. 5). As shown in FIGS. 1 and 5, the holding members 40a and 40b have a frame plate arranged so as to face each end face of the winding portions 21 and 22 constituting the coil 2. Further, the holding members 40a and 40b have an outer wall portion 41 that covers the outer peripheral surfaces of the outer core portions 33 and 34. Of the holding members 40a and 40b, the holding member 40a that covers the outer peripheral surface of the first outer core portion 33 is called the first holding member, and the holding member 40b that covers the outer peripheral surface of the second outer core portion 34 is called the second holding member. Call. The first holding member 40a is the first resin member 4a. The second holding member 40b is a second resin member 4b.

Both the holding members 40a and 40b are members that can be assembled to the coil 2 and the magnetic core 3. The holding members 40a and 40b define the mutual positions of the coil 2 and the magnetic core 3 and hold the positioning state. Further, the holding members 40a and 40b secure electrical insulation between the winding portions 21 and 22 of the coil 2 and the outer core portions 33 and 34 of the magnetic core 3.

In the present embodiment, the basic configurations of both holding members 40a and 40b are the same. However, the difference is that the first holding member 40a has an overhanging portion 7 and the second holding member 40b has a recess 92.

The common components in the holding members 40a and 40b will be described mainly with reference to FIGS. 1 and 5.
The holding members 40a and 40b include a frame plate having a through hole 43 and an outer wall portion 41. The frame plate is an end surface of the winding portions 21 and 22 constituting the coil 2 and an inner end surface of the outer core portions 33 and 34. It is interposed between the 33e and 33e. The outer wall portion 41 covers at least a part of the outer peripheral surface of the outer core portions 33 and 34. In the present embodiment, the outer wall portion 41 covers the entire circumference of the outer peripheral surfaces of the outer core portions 33, 34.

In the present embodiment, the shapes of the holding members 40a and 40b are rectangular frames when viewed from the Z direction (see FIG. 2), and the outer peripheral surface of the outer wall portion 41 is substantially formed of a flat surface. The outer peripheral surface of the outer wall portion 41 includes four planes facing the short side portions 531 and 532 and the long side portions 541 and 542 in the side wall portion 52 of the case 5.

The frame plate mainly secures electrical insulation between the winding portions 21, 22 and the outer core portions 33, 34. In the present embodiment, the shape of the frame plate is rectangular in plan view. As shown in FIGS. 1 and 5, the frame plate has two through holes 43 penetrating the front and back of the rectangular plate. The ends of the inner core portions 31 and 32 are inserted into each through hole 43. The shape of the through hole 43 is a shape substantially corresponding to the outer peripheral shape of the end portions of the inner core portions 31 and 32. In the present embodiment, the four corners of the through hole 43 are formed along the corners of the outer peripheral surfaces of the inner core portions 31 and 32. The inner core portions 31 and 32 are held in the through hole 43 by the four corners of the through hole 43. Further, in the through hole 43, a gap is partially formed between the outer peripheral surface of the inner core portions 31 and 32 and the inner peripheral surface of the through hole 43 with the ends of the inner core portions 31 and 32 inserted. It is provided to be done. This gap communicates with the gap between the inner peripheral surfaces of the winding portions 21 and 22 and the outer peripheral surfaces of the inner core portions 31 and 32.

The outer wall portion 41 is a rectangular cylinder that surrounds the peripheral edge of the frame plate, and is provided so as to surround the entire circumference of the outer core portions 33, 34. The outer wall portion 41 has a recess 44 inside thereof. The inner end surface 33e side of the outer core portions 33 and 34 is fitted into the recess 44. In the present embodiment, in the recess 44, a gap is partially formed between the outer peripheral surface of the outer core portions 33, 34 and the inner peripheral surface of the recess 44 in a state where the outer core portions 33, 34 are fitted. It is provided as follows. This gap is filled with the resin constituting the mold resin portion 8 described later. The outer core portions 33 and 34 and the holding members 40a and 40b are integrated by the mold resin portion 8. In the present embodiment, the holding members 40a and 40b communicate with the gap between the outer core portions 33 and 34 and the recess 44 and the gap between the inner core portions 31 and 32 and the through hole 43 described above. It is configured in. By communicating these gaps, when forming the mold resin portion 8, the resin constituting the mold resin portion 8 can be introduced between the winding portions 21 and 22 and the inner core portions 31 and 32. Is.

Further, the holding members 40a and 40b have an inner intervening portion (not shown). The inner intervening portion projects from the peripheral edge portion of the through hole 43 toward the inside of the winding portions 21 and 22, and is inserted between the winding portions 21 and 22 and the inner core portions 31 and 32. The winding portions 21, 22 and the inner core portions 31, 32 are held at intervals by the inner intervening portion. As a result, electrical insulation is ensured between the winding portions 21 and 22 and the inner core portions 31 and 32.

As described above, the inner core portions 31 and 32 are positioned with respect to the holding members 40a and 40b by inserting the ends of the inner core portions 31 and 32 into the through holes 43 of the holding members 40a and 40b. To. Further, the outer core portions 33 and 34 are positioned by fitting the inner end surface 33e side of the outer core portions 33 and 34 into the recesses 44 of the holding members 40a and 40b. Further, the winding portions 21 and 22 are positioned by the inner intervening portion. As a result, the winding portions 21 and 22 of the coil 2 and the inner core portions 31 and 32 and the outer core portions 33 and 34 of the magnetic core 3 are held in a positioned state by the holding members 40a and 40b.

The constituent materials of the holding members 40a and 40b are typically resins. Specific examples of the resin include thermosetting resins and thermoplastic resins. Examples of the thermosetting resin include epoxy resin, phenol resin, silicone resin, urethane resin, unsaturated polyester resin and the like. Examples of the thermoplastic resin include PPS resin, PA resin, PI resin, LCP, fluororesin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, and acrylonitrile-butadiene-styrene (ABS) resin. Be done. The constituent materials of the holding members 40a and 40b may contain a filler in addition to the above resin. By containing the filler, the heat dissipation of the holding members 40a and 40b can be improved. As the filler, the same filler as that used for the composite material described above can be used. In this embodiment, the holding members 40a and 40b are made of PPS resin.

(Mold resin part)
In the present embodiment, the union body 10 includes a mold resin portion 8 as shown in FIG. The mold resin portion 8 covers at least a part of the outer peripheral surfaces of the outer core portions 33 and 34, and is interposed between the inner peripheral surfaces of the wound portions 21 and 22 and the outer peripheral surfaces of the inner core portions 31 and 32. .. The inner core portions 31, 32 and the outer core portions 33, 34 are integrally held by the mold resin portion 8. As a result, the winding portions 21 and 22 of the coil 2 and the inner core portions 31 and 32 and the outer core portions 33 and 34 of the magnetic core 3 are integrated. Therefore, the coil 2 and the magnetic core 3 can be handled as an integral body. Further, the outer core portions 33 and 34 and the holding members 40a and 40b are integrated by the mold resin portion 8. That is, in this example, the coil 2, the magnetic core 3, and the holding members 40a and 40b are integrated by the mold resin portion 8. Therefore, the union body 10 can be treated as an integral body. The outer peripheral surfaces of the wound portions 21 and 22 are not covered by the mold resin portion 8 and are exposed from the mold resin portion 8.

The mold resin portion 8 may be capable of integrally holding the inner core portions 31, 32 and the outer core portions 33, 34. The mold resin portion 8 does not need to cover the surface of the inner core portions 31 and 32 along the circumferential direction, that is, the outer peripheral surface of the inner core portions 31 and 32 over the entire length. Considering the function of the mold resin portion 8 that integrally holds the inner core portions 31 and 32 and the outer core portions 33 and 34, the formation range of the mold resin portion 8 extends to the vicinity of the ends of the inner core portions 31 and 32. It's fine. That is, if the mold resin portion 8 does not extend to the central portion in the axial direction of the inner core portions 31 and 32, and is formed so as to cover at least the end portion of the outer peripheral surfaces of the inner core portions 31 and 32. good. Of course, the mold resin portion 8 may extend to the central portion in the axial direction of the inner core portions 31 and 32. In this case, the mold resin portion 8 covers the outer peripheral surfaces of the inner core portions 31 and 32 over the entire length, and is formed from the first outer core portion 33 to the second outer core portion 34.

