JP2022143562A - Reactor structure, converter, electric conversion device - Google Patents

Abstract

To provide a reactor structure, a converter, and an electric conversion device, with high productivity.SOLUTION: A reactor structure α comprises: a reactor 1; and a bus bar 4. The bus bar 4 comprises: a first piece 41 connected to a winding end part 21 of a coil in an overlapping state; a second piece 42 arranged at a position separated from the first piece to an X direction; a main body piece 40 connecting the first piece and the second piece; and a pin hole 4h provided to the main body piece or the second piece. The main body piece 40 is elastically deformed to a direction separated from the reactor 1 in a Y direction. The reactor 1 comprises: a fixed part 8 positioning a position of the bus bar 4; and a pin 5 that is projected to a Y direction or a Z direction, and penetrates the pin hole 4h. The main body piece 40 includes: a first region held by the fixed part 8; and a second region that presses a part separated from the fixed part 8 in the reactor 1 to the X direction.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to reactor structures, converters, and power converters.

A reactor structure is a component of a converter provided in a hybrid vehicle or the like. For example, a reactor structure disclosed in Patent Literature 1 includes a reactor and terminal members. A reactor includes a coil and a core. A coil is formed by spirally winding a wire. The reactor described in Patent Document 1 further includes a frame-shaped bobbin, an inner bobbin, and a case. The frame-shaped bobbin and the inner bobbin are insulating members that ensure insulation between the coil and the core. The case houses the assembly of the coil, core and insulating member.

A terminal member provided in the reactor structure is also called a busbar. The busbar electrically connects the coil and the external device. The ends of the busbar are connected to the ends of the coil by welding or the like. The intermediate portion of the bus bar described in Patent Document 1 is screwed to a case that constitutes the reactor. By screwing the busbar to the case, the position of the busbar with respect to the reactor is determined, thereby facilitating the connection between the end of the busbar and the end of the coil.

Japanese Patent Application Laid-Open No. 2014-130949

In the reactor structure of Patent Literature 1, it takes time and effort to screw the bus bar. Moreover, the number of parts constituting the reactor structure increases. Therefore, the productivity of the reactor structure of Patent Document 1 is not good.

Accordingly, one object of the present disclosure is to provide a reactor structure with excellent productivity. Another object of the present disclosure is to provide a converter and a power conversion device with excellent productivity.

The reactor structure of the present disclosure is
a reactor having a coil and a core;
A reactor structure comprising a bus bar that electrically connects the coil to an external device,
The busbar is
a first piece connected to the winding end portion of the coil in an overlapping state;
a second piece arranged at a position separated from the first piece in the X direction and connected to the external device;
a body piece connecting the first piece and the second piece;
a pin hole provided in the body piece or the second piece,
The main body piece is elastically deformed in a direction away from the reactor in the Y direction,
The reactor is
a fixing portion that determines the position of the busbar so that the first piece is in contact with the winding end;
a pin protruding in the Y direction or the Z direction and penetrating the pin hole;
The body piece is
a first region held by the fixing portion;
a second region that presses a portion of the reactor spaced apart from the fixed portion in the X direction;
The X direction is a direction in which the winding end portion and the first piece are arranged in parallel,
The Y direction is a direction that intersects the X direction and is along the extending direction of the winding ends,
The Z direction is a direction crossing the X direction and the Y direction.

The converter of the present disclosure is
A reactor structure of the present disclosure is provided.

The power conversion device of the present disclosure is
A converter of the present disclosure is provided.

The reactor structure of the present disclosure, the converter of the present disclosure, and the power converter of the present disclosure are excellent in productivity.

FIG. 1 is a schematic perspective view of a reactor structure according to Embodiment 1. FIG. 2 is a schematic perspective view of a braid provided in the reactor structure according to Embodiment 1. FIG. 3 is a schematic perspective view of a busbar provided in the reactor structure according to Embodiment 1. FIG. 4 is a schematic top view of a busbar provided in the reactor structure according to the first embodiment. FIG. 5A and 5B are explanatory diagrams showing the manufacturing procedure of the reactor structure according to the first embodiment. 6 is a schematic partial top view of a reactor structure according to Modification 1. FIG. FIG. 7 is a schematic partial top view of a reactor structure according to Embodiment 2. FIG. FIG. 8 is a schematic perspective view of a busbar provided in a reactor structure according to Embodiment 3. FIG. 9 is a schematic front view of a reactor provided in a reactor structure according to Embodiment 4. FIG. FIG. 10 is a configuration diagram schematically showing a power supply system of a hybrid vehicle according to Embodiment 5. As shown in FIG. FIG. 11 is a circuit diagram showing an outline of an example of a power converter including a converter according to Embodiment 5. FIG.