As the resin constituting the mold resin portion 8, the same resin as the resin constituting the holding members 40a and 40b described above can be used. The constituent material of the mold resin portion 8 may contain the above-mentioned filler in addition to the above-mentioned resin. In this embodiment, the mold resin portion 8 is made of PPS resin.

The mold resin portion 8 can also function as the resin member 4. Specifically, the portion of the mold resin portion 8 that covers the outer peripheral surface of the first outer core portion 33 is included in the first resin member 4a. Further, the portion of the mold resin portion 8 that covers the outer peripheral surface of the second outer core portion 34 is included in the second resin member 4b.

(Overhanging part)
The first resin member 4a has an overhanging portion 7 as shown in FIGS. 1 to 3. As shown in FIGS. 1 and 2, the overhanging portion 7 projects toward one short side portion 531 of the side wall portion 52 of the case 5. In the present embodiment, the overhanging portion 7 is provided on the first holding member 40a. The overhanging portion 7 is provided on the surface of the outer wall portion 41 of the first holding member 40a facing the short side portion 531. One overhanging portion 7 is provided at the center of the outer wall portion 41 in the X direction, that is, in the width direction (see FIG. 2). The position of the overhanging portion 7 is not particularly limited, and may be deviated from the central portion of the outer wall portion 41 in the width direction.

In the present embodiment, the shape of the overhanging portion 7 is a tongue piece shape in a plan view (see FIG. 2). The shape of the overhanging portion 7 is not particularly limited, and may be another shape such as a polygonal shape, a semicircular shape, or a semi-elliptical shape. Examples of the polygonal shape include a triangular shape, a rectangular shape, and a trapezoidal shape.

The size of the overhanging portion 7 is not particularly limited. The protruding length of the overhanging portion 7 is, for example, 10 mm or more and 30 mm or less. Specific ranges of the protruding length of the overhanging portion 7 include 10 mm or more and 15 mm or less, and 20 mm or more and 30 mm or less. The protruding length is a length along the Y direction of the protruding portion 7 protruding from the outer wall portion 41 of the first holding member 40a. If the protruding length of the overhanging portion 7 is 20 mm or more, the size of the overhanging portion 7 can be secured, and it is easy to firmly fix the overhanging portion 7 to the mounting seat 56. The mounting seat 56 will be described later. Further, since the protruding length of the overhanging portion 7 is 15 mm or less, the case 5 does not become excessively large and heavy. This is because if the protruding length of the overhanging portion 7 is 15 mm or less, the thickness of the short side portion 531 can be reduced accordingly. The thickness of the short side portion 531 is a dimension of the short side portion 531 in the Y direction.

The width and thickness of the overhanging portion 7 can be appropriately set as long as the overhanging portion 7 is not easily deformed or broken. The width of the overhanging portion 7 is a dimension of the overhanging portion 7 in the X direction. The thickness of the overhanging portion 7 is a dimension of the overhanging portion 7 in the Z direction. The width and thickness of the overhanging portion 7 may be smaller than the width and thickness of the outer wall portion 41 of the first holding member 40a, or may be the same as the width and thickness of the outer wall portion 41. In the present embodiment, the width and thickness of the overhanging portion 7 are smaller than the width and thickness of the outer wall portion 41.

By fixing the overhanging portion 7 to the mounting seat 56, it is possible to prevent the union body 10 from coming out of the case 5. Examples of the method of fixing the overhanging portion 7 to the mounting seat 56 include bolting, welding, and adhesion. In the present embodiment, the overhanging portion 7 is fixed to the mounting seat 56 by bolting. The overhanging portion 7 is provided with a through hole 71 penetrating in the Z direction. A bolt 75 is inserted through the through hole 71, and an overhanging portion 7 is fastened to the mounting seat 56 by the bolt 75.

In the present embodiment, as shown in FIGS. 1 and 5, the overhanging portion 7 is integrally formed with the outer wall portion 41 by insert-molding a metal bracket 70 into the first holding member 40a. The bracket 70 is an L-shaped member having a tongue piece portion protruding from the outer wall portion 41 and a base portion embedded in the outer wall portion 41. The tongue piece portion becomes the overhanging portion 7. The end of the tongue piece on the outer wall 41 side penetrates the inside of the outer wall 41. The base extends along the Z direction from the end of the tongue piece on the outer wall 41 side. Examples of the metal constituting the bracket 70 include non-magnetic metals. Examples of the non-magnetic metal include aluminum and its alloy, magnesium and its alloy, copper and its alloy, silver and its alloy, and austenitic stainless steel. Examples of the austenitic stainless steel include SUS304. In this embodiment, the bracket 70 is made of SUS304. Unlike the present embodiment, the overhanging portion 7 may be integrally molded with the outer wall portion 41 by the resin constituting the first holding member 40a.

In the present embodiment, as described above, the first holding member 40a has the overhanging portion 7. Unlike the present embodiment, the mold resin portion 8 may have an overhanging portion 7. For example, a portion corresponding to the outer wall portion 41 of the first holding member 40a may be formed by the mold resin portion 8, and the overhanging portion 7 may be integrally formed with the mold resin portion 8.

(Recess)
The second resin member 4b has a recess 92 as shown in FIGS. 1, 4, and 5. The recess 92 extends in the Z direction from the bottom plate portion 51 side of the case 5 toward the opening 55 side. As shown in FIGS. 6 to 8, the concave portion 92 fits into the convex portion 91 provided on the side wall portion 52 of the case 5. The convex portion 91 will be described later. In the present embodiment, the recess 92 is provided in the second holding member 40b. The concave portion 92 is provided on the surface of the outer wall portion 41 of the second holding member 40b facing the convex portion 91.

In the present embodiment, as shown in FIG. 6, the recess 92 is provided on each surface of the outer wall portion 41 of the second holding member 40b facing each of the long side portions 541 and 542. The cross-sectional shape of the concave portion 92 is a shape corresponding to the cross-sectional shape of the convex portion 91. The cross-sectional shape of the convex portion 91 and the concave portion 92 is a cross-sectional shape orthogonal to the Z direction. In the present embodiment, as shown in FIG. 7, the cross-sectional shape of the recess 92 is rectangular, specifically rectangular. The cross-sectional shape of the recess 92 is not limited to a rectangular shape, and may be another shape such as a polygonal shape, a semicircular shape, or a semi-elliptical shape. Examples of the polygonal shape include a triangular shape, a trapezoidal shape, a pentagonal shape, and a hexagonal shape.

Details such as the fitting relationship between the convex portion 91 and the concave portion 92 and the positions of the convex portion 91 and the concave portion 92 will be described later.

In the present embodiment, as described above, the second holding member 40b has a recess 92. Unlike the present embodiment, the mold resin portion 8 may have a recess 92. For example, a portion corresponding to the outer wall portion 41 of the second holding member 40b may be formed by the mold resin portion 8 and formed in the recess 92 in the mold resin portion 8.

(Case)
By accommodating the union body 10 as shown in FIG. 1, the case 5 can be mechanically protected and protected from the external environment. The purpose of protection from the external environment is to improve anticorrosion. In this embodiment, the case 5 is made of a non-magnetic metal, specifically aluminum. Metal has a higher thermal conductivity than resin. Therefore, the metal case 5 easily releases the heat of the union body 10 to the outside through the case 5. Therefore, the metal case 5 contributes to the improvement of the heat dissipation property of the union body 10.

As shown in FIG. 1, the case 5 has a bottom plate portion 51, a side wall portion 52, and an opening portion 55 (see also FIG. 4). The case 5 is a bottomed cylindrical container having an opening 55 on the side facing the bottom plate portion 51. The bottom plate portion 51 is a flat plate member on which the union body 10 is placed. The side wall portion 52 is a square tubular body that surrounds the union body 10. A storage space for the union body 10 is formed by the bottom plate portion 51 and the side wall portion 52. In the present embodiment, the bottom plate portion 51 and the side wall portion 52 are integrally formed. The side wall portion 52 has a height equal to or higher than the height of the union body 10. The height is the dimension of the union 10 in the Z direction. The height of the union body 10, that is, the length along the Z direction is the distance between the end surface 101 on the bottom plate portion 51 side and the end surface 105 on the opening 55 side in the union body 10. The end surface 101 on the bottom plate portion 51 side faces the inner bottom surface 510 of the bottom plate portion 51. The end face 101 corresponds to the bottom surface of the union body 10, that is, the bottom surface. The end face 105 corresponds to the upper surface of the union body 10. Even if the end of the winding forming the coil 2 protrudes from the opening 55, the length of the end of the winding protruding from the opening 55 is included in the height of the union 10, that is, the length in the Z direction. I can't.

In the present embodiment, the bottom plate portion 51 has a square plate shape. In the bottom plate portion 51, the inner bottom surface 510 on which the union body 10 is placed is substantially formed of a flat surface. The side wall portion 52 has a square tubular shape. The side wall portion 52 has a pair of facing short side portions 531 and 532 and a pair of facing long side portions 541 and 542. Of the inner peripheral surfaces of the side wall portion 52, the inner surfaces of the short side portions 532 facing the wound portions 21 and 22 and the long side portions 541 and 542 are substantially formed of a flat surface.

Specifically, as shown in FIG. 2, the side wall portion 52 has a rectangular tubular shape in a plan view seen from the Z direction (see also FIG. 4). The rectangular tubular shape means that the shape surrounded by the inner peripheral surface of the side wall portion 52 is substantially rectangular when the case 5 is viewed in a plan view. The rectangular shape here does not have to be a rectangle in a geometrically strict sense, and is considered to be substantially a rectangle including a shape in which the corners are chamfered such as R chamfer or C chamfer. Includes range. In the present embodiment, the corners of the inner peripheral surface of the side wall portion 52 are not chamfered, but the corners of the inner peripheral surface may be chamfered.

(Mounting seat)
As shown in FIGS. 1 and 2, of the short side portions 531 and 532 of the side wall portion 52, the inner surface of one of the short side portions 531 has a mounting seat 56 (see also FIG. 4). The overhanging portion 7 described above is fixed to the mounting seat 56. The mounting seat 56 is provided at a position corresponding to the position of the overhanging portion 7. The shape of the mounting seat 56 substantially corresponds to the shape of the overhanging portion 7 when viewed in a plan view. The mounting seat 56 supports the surface of the overhanging portion 7 on the bottom plate portion 51 side. The mounting seat 56 is provided so as to overlap the overhanging portion 7 in the Z direction. In the present embodiment, the mounting seat 56 is formed by denting the end surface of the short side portion 531 on the opening 55 side, that is, the upper surface of the short side portion 531 downward.

In the present embodiment, the overhanging portion 7 and the mounting seat 56 are fastened by bolts 75. The seat surface of the mounting seat 56 that supports the overhanging portion 7 has a screw hole 58 into which a bolt 75 is screwed. The screw hole 58 is formed at a position overlapping the through hole 71 of the overhanging portion 7 in the Z direction. The bolt 75 is inserted into the through hole 71 of the overhanging portion 7 from the opening 55 side of the case 5, and is screwed into the screw hole 58 of the mounting seat 56.

(Convex part)
The side wall portion 52 has a convex portion 91 as shown in FIG. The convex portion 91 is provided on the inner surface of the side wall portion 52. The convex portion 91 extends in the Z direction from the bottom plate portion 51 side toward the opening 55 side. As shown in FIGS. 6 to 8, the convex portion 91 projects from the inner surface of the side wall portion 52 toward the concave portion 92.

In the present embodiment, as shown in FIG. 6, the convex portion 91 is provided on the inner surface of each of the long side portions 541 and 542 of the side wall portion 52. The convex portion 91 extends from the bottom plate portion 51 along the inner surfaces of the long side portions 541 and 542 in the Z direction. The length of the convex portion 91 along the Z direction is longer than the length of the concave portion 92 along the Z direction. The cross-sectional shape of the convex portion 91 orthogonal to the Z direction is rectangular, specifically rectangular. The cross-sectional shape of the convex portion 91 may be any shape corresponding to the cross-sectional shape of the concave portion 92. The cross-sectional shape of the convex portion 91 is not limited to a rectangular shape, and may be another shape such as a polygonal shape, a semicircular shape, or a semi-elliptical shape. Examples of the polygonal shape include a triangular shape, a trapezoidal shape, a pentagonal shape, and a hexagonal shape.

<Mating relationship between convex and concave parts>
The fitting relationship between the convex portion 91 and the concave portion 92 will be described.

In the present embodiment, the union body 10 is positioned with a gap between the convex portion 91 and the concave portion 92 by fitting the convex portion 91 and the concave portion 92. In a state where the convex portion 91 and the concave portion 92 are fitted, as shown in FIG. 8, the end surface 910 on the opening 55 side of the convex portion 91 and the end surface 920 on the opening 55 side of the concave portion 92 are in contact with each other. The end surface 910 of the convex portion 91 and the end surface 920 of the concave portion 92 are in contact with each other, so that the position of the union body 10 in the Z direction is restricted. Therefore, the convex portion 91 and the concave portion 92 function as stoppers for positioning the position of the combined body 10 in the Z direction with respect to the case 5. As a result, a predetermined distance can be secured between the end surface 101 on the bottom plate portion 51 side and the inner bottom surface 510 of the bottom plate portion 51 in the union body 10.

The distance E (see FIG. 8) between the end surface 101 of the union body 10 and the inner bottom surface 510 of the bottom plate portion 51 is, for example, 0.5 mm or more and 1.5 mm or less, and further 0.5 mm or more and 1.0 mm or less. .. When this distance E is 0.5 mm or more, the resin to be the sealing resin portion 6 easily wraps around between the union body 10 and the bottom plate portion 51. Therefore, the sealing resin portion 6 is likely to be filled between the union body 10 and the bottom plate portion 51. By filling the sealing resin portion 6 between the end surface 101 of the union body 10 and the inner bottom surface 510 of the bottom plate portion 51, the heat of the union body 10 is transferred to the bottom plate portion 51 via the sealing resin portion 6. Can be done. When the distance E is 1.5 mm or less and 1.0 mm or less, the distance between the end surface 101 of the union body 10 and the inner bottom surface 510 of the bottom plate portion 51 is short. Therefore, the heat of the union body 10 can be easily transferred to the bottom plate portion 51. Therefore, the heat dissipation of the union body 10 can be improved.

The distance between the convex portion 91 and the concave portion 92 may be, for example, 0.5 mm or less, further 0.3 mm or less. The distance is the distance between the convex portion 91 and the concave portion 92 as seen from the Z direction, as shown in FIG. 7, in a state where the convex portion 91 and the concave portion 92 are fitted. That is, the above-mentioned interval is a horizontal interval orthogonal to the Z direction between the convex portion 91 and the concave portion 92. As shown in FIG. 7, the above intervals include intervals A and B in the Y direction and intervals C in the X direction. In this embodiment, the intervals A, B, and C are 0.5 mm or less. The smaller the intervals A and B are, the more the displacement of the union body 10 with respect to the case 5 in the Y direction can be suppressed. The smaller the interval C, the more the displacement of the union body 10 in the X direction with respect to the case 5 can be suppressed. When the distance between the convex portion 91 and the concave portion 92 is 0.5 mm or less, the displacement of the union body 10 in the X direction and the Y direction can be effectively suppressed. The distance between the convex portion 91 and the concave portion 92 may be 0. The sealing resin portion 6 may or may not be filled between the convex portion 91 and the concave portion 92.