[Description of Embodiments of the Present Disclosure]
First, the embodiments of the present disclosure are listed and described.

<1> The reactor structure according to the embodiment is
a reactor having a coil and a core;
A reactor structure comprising a bus bar that electrically connects the coil to an external device,
The busbar is
a first piece connected to the winding end portion of the coil in an overlapping state;
a second piece arranged at a position separated from the first piece in the X direction and connected to the external device;
a body piece connecting the first piece and the second piece;
a pin hole provided in the body piece or the second piece,
The main body piece is elastically deformed in a direction away from the reactor in the Y direction,
The reactor is
a fixing portion that determines the position of the busbar so that the first piece is in contact with the winding end;
a pin protruding in the Y direction or the Z direction and penetrating the pin hole;
The body piece is
a first region held by the fixing portion;
a second region that presses a portion of the reactor spaced apart from the fixed portion in the X direction;
The X direction is a direction in which the winding end portion and the first piece are arranged in parallel,
The Y direction is a direction that intersects the X direction and is along the extending direction of the winding ends,
The Z direction is a direction crossing the X direction and the Y direction.

In the reactor structure, the position of the busbar with respect to the reactor is determined by the fixed portion provided on the reactor. When the busbar is attached to the reactor, the busbar is arranged at a predetermined position of the reactor only by arranging a part of the busbar on the fixing portion. Therefore, the reactor structure has excellent productivity.

In the reactor structure described above, the main body piece of the busbar is elastically deformed in the direction away from the reactor in the Y direction. The reaction force of the elastic deformation of the main body piece acts in the direction of approaching the reactor in the Y direction. Therefore, the second region of the elastically deformed body piece presses the portion of the reactor that is away from the fixed portion in the X direction. As a result, it is difficult for the busbar to move relative to the reactor. Furthermore, in the above reactor structure, the pin of the reactor penetrates the pin hole of the busbar, so that the pin restricts the movement of the busbar with respect to the reactor. As described above, in the reactor structure, since the movement of the busbar with respect to the reactor is sufficiently restricted, the reactor structure does not require screws for fixing the busbar to the reactor. Thus, the reactor structure that does not require screws for fixing the busbars and does not require work for attaching screws is excellent in productivity.

<2> As one form of the reactor structure according to the embodiment,
The axis of the pin hole may extend in the Y direction.

In the configuration of form <2> above, when the bus bar moves in the X direction intersecting the Y direction, the inner peripheral surface of the pin hole is caught by the outer peripheral surface of the pin, thereby suppressing vibration of the bus bar in the X direction. Similarly, when the busbar moves in the Z direction intersecting the Y direction, the inner peripheral surface of the pin hole catches the outer peripheral surface of the pin, thereby suppressing vibration of the busbar in the Z direction. Therefore, in the configuration of form <2>, the vibration of the bus bar in the X direction and the vibration in the Z direction are effectively suppressed.

<3> As one form of the reactor structure according to the embodiment,
The reactor has a through hole through which a screw for fixing the reactor to an installation target is passed,
The axis of the through-hole may be aligned with the Z direction.

In general, a reactor fixed to an installation object tends to vibrate in the direction along the axis of the through hole during use. If the axis of the through hole coincides with the X direction, the busbar vibrates violently in the direction of separating the first piece of the busbar and the winding end. Strong stress is likely to act on the connection point of On the other hand, in the configuration of form <3>, the axes of the through holes are arranged so as to intersect the X direction, so that a strong stress is less likely to act on the connection portion.

<4> As one form of the reactor structure according to the embodiment,
The reactor includes a pedestal provided at the base of the pin,
The pedestal may be in contact with the second region of the busbar.

Since the pedestal is provided at the base of the pin, the force of the busbar pressing the reactor is concentrated on the pedestal. As a result, the bus bar strongly presses the reactor, and the state of holding the bus bar with respect to the reactor is stabilized.