Further, as shown in FIG. 8, the length D along the Z direction of the portion where the convex portion 91 and the concave portion 92 are fitted is 10% or more of the height of the union body 10 (see FIG. 1). Can be mentioned. As described above, the height of the union body 10 is the length along the Z direction of the union body 10, and corresponds to the distance between the end face 101 and the end face 105 in the union body 10. In the present embodiment, since the overhanging portion 7 is fixed to the mounting seat 56, the union body 10 is displaced with the overhanging portion 7 as a fulcrum. More specifically, the combined body 10 is displaced in a direction of swinging around a fixed point P (see FIG. 9) described later. When the union body 10 is displaced in the Z direction about the fixed point P with respect to the case 5, the convex portion 91 and the concave portion 92 extend in the direction intersecting the arc accompanying the above-mentioned swing, so that the Z- The swing of the union body 10 on the Y plane can be suppressed. In particular, if the length D is at least a certain value, the swing can be effectively suppressed, so that the displacement of the union body 10 in the Z direction can be suppressed. When the length D is 10% or more of the length along the Z direction of the union body 10, the displacement of the union body 10 in the Z direction with respect to the case 5 can be effectively suppressed. The upper limit of the length D is, for example, 25% or less of the length along the Z direction of the union body 10, and further 20% or less.

<Position of convex and concave parts>
The positions of the convex portion 91 and the concave portion 92 will be described mainly with reference to FIG. The convex portion 91 and the concave portion 92 are provided at diagonal portions of the fixing point P of the overhanging portion 7 to the mounting seat 56 when viewed from the X direction. That is, the overhanging portion 7 and the mounting seat 56, and the convex portion 91 and the concave portion 92 are provided at positions separated from each other. The fixed point P is the center of the seat surface of the mounting seat 56 to which the overhanging portion 7 is fixed. When the overhanging portion 7 is fastened to the mounting seat 56 by the bolt 75 as in the present embodiment, the intersection of the axis of the bolt 75 and the seat surface of the mounting seat 56 is set as the fixed point P.

The diagonal portion is a portion located diagonally on the side far from the fixed point P in the union body 10 when viewed from the X direction. In other words, it is a portion of the union body 10 located diagonally from the overhanging portion 7. Specifically, the overhanging portion 7 is one side of the line Yc that bisects the union body 10 in the Y direction when the union body 10 is viewed from the X direction, and the union body 10 is bisected in the Z direction. It is located on the opening 55 side of the bisector Zc. Then, a region located on the other side of the line Yc that bisects the union body 10 in the Y direction and on the bottom plate portion 51 side of the line Zc that bisects the union body 10 in the Z direction is a diagonal portion. And. In other words, one side in the Y direction in which the overhanging portion 7 is located is the side facing the short side portion 531 on which the mounting seat 56 is provided. The other side in the Y direction where the diagonal portion is located is the side opposite to the side where the overhanging portion 7 is located and faces the other short side portion 532. The bisector Yc is a line that bisects the length of the union 10 along the Y direction. The protruding length of the overhanging portion 7 is not included in the length of the union body 10 in the Y direction. The bisector Zc is a line that bisects the length of the union 10 along the Z direction. If at least a part of the portion where the convex portion 91 and the concave portion 92 are fitted is within the above-mentioned region, it is assumed that the convex portion 91 and the concave portion 92 are located diagonally.

Strictly speaking, the diagonal portion is preferably a region among the above regions that satisfies the following conditions. In the region located within the range between the straight line PGa and PGb in which the straight line PG passing through the center of gravity G of the union body 10 is drawn from the fixed point P and the straight line PG is rotated ± 10 ° in the Z direction around the fixed point P. be.

In addition, the inner peripheral surface of the side wall portion 52 may be inclined so as to spread from the bottom plate portion 51 side toward the opening 55 side. More specifically, at least one of the inner surfaces of the short side portions 531 and 532 of the side wall portion 52 and the inner surfaces of the long side portions 541 and 542 are spaced from each other from the bottom plate portion 51 side toward the opening 55 side. It may be tilted to be large. That is, at least one of the inner surfaces of the short side portions 531 and 532 and the long side portions 541 and 542 is formed so as to be inclined outward from the case 5 with respect to the vertical direction of the inner bottom surface 510 of the bottom plate portion 51. May be. The vertical direction corresponds to the Z direction.

When the inner surfaces of the short side portions 531 and 532 and the long side portions 541 and 542 are inclined so as to increase the distance from each other from the bottom plate portion 51 side toward the opening 55 side, in the manufacturing process of the reactor 1. , The work of storing the union body 10 in the case 5 is easy to perform. Further, when the metal case 5 is die-cast, at least one of the inner surfaces of the short side portions 531 and 532 and the long side portions 541 and 542 is inclined, so that the case 5 is extracted from the mold. Is easy to do. In the present embodiment, as shown in FIGS. 1 and 3, the inner peripheral surface of the side wall portion 52 is inclined so as to spread from the bottom plate portion 51 side toward the opening 55 side.

The inclination angle formed by the inner surfaces of the short side portions 531 and 532 and the long side portions 541 and 542 and the vertical line of the inner bottom surface 510 of the bottom plate portion 51 can be appropriately selected. The inclination angle may be, for example, 0.5 ° or more and 5 ° or less, and further 1 ° or more and 2 ° or less. If the inclination angle is too large, the distance between the outer peripheral surface of the union body 10 and the inner peripheral surface of the side wall portion 52 becomes large on the opening 55 side. If the interval is too large, it is difficult to efficiently transfer the heat of the union body 10 on the opening 55 side to the case 5. Therefore, it is not preferable that the inclination angle is too large from the viewpoint of heat dissipation. Therefore, the upper limit of the tilt angle is 5 ° or less, and further 2 ° or less.

The length, width, height, and volume of the case 5 can be appropriately selected. The length of the case 5 is, for example, 80 mm or more and 120 mm or less, and further 90 mm or more and 115 mm or less. The width of the case 5 is, for example, 30 mm or more and 80 mm or less, and further 35 mm or more and 70 mm or less. The height of the case 5 is, for example, 70 mm or more and 140 mm or less, and further 80 mm or more and 130 mm or less. The length of the case 5 is a dimension of the case 5 in the Y direction. The width of the case 5 is the dimension of the case 5 in the X direction. The height of the case 5 is a dimension of the case 5 in the Z direction. The volume of the case 5 is, for example, 120 cm ³ or more and 1200 cm ³ or less, and further 200 cm ³ or more and 900 cm ³ or less. In the present embodiment, the case 5 has a length larger than the width and a height larger than the width. Therefore, the area obtained by the length × width of the case 5 is smaller than the area obtained by the length × height of the case 5.

Examples of the non-magnetic metal constituting the case 5 include aluminum and its alloy, magnesium and its alloy, copper and its alloy, silver and its alloy, and austenitic stainless steel. The thermal conductivity of these metals is relatively high. Therefore, the case 5 can be easily used as a heat dissipation path. The heat of the union 10 is easily released to the outside efficiently through the case 5. Therefore, the heat dissipation of the union body 10 is improved. As the material constituting the case 5, a resin or the like can be used in addition to the metal.

The metal case 5 can be manufactured, for example, by die casting. In the present embodiment, the case 5 is made of a die-cast product made of aluminum.