<5> As one form of the reactor structure according to the embodiment,
The bus bar may include an elastically deformable portion formed by bending a portion of the main body piece.

The elastically deformable portion is a portion to which springiness in the Y direction is imparted by bending. This elastically deformable portion is more likely to be elastically deformed in the Y direction than the portions other than the elastically deformable portion. Since the bus bar has an elastic deformation portion, the possibility of plastic deformation of the body piece when the body piece is bent in the Y direction is reduced.

<6> As the reactor structure of the above form <5>,
A form in which the elastically deformable portion is bent in an S shape when viewed from the Z direction is exemplified.

The elastically deformable portion bent in an S shape when viewed from the Z direction has excellent elastic deformability in the Y direction. As the amount of elastic deformation of the busbar increases, the force with which the second region of the busbar presses the reactor also increases. As a result, the busbar is strongly pressed against the reactor, making it difficult for the busbar to move relative to the reactor.

<7> As the reactor structure of the above form <6>,
The fixed part includes a rod extending in the Z direction,
A form in which the S-shaped curved portion of the elastically deformable portion is hooked on the rod may be mentioned.

In the configuration of form <7>, the S-shaped elastically deforming portion constitutes the first region fixed to the fixing portion. In this configuration, the position of the first piece relative to the winding end is determined simply by hooking the elastically deformable portion on the rod. Therefore, the work of attaching the busbar to the reactor is facilitated.

In addition, in a structure in which the busbar is hooked on a rod extending in the Z direction, the movement of the busbar in the X and Y directions is restricted by the rod. Also, the movement of the busbar in the Z direction is restricted by the friction between the outer peripheral surface of the rod and the S-shaped bent portion. Therefore, in the configuration <7>, the vibration of the busbar with respect to the reactor is easily suppressed.

<8> As one form of the reactor structure according to the embodiment,
The reactor includes an insulating member that determines the relative position of the coil and the core,
A mode in which the pin and the fixing portion are provided in the insulating member is exemplified.

Since the busbar is a conductive member, it is necessary to ensure insulation between the busbar and the core. In the form <8>, the insulation is ensured because the pin and the fixing portion are formed of a part of the insulating member. Here, examples of the insulating member that determines the relative position of the coil and the core include a holding member arranged between the end of the coil and the core. Further, as the insulating member, there is a resin molded portion that integrates the coil and the core.

<9> As the reactor structure of the above form <8>,
A mode in which the insulating member is a resin molded portion that integrates the coil and the core may be mentioned.

The resin molded portion makes it difficult to disassemble the coil and the core. Therefore, the assembly of the coil and core becomes easy to handle.

<10> As one form of the reactor structure according to the embodiment,
The reactor includes a case that houses the assembly of the core and the coil,
The case includes a resin portion made of an insulating material,
The pin and the fixing portion may be provided in the resin portion.

Insulation between the bus bar and the core is ensured by forming the pin and the fixed portion from a part of the resin portion of the case. The entire case may be made of an insulating material, or part of the case may be made of an insulating material.

<11> The converter according to the embodiment,
The reactor structure according to any one of the above modes <1> to <10> is provided.

The converter includes the reactor structure of the embodiment with excellent productivity. Therefore, the converter is excellent in productivity.

<12> The power conversion device according to the embodiment,
The converter of form <11> is provided.

The power conversion device includes the converter of the embodiment with excellent productivity. Therefore, the power converter is excellent in productivity.

[Details of the embodiment of the present disclosure]
Hereinafter, embodiments of a reactor structure, a converter, and a power converter according to the present disclosure will be described based on the drawings. The same reference numerals in the drawings indicate the same names. The present invention is not limited to the configurations shown in the embodiments, but is indicated by the scope of claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of claims.

<Embodiment 1>
In Embodiment 1, the configuration of the reactor structure α will be described based on FIGS. 1 to 5. FIG. A reactor structure α shown in FIG. 1 includes a reactor 1 having a coil 2 and a core 3 (FIG. 2), and a busbar 4 electrically connecting the coil 2 to an external device. One of the features of this reactor structure α is the configuration of the bus bar 4 . Each configuration provided in the reactor structure α will be described in detail below.