(Arrangement form of union)
The arrangement form of the union body 10 with respect to the case 5 is an upright type. In this case, as shown in FIG. 1, the combined body 10 is housed in the case 5 so that the axial direction of the winding portions 21 and 22 constituting the coil 2 is orthogonal to the inner bottom surface 510 of the bottom plate portion 51. Further, the union body 10 is housed in the case 5 so that the parallel direction of both winding portions 21 and 22 is along the long side portions 541 and 542.

When the arrangement form of the union body 10 is an upright type, the installation area of the union body 10 with respect to the bottom plate portion 51 can be reduced as compared with the following flat type. The flat placement type is the form described in Patent Documents 1 and 2, and the union is housed in the case so that both the parallel direction and the axial direction of both winding portions are orthogonal to the Z direction. That is, in the flat placement type, the union is housed in the case so that both the parallel direction and the axial direction of both winding portions are parallel to the inner bottom surface of the bottom plate portion. Generally, the length of the union 10 along the parallel direction of both winding portions 21 and 22 and the direction orthogonal to both the axial directions of both winding portions 21 and 22 is the length of both winding portions 21 and 22. It is shorter than the length of the union 10 along the axial direction of. That is, the width of the union 10 is shorter than the height of the union 10. Therefore, the upright type has a smaller installation area of the union body 10 than the flat type. Therefore, when the arrangement form of the union body 10 is an upright type, the area of the bottom plate portion 51 can be reduced, so that the installation area of the reactor 1 can be saved.

Further, when the arrangement form of the union body 10 is an upright type and the outer peripheral surfaces of the winding portions 21 and 22 are substantially formed of a flat surface as in the present embodiment, the winding portions 21 and 22 and the side wall are formed. A large area facing the portion 52 is secured. Further, the distance between the outer peripheral surface of the wound portions 21 and 22 and the inner peripheral surface of the side wall portion 52 tends to be uniform. In the case of the present embodiment, the distance between the outer peripheral surface of the winding portions 21 and 22 and the inner surface of the long side portions 541 and 542, the distance between the outer peripheral surface of the winding portion 21 and the inner surface of the short side portion 531 and the winding portion. The distance between the outer peripheral surface of 22 and the inner surface of the short side portion 532 tends to be small. Therefore, the reactor 1 can efficiently use the case 5 as a heat dissipation path. Therefore, the reactor 1 easily releases the heat of the coil 2 to the case 5, and the combined body 10 is excellent in heat dissipation.

The distance between the outer peripheral surface of the union body 10 and the inner peripheral surface of the side wall portion 52 is, for example, 0.5 mm or more and 1.5 mm or less, and further 0.5 mm or more and 1.0 mm or less. The distance is the distance between the outer peripheral surface of the outer wall portion 41 of the second holding member 40b located on the bottom plate portion 51 side and the long side portions 541, 542 and the short side portion 532 of the side wall portion 52. The reason for this is that, in the union body 10, the member closest to the side wall portion 52, except for the overhanging portion 45, is the second holding member 40b. However, the above interval does not include the portion where the convex portion 91 and the concave portion 92 fit. As will be described later, when the inner surfaces of the long side portions 541, 542 and the short side portion 532 of the side wall portion 52 are inclined, the minimum value may be adopted for the above interval. When this distance is 0.5 mm or more, the resin to be the sealing resin portion 6 easily wraps around between the union body 10 and the side wall portion 52. Therefore, the sealing resin portion 6 is likely to be filled between the union body 10 and the side wall portion 52. When the distance is 1.5 mm or less, and further 1.0 mm or less, the distance between the outer peripheral surfaces of the wound portions 21 and 22 and the inner peripheral surface of the side wall portion 52 becomes smaller. Therefore, the heat dissipation of the union body 10 can be improved.

(Encapsulating resin part)
The sealing resin portion 6 is filled in the case 5 to seal at least a part of the union body 10. The sealing resin portion 6 can mechanically protect the union body 10 and protect it from the external environment. The purpose of protection from the external environment is to improve anticorrosion.

In the present embodiment, the sealing resin portion 6 is filled up to the open end of the case 5. Therefore, the entire union body 10 is embedded in the sealing resin portion 6. Only a part of the union body 10 may be sealed in the sealing resin portion 6. For example, in the union body 10, up to the height of the upper end surfaces of the winding portions 21 and 22 constituting the coil 2, the sealing resin portion 6 may be sealed. The sealing resin portion 6 is interposed between the union body 10 and the bottom plate portion 51 and the side wall portion 52 of the case 5. As a result, the heat of the union body 10 can be transferred to the case 5 via the sealing resin portion 6. Therefore, the heat dissipation of the union body 10 is improved.

Examples of the resin of the sealing resin portion 6 include a thermosetting resin and a thermoplastic resin. Examples of the thermosetting resin include epoxy resin, urethane resin, silicone resin, and unsaturated polyester resin. Examples of the thermoplastic resin include PPS resin and the like. In the present embodiment, the sealing resin portion 6 is made of a silicone resin. Silicone resin has a higher thermal conductivity than resins such as epoxy resin. The higher the thermal conductivity of the sealing resin portion 6, the more preferable. The reason for this is that the heat of the union body 10 can be easily transferred to the case 5, so that the heat dissipation of the union body 10 is further improved. Therefore, the material constituting the sealing resin portion 6 may contain, for example, a filler as described above in addition to the above resin. In order to increase the thermal conductivity of the sealing resin portion 6, the components of the above material may be adjusted. The thermal conductivity of the sealing resin portion 6 is preferably, for example, 1 W / m · K or more, more preferably 1.5 W / m · K or more.

<Manufacturing method>
An example of the above-mentioned manufacturing method of the reactor 1 will be described.
The reactor 1 can be manufactured, for example, by a manufacturing method including the following first to third steps.
In the first step, the union body 10 and the case 5 are prepared.
In the second step, the union body 10 is stored in the case 5.
In the third step, the sealing resin portion 6 is formed in the case 5.

(First step)
In the first step, the union body 10 and the case 5 are prepared. In this example, the union body 10 is manufactured by assembling the coil 2, the magnetic core 3, and the holding members 40a and 40b, as shown in FIG. The first holding member 40a has an overhanging portion 7. As described above, the overhanging portion 7 is integrally formed with the outer wall portion 41 of the first holding member 40a by insert-molding the metal bracket 70. The outer wall portion 41 of the second holding member 40b is formed with a recess 92. Further, the mold resin portion 8 (see FIG. 1) is formed. Specifically, in a state where the coil 2 and the magnetic core 3 are held at predetermined positions by the holding members 40a and 40b, the mold resin portion 8 is formed so as to cover the outer peripheral surfaces of the outer core portions 33 and 34. As described above, a part of the resin constituting the mold resin portion 8 includes a gap between the outer core portions 33, 34 and the recess 44, and a gap between the inner core portions 31, 32 and the through hole 43. Through, it is filled between the winding portions 21, 22 and the inner core portions 31, 32. Therefore, the mold resin portion 8 is formed so as to be interposed between the winding portions 21 and 22 and the inner core portions 31 and 32. Further, the coil 2, the magnetic core 3, and the holding members 40a and 40b are integrated by the mold resin portion 8.

The case 5 to be prepared is made of, for example, a non-magnetic metal. The case 5 has a mounting seat 56 as shown in FIG. As described above, the mounting seat 56 is formed on the inner surface of one of the short side portions 531. Further, a recess 92 is formed on the inner surface of the side wall portion 52. In this example, the case 5 is a die-cast product made of aluminum.