≪Reactor≫
The reactor 1 of this example includes a braid 10 ( FIG. 2 ) and an insulating member 9 . Braid 10 is a combination of coil 2 and core 3, as shown in FIG. The insulating member 9 determines the relative positions of the coil 2 and the core 3 .

[coil]
The coil 2 of this example includes a winding portion 20 formed by winding a wire. A known winding can be used for the winding. The winding wire of this example is a coated rectangular wire. The conductor wire of the coated rectangular wire is composed of a copper rectangular wire. The insulating coating of the coated rectangular wire is made of enamel. The wound portion 20 is formed of an edgewise coil obtained by edgewise winding a covered rectangular wire. The coil 2 used in this example includes one winding portion 20 . Unlike this example, the coil 2 may have a plurality of windings 20 . For example, a coil 2 with two windings 20 arranged in parallel can be mentioned.

The shape of the winding portion 20 is a rectangular tube. Rectangles include squares. That is, the end face shape of the winding portion 20 is a rectangular frame shape. Since the shape of the winding portion 20 is a rectangular tube, the contact area between the winding portion 20 and the installation target tends to be larger than when the winding portion is cylindrical with the same cross-sectional area. As a result, the heat of the reactor structure α is easily radiated to the installation target via the winding portion 20 . Furthermore, the stability of the winding portion 20 with respect to the installation target is improved. The corners of the winding portion 20 are preferably rounded.

Winding end portions 21 and 22 of coil 2 are each extended to the outer peripheral side of winding portion 20 . The insulating coating is peeled off from the winding end portions 21 and the winding end portions 22 to expose the conductor wires. A bus bar 4 is connected to the exposed conductor line. In the drawing of this example, only the bus bar 4 attached to the winding end portion 21 is illustrated. The configuration of the busbars attached to the winding end portions 22 may be the same as or different from that of the busbars 4 illustrated. An external device is connected to the coil 2 via a busbar 4 . Illustration of the external device is omitted. An example of the external device is a power source that supplies power to the coil 2 .

Here, the direction in the reactor structure α is defined with reference to the coil 2 and the bus bar 4 . First, the direction in which the winding end portion 21 of the coil 2 and the first piece 41 of the busbar 4 are arranged in parallel is defined as the X direction. The first piece 41 is a portion of the bus bar 4 that is connected to the winding end portion 21 while being superimposed thereon. A detailed configuration of the first piece 41 will be described later. A direction intersecting with the X direction and along the extending direction of the winding end portion 21 is defined as a Y direction. In this example, the Y direction is orthogonal to the X direction. A direction intersecting both the X direction and the Y direction is defined as the Z direction. In this example, the Z direction is orthogonal to the X and Y directions. Furthermore, the following directions are defined.
・X1 direction: the direction toward the winding end portion 21 when viewed from the busbar 4 among the X directions ・X2 direction: the direction opposite to the X1 direction ・Y1 direction: the direction toward the tip of the winding end portion 21 among the Y directions・Y2 direction: the direction opposite to the Y1 direction ・Z1 direction: the direction away from the installation target of the reactor 1 among the Z directions (upward direction on the paper surface)
・Z2 direction…opposite direction of Z1 direction

[core]
The core 3 is a magnetic body in which a closed magnetic circuit is formed. The core 3 is composed of a powder compact, a composite material compact, or the like. The powder compact is obtained by pressure-molding raw material powder containing soft magnetic powder. Soft magnetic powders include pure iron and iron alloys. The molded composite material is obtained by filling a mold with a mixture of soft magnetic powder and unsolidified resin and solidifying the resin. Soft magnetic powder is dispersed in a resin in the molded body of the composite material.

The core 3 has an inner core portion 31 and an outer core portion 32 . The inner core portion 31 is arranged inside the winding portion 20 of the coil 2 and is a portion along the axial direction of the winding portion 20 . In this example, both ends of the portion of the core 3 along the axial direction of the winding portion 20 protrude from the end surface of the winding portion 20 . The projecting portion is also part of the inner core portion 31 .

The shape of the inner core portion 31 is not particularly limited as long as it conforms to the internal shape of the winding portion 20 . The inner core portion 31 of this example has a substantially rectangular parallelepiped shape. The inner core portion 31 may be configured by connecting a plurality of split cores and a gap plate, or may be a single member.

The outer core portion 32 is a portion of the core 3 that is arranged outside the winding portion 20 . The shape of the outer core portion 32 is not particularly limited as long as it is a shape that connects the ends of the inner core portion 31 . The outer core portion 32 of this example includes an end core piece facing the Y1-direction end surface of the winding portion 20, an end core piece facing the Y2-direction end surface of the winding portion 20, and an X1-direction side surface of the winding portion 20. A side core piece and a side core piece facing the side surface of the winding portion 20 in the X2 direction are provided. Therefore, the outer core portion 32 of this example has a rectangular annular shape when viewed from the Z direction.

The core 3 of this example is composed of two split cores 3A and 3B. The split core 3A is substantially T-shaped when viewed from the Z direction. The split core 3B is substantially E-shaped when viewed from the Z direction. The shape of split cores 3A and 3B is not particularly limited. For example, a combination of a substantially I-shaped split core serving as the inner core portion 31 and a substantially O-shaped split core serving as the outer core portion 32 may be used. The core 3 may be composed of three or more split cores. For example, a combination of a substantially I-shaped split core serving as the inner core portion 31 and two substantially U-shaped split cores serving as the outer core portion 32 may be used.

[Insulating material]
The insulating member 9 of this example is a resin molded portion 6 that integrates the coil 2 and the core 3 . The resin molded portion 6 also has a function of protecting the coil 2 and the core 3 from the external environment. The resin molded portion 6 of this example does not cover the outer surface of the wound portion 20 in the Z direction. That is, the Z-direction outer surface of the wound portion 20 is exposed from the resin mold portion 6 . As a result, the heat generated by the coil 2 is easily released to the outside.

The resin mold part 6 is made of, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene ( It is made of a thermoplastic resin such as ABS) resin. In addition, the resin mold portion 6 may be made of a thermosetting resin such as unsaturated polyester resin, epoxy resin, urethane resin, silicone resin, or the like. By containing a ceramic filler in these resins, the heat dissipation of the resin mold portion 6 is improved. Ceramic fillers include, for example, non-magnetic powders such as alumina and silica.

The resin mold portion 6 has a terminal block 61 . The terminal block 61 is a pedestal for supporting connection terminals of an external device (not shown). A connection terminal is placed on the surface of the bus bar 4 facing the Z1 direction and screwed. The terminal block 61 is provided with screw holes 61h into which screws for fixing connection terminals are attached. The screw hole 61h of this example extends in the Z direction. In this example, a nut is embedded in the terminal block 61 . The inner peripheral surface of this nut constitutes a screw hole 61h. The axis of this screw hole 61h coincides with the axis of a terminal hole 42h of the bus bar 4, which will be described later. Therefore, by screwing the connection terminal, the connection terminal is fixed to the terminal block 61 and electrically connected to the bus bar 4 . Here, a nut is not essential. Also, the axis of the screw hole 61h may extend in a direction crossing the Z direction.

The resin mold part 6 does not have to cover the entire braid 10 . For example, the resin mold part 6 may be configured to cover only the portion on the lower side of the braid 10 . Preferably, the lower surface of the resin mold portion 6 is in surface contact with an installation target (not shown) of the reactor 1 . It is preferable that the resin molded portion 6 include a mounting portion (not shown). It is preferable that the mounting portion is provided with a through hole through which a screw for fixing the reactor 1 to the installation target is passed. In this case, it is preferable that the axis of the through hole is aligned with the Z direction.

The resin molded portion 6 includes a fixing portion 8 that determines the position of the busbar 4 with respect to the winding end portion 21 . The fixing portion 8 positions the busbar 4 so that the winding end portion 21 and the first piece 41 of the busbar 4 are in contact with each other. The fixed part 8 of this example includes two rods 81 and 82 extending along the Z1 direction. The two rods 81, 82 are spaced apart and parallel to each other. The ends of the rods 81 and 82 are tapered. In the configuration of this example, the position of the first piece 41 of the busbar 4 with respect to the winding end portion 21 is determined by sandwiching the body piece 40 of the busbar 4 between the two rods 81 and 82 . Details of the first piece 41 will be described later.