(Second step)
In the second step, as shown in FIG. 4, the union body 10 is housed in the case 5 through the opening 55 of the case 5. The union body 10 is housed in the case 5 so that the union body 10 is arranged in the above-mentioned upright type. In this example, as shown in FIGS. 6 to 8, the combined body 10 is positioned with respect to the case 5 by fitting the convex portion 91 of the side wall portion 52 and the concave portion 92 of the second holding member 40b. .. Further, by fitting the convex portion 91 and the concave portion 92, the union body 10 is arranged in a state where a predetermined distance is provided between the convex portion 91 and the bottom plate portion 51. After the union body 10 is housed in the case 5, the overhanging portion 7 of the second holding member 41a is fixed to the mounting seat 56. Specifically, the overhanging portion 7 is fastened to the mounting seat 56 by inserting the bolt 75 into the through hole 71 of the overhanging portion 7 and screwing the bolt 75 into the screw hole 58 of the mounting seat 56.

(Third step)
In the third step, the case 5 is filled with resin to form the sealing resin portion 6 (see FIG. 1). Specifically, the case 5 is filled with the resin to be the sealing resin portion 6 in the state where the union body 10 is housed. In this example, the resin that becomes the sealing resin portion 6 is a silicone resin.

For filling the resin to be the sealing resin portion 6, it is preferable to put the case 5 containing the union body 10 in a vacuum chamber and inject the resin in a vacuum state. By injecting the resin in a vacuum state, it is possible to prevent the sealing resin portion 6 from containing air bubbles.

After filling the case 5 with the above-mentioned resin, the resin is solidified to form the sealing resin portion 6 (FIG. 1). The solidification of the resin may be carried out under appropriate conditions depending on the resin to be used.

{Use}
The reactor 1 can be used as a component of a circuit that performs a voltage step-up operation or a voltage step-down operation. The reactor 1 can be used, for example, as a component of various converters and power conversion devices. Examples of the converter include an in-vehicle converter mounted on a vehicle, typically a DC-DC converter, an air conditioner converter, and the like. Examples of the vehicle include a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, a fuel cell vehicle, and the like.

{Main effect}
In the reactor 1 of the first embodiment, the overhanging portion 7 is fixed to the mounting seat 56, and the convex portion 91 and the concave portion 92 are fitted to each other, so that the displacement of the union body 10 in the case 5 can be suppressed. One of the reasons for this is that since the overhanging portion 7 is fixed to the mounting seat 56, there is only one fixing point between the union body 10 and the case 5. In this case, the vibration transmission path between the union body 10 and the case 5 is basically one place. Therefore, it is difficult for vibration to be transmitted between the union body 10 and the case 5. Further, the fitting of the convex portion 91 and the concave portion 92 causes the union body 10 to be arranged at a distance from the bottom plate portion 51, so that vibration also occurs between the union body 10 and the case 5 at that point as well. It's hard to convey. As a result, displacement of the union body 10 is unlikely to occur. Another reason is that the displacement range of the union body 10 is restricted in the case 5 by fitting the convex portion 91 and the concave portion 92. In particular, the convex portion 91 and the concave portion 92 are located at diagonal portions of the fixed point P. Since the convex portion 91 and the concave portion 92 are fitted at the diagonal portion away from the fixed point P, the displacement of the combined body 10 can be effectively suppressed. More specifically, it is possible to prevent the union body 10 from being displaced in the direction in which the line segment PG passing through the fixed point P and the center of gravity G of the union body 10 swings around the fixed point P. Since the convex portion 91 and the concave portion 92 extend in the Z direction, which is the direction intersecting the arc accompanying the swing, the swing of the combined body 10 in the ZZ plane can be effectively suppressed. As a result, the displacement amount of the union body 10 tends to be small.

Further, the reactor 1 of the first embodiment can more effectively suppress the displacement of the union body 10 for the following reasons.

(1) The distance between the convex portion 91 and the concave portion 92 is 0.5 mm or less. The smaller this interval is, the more the displacement range of the union body 10 is restricted in the case 5. Therefore, the displacement of the union body 10 in the case 5 can be suppressed. When the interval is 0.5 mm or less, the displacement of the union body 10 in the X direction and the Y direction can be effectively suppressed.

(2) The length along the Z direction of the portion where the convex portion 91 and the concave portion 92 are fitted is 10% or more of the length along the Z direction of the union body 10. When the length is longer than a certain level, the displacement of the union body 10 in the Z direction can be effectively suppressed.

(3) The cross-sectional shape of the convex portion 91 orthogonal to the Z direction is rectangular. If the cross-sectional shape of the convex portion 91 is rectangular, particularly rectangular, it is easy to regulate the displacement range of the combined body 10. Therefore, it is easy to effectively suppress the displacement of the union body 10.

In the reactor 1 of the first embodiment, the union body 10 is displaced in each of the X direction, the Y direction, and the Z direction by fixing the overhanging portion 7 to the mounting seat 56 and fitting the convex portion 91 and the concave portion 92. It can be suppressed. Therefore, since the reactor 1 can suppress the displacement of the union body 10 in the case 5, it is possible to suppress the cracking of the sealing resin portion 6 due to the displacement of the union body 10. Therefore, in the reactor 1, the sealing resin portion 6 can protect the union body 10 for a long period of time. Further, the heat of the union body 10 can be satisfactorily transferred to the case 5 via the sealing resin portion 6. Such a reactor 1 is highly reliable.

Further, the reactor 1 of the first embodiment also has the following effects.

(I) Miniaturization is possible.
Since the arrangement form of the union body 10 is an upright type, the installation area of the union body 10 with respect to the bottom plate portion 51 of the case 5 can be reduced as compared with the above-mentioned flat placement type.

(Ii) Excellent heat dissipation.
(1) Since the arrangement of the combined body 10 is an upright type, it is possible to secure a large area where the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall portion 52 face each other as compared with the flat placement type. Further, the distance between the outer peripheral surface of the coil 2 and the inner peripheral surface of the side wall portion 52 tends to be small. Therefore, the heat of the coil 2 can be easily transferred to the side wall portion 52. Therefore, the case 5 can be efficiently used as a heat dissipation path.
(2) When the distance between the end surface 101 on the bottom plate portion 51 side and the inner bottom surface 510 of the bottom plate portion 51 in the union body 10 is within a predetermined range, the sealing resin portion is provided between the union body 10 and the bottom plate portion 51. 6 is thinly filled and easily filled. Therefore, the heat of the union body 10 can be efficiently transferred to the bottom plate portion 51 via the sealing resin portion 6.
(3) The resin constituting the sealing resin portion 6 is a silicone resin. Therefore, the heat of the union body 10 can be easily transferred to the case 5 via the sealing resin portion 6.

(Iii) Excellent manufacturability.
(1) When the union body 10 is stored in the case 5, the convex portion 91 and the concave portion 92 are fitted so that the union body 10 can be positioned at a predetermined position of the case 5.
(2) The case 5 can be easily manufactured by having the convex portion 91 on the side wall portion 52 of the case 5.

[Modification 1-1]
A modified example of the reactor 1 of the first embodiment will be described with reference to FIG. FIG. 10 is a cross-sectional view of the reactor 1 cut along a plane orthogonal to the Z direction, as in FIG.

In the modified example 1-1, the positions of the convex portion 91 and the concave portion 92 are different from those of the first embodiment. Specifically, the convex portion 91 is provided on the inner surface of the other short side portion 532 of the side wall portion 52 of the case 5. The recess 92 is provided on the surface of the outer wall portion 41 of the second holding member 40b facing the short side portion 532. In the modified example 1-1, the length of each of the convex portion 91 and the concave portion 92 in the Z direction and the fitting relationship between the convex portion 91 and the concave portion 92 are the fitting between the convex portion 91 and the concave portion 92 described in the first embodiment. Similar to a relationship. Further, the convex portion 91 and the concave portion 92 are located at diagonal portions of the fixing point P to the mounting seat 56 of the overhanging portion 7, as described in the first embodiment with reference to FIG. In the modified example 1-1, the number of the convex portion 91 and the number of the concave portions 92 are one each. Similar to the reactor 1 of the first embodiment, the reactor 1 of the modified example 1-1 can suppress the displacement of the union body 10 by fitting the convex portion 91 and the concave portion 92.