The resin mold portion 6 includes a pedestal portion 60 having the pin 5, as shown in FIG. The pedestal portion 60 is provided on the first surface 6a facing the Y1 direction. The surface of the pedestal 60 facing the Y1 direction is parallel to the XZ plane. The pedestal portion 60 is a portion that makes surface contact with the second region R2 of the busbar 4 and is pressed by the elastically deformed busbar 4 . The state of elastic deformation of the busbar 4 and the second region R2 will be described later. The pedestal portion 60 and the pin 5 are provided integrally with the resin mold portion 6 . Here, the pedestal portion 60 is not essential. Without the pedestal portion 60, the second region R2 of the busbar 4 is in surface contact with the first surface 6a.

The pin 5 protrudes from the base portion 60 in the Y1 direction. The pin 5 is a member that determines the position of the second piece 42 of the busbar 4 with respect to the reactor 1 and is also a member that suppresses vibration of the busbar 4 with respect to the reactor 1 . The details of the function of pin 5 will be explained when bus bar 4 is explained.

The pin 5 in this example has a tapered shape. More specifically, the pin 5 has a base portion with a uniform thickness and a tip portion with a gradually decreasing thickness. The root part of this example is a cylinder. The tip in this example is a truncated cone. The outer dimensions of the root portion are slightly smaller than a pin hole 4h of the bus bar 4, which will be described later. For example, the outer diameter of the root portion is about 0.5 mm to 1.0 mm smaller than the inner diameter of the pin hole 4h.

[others]
Reactor 1 may include a holding member (not shown) that holds coil 2 and core 3 shown in FIG. The holding member is interposed between the end surface of the winding portion 20 and the outer core portion 32 and has a function of ensuring insulation between the coil 2 and the core 3 . The holding member is made of an insulating material that can be used to manufacture the resin molded portion 6 . That is, the holding member is the insulating member 9 that determines the relative positions of the coil 2 and the core 3 . If the reactor 1 includes a holding member, the resin mold portion 6 may be omitted. In that case, the pin 5 is preferably provided on the holding member.

≪Bus bar≫
The busbar 4 is a member that electrically connects the coil 2 and an external device (not shown), as shown in FIG. Therefore, the bus bar 4 is made of metal with excellent conductivity. Such metals include copper, copper alloys, aluminum, aluminum alloys, and the like. The busbar 4 is provided with the 1st piece 41, the 2nd piece 42, and the main body piece 40, as FIG.3, 4 shows.

The first piece 41 is a portion connected to the winding end portion 21 of the coil 2 in an overlapping state. The first piece 41 of this example has a rectangular plate shape. The thickness direction of the rectangular plate-shaped first piece 41 coincides with the X direction. Further, the thickness direction of the winding end portion 21 made of a rectangular wire also coincides with the X direction. Therefore, the surface of the first piece 41 facing in the X1 direction and the surface of the winding end portion 21 facing in the X2 direction are in surface contact. The first piece 41 and the winding end portion 21 are connected by welding, pressure welding, or the like. Welding includes TIG welding and the like. Friction stir welding etc. are mentioned as pressure welding. In addition, the first piece 41 and the winding end portion 21 may be connected by an annular fastener or the like that tightens the first piece 41 and the winding end portion 21 from the outer periphery.

The second piece 42 is a portion connected to an external device. The second piece 42 is arranged at a position away from the first piece 41 in the X2 direction. The second piece 42 of this example is formed in a flat plate shape to be connected to a connection terminal of an external device. The thickness direction of the second piece 42 coincides with the Z direction. The second piece 42 is provided with a terminal hole 42h penetrating the second piece 42 in the thickness direction. The axis of the terminal hole 42h coincides with the Z direction. The terminal hole 42 h is aligned with the screw hole 61 h of the terminal block 61 of the resin mold portion 6 . The second piece 42 and the connection terminal are electrically connected by overlapping the connection terminal of the external device on the surface facing the Z1 direction of the second piece 42 and screwing it.

The body piece 40 is a portion that connects the first piece 41 and the second piece 42 . The body piece 40 of this example is a plate-like piece extending substantially along the X direction. More specifically, the body piece 40 is formed by bending a part of the plate-like piece in the thickness direction of the plate-like piece. This body piece 40 is divided into a first region R1 and a second region R2. The first region R1 is a portion that connects to the first piece 41 and contacts the fixing portion 8 (see FIGS. 1 and 5). The first region R1 is held by the fixed portion 8 as shown in FIG. The first region R1 of this example is bent in an S shape when viewed from the Z direction. The S-shaped bent portion is hooked on rods 81 and 82 . More specifically, rods 81 and 82 are arranged respectively on the inner peripheral sides of the two curved portions in the S-shaped bent portion.

The S-shaped first region R1 of this example also functions as an elastic deformation portion 40s that facilitates elastic deformation of the main body piece 40 in the Y direction. Since the first region R1 is the elastic deformation portion 40s, the body piece 40 is less likely to be plastically deformed when the body piece 40 is bent in the Y direction.

The second region R2 is a portion between the first region R1 and the second piece 42. As shown in FIG. That is, the second region R2 is a portion of the body piece 40 excluding the first region R1. The second region R2 of this example includes a portion extending from the first region R1 in a direction between the X2 direction and the Y2 direction, a portion curved so as to be convex in a direction between the X1 direction and the Y2 direction, and an approximately X2 direction. and a portion extending in the direction of The curved portion in the second region R2 has a function of facilitating elastic deformation of the main body piece 40 in the Y direction, but is more difficult to elastically deform than the elastic deformation portion 40s.

The linear portion of the second region R2 of this example when the busbar 4 is viewed from the Z direction in the unloaded state extends in the Y2 direction as the distance from the first piece 41 increases, as shown in FIG. That is, when the bus bar 4 is viewed from the Z direction, the angle between the imaginary line along the first piece 41 and the imaginary line along the straight portion of the second region R2 is more than 90°. As shown in FIG. 1, the second region R2 of the body piece 40 abuts on the pedestal portion 60 parallel to the XZ plane when the busbar 4 is attached to the reactor 1. As shown in FIG. A body piece 40 in the reactor structure α is elastically deformed in the Y1 direction and is substantially parallel to the XZ plane. The reaction force of the elastic deformation of the body piece 40 acts in the Y2 direction. Since the second region R2 is in contact only with the pedestal portion 60, the second region R2 strongly presses the pedestal portion 60 in the Y2 direction. As a result, it becomes difficult for the bus bar 4 to move relative to the reactor 1 .

Here, the angle formed by the first piece 41 and the second region R2 when viewed in the Z direction is not limited to more than 90°. If the body piece 40 in the reactor structure α is elastically deformed in the Y1 direction, the angle formed by the virtual line along the first piece 41 and the virtual line along the second region R2 is 90°. It may be below.

As shown in FIG. 3, the portion of the second region R2 near the second piece 42 is locally widened. A pin hole 4h is provided in this wide portion. The pin hole 4h is a through hole penetrating through the second region R2 in the thickness direction. As shown in FIG. 1, the pin 5 is passed through the pin hole 4h. The inner diameter of the pin hole 4 h is slightly larger than the outer diameter of the pin 5 . By fitting the pin 5 into the pin hole 4h, the position of the second piece 42 of the busbar 4 in the X direction and the Z direction is determined. The position of the second piece 42 in the Y direction is determined by the contact of the busbar 4 with the pedestal portion 60 .

In the configuration in which the pin 5 protrudes in the Y1 direction, when the busbar 4 moves in the X direction intersecting the Y direction, the outer peripheral surface of the pin 5 catches the inner peripheral surface of the pin hole 4h, so the busbar 4 vibrates in the X direction. Suppressed. Similarly, when the bus bar 4 moves in the Z direction that intersects the Y direction, the inner peripheral surface of the pin hole 4h is caught by the outer peripheral surface of the pin 5, so vibration of the bus bar 4 in the Z direction is suppressed.

[Busbar installation procedure]
A procedure for mounting the bus bar 4 will be described with reference to FIG. First, as shown in FIG. 5 , the S-shaped first region R1 of the busbar 4 is inserted between the two rods 81 and 82 . The busbar 4 is inserted from the Z1 direction toward the Z2 direction. At that time, the second piece 42 of the busbar 4 is pulled in the Y1 direction as indicated by the downward white arrow. The body piece 40 is elastically deformed in the Y1 direction.

When the first region R1 comes into contact with the end face of the pedestal on which the rods 81 and 82 are provided, the pin hole 4h of the busbar 4 is arranged at a position corresponding to the pin 5. As shown in FIG. In this state, when the tension on the second piece 42 is released, the pin 5 is passed through the pin hole 4h, and the second region R2 of the busbar 4 is pressed against the pedestal portion 60. As shown in FIG. As a result, the first piece 41 comes into contact with the winding end portion 21 , and the terminal hole 42 h of the second piece 42 is arranged coaxially with the screw hole 61 h of the terminal block 61 .