[Modification 1-2]
A modified example of the reactor 1 of the first embodiment will be described with reference to FIG. FIG. 11 is a cross-sectional view of the reactor 1 cut along a plane orthogonal to the Z direction, as in FIG.

Modification 1-2 is different from the first embodiment in that the side wall portion 52 of the case 5 has a concave portion 92 and the second holding member 40b has a convex portion 91. The convex portion 91 and the concave portion 92 are located diagonally to the fixing point P of the overhanging portion 7 to the mounting seat 56, as described in the first embodiment with reference to FIG. In the modification 1-2, the recess 92 is provided on the inner surface of each of the long side portions 541 and 542 of the side wall portion 52. The convex portion 91 is provided on each surface of the outer wall portion 41 of the second holding member 40b facing each of the long side portions 541 and 542. When the recess 92 is provided on the inner surface of the side wall portion 52 as in the modified example 1-2, the recess 92 extends from the opening 55 along the inner surface of the side wall portion 52 in the Z direction. Therefore, when the combined body 10 is housed in the case 5, the convex portion 91 of the second holding member 40b can be fitted into the concave portion 92 of the side wall portion 52. However, the recess 92 does not reach the bottom plate portion 51, but extends from the opening 55 to the vicinity of the bottom plate portion 51. As a result, when the union body 10 is housed in the case 5, the lower end surface of the convex portion 91 and the lower end surface of the concave portion 92 are in contact with each other in a state where the convex portion 91 and the concave portion 92 are fitted. Therefore, by fitting the convex portion 91 and the concave portion 92, the combined body 10 can be positioned with a gap between the convex portion 91 and the bottom plate portion 51.

Similar to the reactor 1 of the first embodiment, the reactor 1 of the modification 1-2 can suppress the displacement of the union body 10 by fitting the convex portion 91 and the concave portion 92. In the reactor 1 of the modified example 1-2, the positions of the convex portion 91 and the concave portion 92 can be changed to the other short side portion 532 side as in the modified example 1-1.

[Embodiment 2]
[Converter / Power converter]
The reactor 1 of the first embodiment and the modified examples 1-1 and 1-2 can be used for applications that satisfy the following energization conditions. Examples of the energization conditions include a maximum direct current of 100 A or more and 1000 A or less, an average voltage of 100 V or more and 1000 V or less, and an operating frequency of 5 kHz or more and 100 kHz or less. The reactor 1 of the first embodiment and the modifications 1-1 and 1-2 is typically a component of a converter mounted on a vehicle such as an electric vehicle or a hybrid vehicle, or a configuration of a power conversion device including the converter. Can be used for parts.

As shown in FIG. 12, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is driven by a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and power supplied from the main battery 1210, and is used for traveling. It is equipped with a motor 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheels 1250 during traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 comprises an engine 1300 in addition to the motor 1220. In FIG. 12, an inlet is shown as a charging point of the vehicle 1200, but it may be provided with a plug.

The power conversion device 1100 has a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 to perform mutual conversion between direct current and alternating current. The converter 1110 shown in this example boosts the input voltage of the main battery 1210 of about 200 V or more and 300 V or less to about 400 V or more and 700 V or less while the vehicle 1200 is running, and supplies power to the inverter 1120. At the time of regeneration, the converter 1110 lowers the input voltage output from the motor 1220 via the inverter 1120 to a DC voltage suitable for the main battery 1210, and charges the main battery 1210. The input voltage is a DC voltage. When the vehicle 1200 is running, the inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current and supplies power to the motor 1220, and during regeneration, converts the alternating current output from the motor 1220 into a direct current and outputs it to the converter 1110. are doing.

As shown in FIG. 13, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor 1115, and converts the input voltage by repeating ON / OFF. The conversion of the input voltage is performed here as a step-up / down pressure. Power devices such as field effect transistors and insulated gate bipolar transistors are used for the switching element 1111. The reactor 1115 utilizes the property of the coil that tries to prevent the change of the current flowing in the circuit, and has a function of smoothing the change when the current tries to increase or decrease due to the switching operation. As the reactor 1115, the reactor 1 of any one of the first embodiment and the modified examples 1-1 and 1-2 is provided. By providing the reactor 1, the power converter 1100 and the converter 1110 are highly reliable.

The vehicle 1200 is connected to the converter 1110, the converter 1150 for a power feeding device connected to the main battery 1210, the sub-battery 1230 and the main battery 1210 which are the power sources of the accessories 1240, and the high voltage of the main battery 1210 is applied. A converter 1160 for auxiliary power supply that converts to low voltage is provided. The converter 1110 typically performs DC-DC conversion, but the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some converters 1150 for power feeding devices perform DC-DC conversion. The reactor of the converter 1150 for the power supply device and the converter 1160 for the auxiliary power supply has the same configuration as that of the reactor 1 of the first embodiment and the modifications 1-1 and 1-2, and the size and shape are appropriately adjusted. A modified reactor is available. Further, as a converter that converts input power and performs only step-up or only step-down, the reactor 1 of any one of the first embodiment and the modified examples 1-1 and 1-2 is used. You can also.

1 Reactor 10 Combined 101, 105 End face 2 Coil 21, 22 Winding part 3 Magnetic core 31, 32 Inner core part 33, 34 Outer core part 33 First outer core part, 34 Second outer core part 33e Inner end face 4 Resin Member 4a 1st resin member 4b 2nd resin member 40a, 40b Holding member 40a 1st holding member, 40b 2nd holding member 41 Outer wall part 43 Through hole, 44 Recess 5 Case 51 Bottom plate part, 510 Inner bottom surface 52 Side wall part 531 532 Short side part 541, 542 Long side part 55 Opening part 56 Mounting seat 58 Screw hole 6 Encapsulating resin part 7 Overhanging part 70 Bracket 71 Through hole 75 Bolt 8 Molded resin part 91 Convex part, 910 End face 92 Concave, 920 End face A, B, C, E Interval, D Length P Fixed point, G Center of gravity 1100 Power converter 1110 Converter 1111 Switching element 1112 Drive circuit 1115 Reactor 1120 Inverter 1150 Power supply converter 1160 Auxiliary power supply converter 1200 Vehicle 1210 Main Battery, 1220 Motor 1230 Sub Battery, 1240 Auxiliary Equipment, 1250 Wheels, 1300 Engine

The common components in the holding members 40a and 40b will be described mainly with reference to FIGS. 1 and 5.
The holding members 40a and 40b include a frame plate having a through hole 43 and an outer wall portion 41 . The frame plate is interposed between the end faces of the winding portions 21 and 22 constituting the coil 2 and the inner end faces 33e of the outer core portions 33 and 34. The outer wall portion 41 covers at least a part of the outer peripheral surface of the outer core portions 33 and 34. In the present embodiment, the outer wall portion 41 covers the entire circumference of the outer peripheral surfaces of the outer core portions 33, 34.

In the present embodiment, the shapes of the holding members 40a and 40b are rectangular frames in a plan view from the Z direction (see FIG. 2) . The outer peripheral surface of the outer wall portion 41 is substantially formed of a flat surface. The outer peripheral surface of the outer wall portion 41 includes four planes facing the short side portions 531 and 532 and the long side portions 541 and 542 in the side wall portion 52 of the case 5.

In the present embodiment, the bottom plate portion 51 has a square plate shape. In the bottom plate portion 51, the inner bottom surface 510 on which the union body 10 is placed is substantially formed of a flat surface. The side wall portion 52 has a square tubular shape. The side wall portion 52 has a pair of facing short side portions 531 and 532 and a pair of facing long side portions 541 and 542. Of the inner peripheral surfaces of the side wall portion 52, the inner surfaces of the short side portions 531 and 532 facing the wound portions 21 and 22 and the inner surfaces of the long side portions 541 and 542 are substantially formed of a flat surface.

Strictly speaking, the diagonal portion is preferably a region among the above regions that satisfies the following conditions. A region located within the range between the straight line PGa and the straight line PGb obtained by drawing a straight line PG passing through the center of gravity G of the union body 10 from the fixed point P and rotating the straight line PG by ± 10 ° in the Z direction around the fixed point P. Is.

The distance between the outer peripheral surface of the union body 10 and the inner peripheral surface of the side wall portion 52 is, for example, 0.5 mm or more and 1.5 mm or less, and further 0.5 mm or more and 1.0 mm or less. The distance is the distance between the outer peripheral surface of the outer wall portion 41 of the second holding member 40b located on the bottom plate portion 51 side and the long side portions 541, 542 and the short side portion 532 of the side wall portion 52. The reason for this is that, in the union body 10, the member closest to the side wall portion 52, except for the overhanging portion 7 , is the second holding member 40b. However, the above interval does not include the portion where the convex portion 91 and the concave portion 92 fit. When the inner surfaces of the long side portions 541, 542 and the short side portion 532 of the side wall portion 52 are inclined as described above , the minimum value may be adopted for the above interval. When this distance is 0.5 mm or more, the resin to be the sealing resin portion 6 easily wraps around between the union body 10 and the side wall portion 52. Therefore, the sealing resin portion 6 is likely to be filled between the union body 10 and the side wall portion 52. When the distance is 1.5 mm or less, and further 1.0 mm or less, the distance between the outer peripheral surfaces of the wound portions 21 and 22 and the inner peripheral surface of the side wall portion 52 becomes smaller. Therefore, the heat dissipation of the union body 10 can be improved.

The case 5 to be prepared is made of, for example, a non-magnetic metal. The case 5 has a mounting seat 56 as shown in FIG. As described above, the mounting seat 56 is formed on the inner surface of one of the short side portions 531. Further, a convex portion 91 is formed on the inner surface of the side wall portion 52. In this example, the case 5 is a die-cast product made of aluminum.

(Second step)
In the second step, as shown in FIG. 4, the union body 10 is housed in the case 5 through the opening 55 of the case 5. The union body 10 is housed in the case 5 so that the union body 10 is arranged in the above-mentioned upright type. In this example, as shown in FIGS. 6 to 8, the combined body 10 is positioned with respect to the case 5 by fitting the convex portion 91 of the side wall portion 52 and the concave portion 92 of the second holding member 40b. .. Further, due to the fitting of the convex portion 91 and the concave portion 92, the union body 10 is arranged in a state where a predetermined distance is provided between the convex portion 91 and the bottom plate portion 51. After the union body 10 is housed in the case 5 , the overhanging portion 7 of the first holding member 40 a is fixed to the mounting seat 56. Specifically, the overhanging portion 7 is fastened to the mounting seat 56 by inserting the bolt 75 into the through hole 71 of the overhanging portion 7 and screwing the bolt 75 into the screw hole 58 of the mounting seat 56.

1 Reactor 10 Combined body 101, 105 End face 2 Coil 21, 22 Winding part 3 Magnetic core 31, 32 Inner core part
3 3 1st outer core part, 34 2nd outer core part 33e Inner end surface 4 Resin member 4a 1st resin member 4b 2nd resin member
40a 1st holding member, 40b 2nd holding member 41 Outer wall part 43 Through hole, 44 Recessed part 5 Case 51 Bottom plate part, 510 Inner bottom surface 52 Side wall part 531, 532 Short side part 541, 542 Long side part 55 Opening part 56 Mounting Seat 58 Screw hole 6 Sealing resin part 7 Overhanging part 70 Bracket 71 Through hole 75 Bolt 8 Mold resin part 91 Convex part, 910 End face 92 Concave part, 920 End face A, B, C, E spacing, D Length P Fixed point, G center of gravity
Yc, Zc bisector
PG line segment
PGa, PGb straight line
1100 Power Converter, 1110 Converter 1111 Switching Element, 1112 Drive Circuit 1115 Reactor, 1120 Inverter 1150 Power Supply Converter, 1160 Auxiliary Power Supply Converter 1200 Vehicle 1210 Main Battery, 1220 Motor 1230 Sub Battery, 1240 Auxiliary Equipment, 1250 Wheels 1300 engine

Claims (11)

With the coil
A magnetic core having portions arranged inside and outside the coil,
A resin member that defines the mutual position between the coil and the magnetic core,
A case for accommodating the coil, the magnetic core, and the union including the resin member, and
It is provided with a sealing resin portion to be filled in the case.
The magnetic core is
The inner core portion arranged inside the coil and
It has an outer core portion arranged outside the coil and has an outer core portion.
The case is
The bottom plate on which the union is placed and
A square cylindrical side wall that surrounds the union and
It has an opening facing the bottom plate and has an opening.
The side wall portion has a pair of facing short sides and a pair of facing long sides.
The union is housed in the case so that the axial direction of the coil is along the Z direction.
The outer core portion includes a first outer core portion arranged on the opening side and a second outer core portion arranged on the bottom plate portion side.
The resin member includes a first resin member provided on the outer peripheral surface of the first outer core portion and a second resin member provided on the outer peripheral surface of the second outer core portion.
The first resin member has an overhanging portion that protrudes toward the short side portion of one of the pair of short side portions.
The inner surface of the one short side portion has a mounting seat on which the overhanging portion is fixed.
When the union housed in the case is viewed from the X direction,
At the diagonal portion of the fixing point of the overhanging portion to the mounting seat,
One of the second resin member and the side wall portion has a convex portion extending in the Z direction.
The other of the second resin member and the side wall portion has a concave portion that fits with the convex portion.
The union is positioned with a gap between the bottom plate portion by fitting the convex portion and the concave portion.
The X direction is a direction along the short side portion.
The Z direction is a direction orthogonal to both the X direction and the Y direction.
The Y direction is a direction along the long side portion.
Reactor. The overhanging portion is a line that bisects the union in the Z direction on one side of the line that bisects the union in the Y direction when the union is viewed from the X direction. Located on the side of the opening,
The diagonal portion is located on the opposite side of the line that bisects the union in the Y direction and on the bottom plate side of the line that bisects the union in the Z direction. The reactor according to item 1. The convex portion is arranged on one of the inner surfaces of each of the pair of long side portions and each surface of the second resin member facing each of the pair of long side portions.
Claim 1 or claim 1 or claim, wherein the recess is arranged on the inner surface of each of the pair of long side portions and on the other side of each surface of the second resin member facing each of the pair of long side portions. The reactor described in 2. The reactor according to any one of claims 1 to 3, wherein the distance between the convex portion and the concave portion is 0.5 mm or less. Any one of claims 1 to 4, wherein the length of the portion where the convex portion and the concave portion are fitted along the Z direction is 10% or more of the length of the union along the Z direction. The reactor described in paragraph 1. The reactor according to any one of claims 1 to 5, wherein the distance between the end surface on the bottom plate portion side and the inner bottom surface of the bottom plate portion in the union is 0.5 mm or more and 1.0 mm or less. The reactor according to any one of claims 1 to 6, wherein the second resin member has the concave portion and the side wall portion has the convex portion. The reactor according to any one of claims 1 to 7, wherein the convex portion has a rectangular cross-sectional shape orthogonal to the Z direction. The reactor according to any one of claims 1 to 8, wherein the resin constituting the sealing resin portion is a silicone resin. The reactor according to any one of claims 1 to 9 is provided.
converter. The converter according to claim 10 is provided.
Power converter.

Images