Finally, the first piece 41 and the winding end portion 21 are joined by welding or the like. At this time, the movement of the busbar 4 in the Y direction is restricted by the elasticity of the busbar 4 . The movement of the busbar 4 in the X and Z directions is restricted by the pins 5 . Since the position of the first piece 41 is less likely to shift with respect to the winding end portion 21, the first piece 41 of the busbar 4 and the winding end portion 21 can be easily joined.

≪Installation procedure of the reactor structure≫
The reactor structure α in FIG. 1 is, for example, screwed to an installation target. Installation targets include, for example, a converter case for housing a converter. A connection terminal of an external device is attached to the reactor structure α screwed to the installation target. Here, when the connection terminal is screwed to the terminal block 61, torque is generated to rotate the bus bar 4 around the screw shaft. In the configuration of this example, since the movement of the busbar 4 is restricted by the fixing portion 8 and the pin 5, excessive torque acting on the connecting portion between the first piece 41 and the winding end portion 21 is suppressed.

≪Effect≫
In the reactor structure α of this example, screws for fixing the busbar 4 to the reactor 1 are not required. Thus, the reactor structure α does not require a screw for fixing the busbar 4, and does not require the work of attaching the screw. Therefore, the reactor structure α of this example is excellent in productivity.

In the reactor structure α of this example, vibration of the bus bar 4 in the X, Y and Z directions is suppressed. Therefore, the stress caused by the vibration of the bus bar 4 is less likely to act on the connecting portion between the first piece 41 and the winding end portion 21 . Therefore, even if the intermediate portion of the bus bar 4 is not screwed as in the prior art, the reliability of the connecting portion is ensured.

<Modification 1>
As shown in FIG. 6, the number of rods 81 that hold the first region R1 of the busbar 4 may be one. A configuration in which only the rod 82 of the first embodiment is provided instead of the rod 81 may be used.

<Modification 2>
The pin 5 may be provided on the core 3 . For example, pins may be provided on the outer core portion 32 of the core 3 . In that case, it is necessary to ensure insulation between the pin 5 and the bus bar 4 . For example, the entire pin 5 may be made of an insulating material. In addition, forming an insulating coating on at least one of the outer periphery of the pin 5 and the outer periphery of the bus bar 4 can be mentioned. When the core 3 is made of a molded composite material, the pins 5 are easy to form.

<Embodiment 2>
In the second embodiment, a reactor structure in which the shape of the busbar 4 and the shape of the fixing portion 8 are different from those of the first embodiment will be described with reference to FIG.

The fixed portion 8 of this example includes a linear groove 83 extending in the X direction. The position of the busbar 4 is determined by fitting the first region R1 of the busbar 4 into the groove 83 .

The first region R1 of the busbar 4 of this example is connected to the first piece 41 at right angles. The first region R1 of this example is hardly elastically deformed. The first region R1 in this example is exclusively for determining the position of the first piece 41 .

The second region R2 of the busbar 4 of this example includes an elastic deformation portion 40s configured by bending a portion of the second region R2. The elastic deformation portion 40s is connected to the first region R1. The elastically deformable portion 40s of this example is a portion that curves in the X2 direction after being curved in the Y2 direction as it goes from the X1 direction to the X2 direction. Since the second region R2 has the elastic deformation portion 40s, the main body piece 40 can be elastically deformed in the Y1 direction without being plastically deformed.

The configuration of this example also provides the same effects as those of the first embodiment.

<Embodiment 3>
In Embodiment 3, a reactor structure in which a pin hole 4h is provided in the second piece 42 will be described with reference to FIG. Only the busbar 4 is illustrated in FIG.

As shown in FIG. 8, the pin hole 4h of the busbar 4 of this example is provided in the second piece 42. As shown in FIG. Therefore, the axis of the pin hole 4h is aligned with the Z direction. A pin (not shown) penetrating through the pin hole 4h extends in the Z1 direction. In the configuration of this example, the vibration of the bus bar 4 in the X direction and the vibration in the Y direction are effectively suppressed by the pins.

<Embodiment 4>
In Embodiment 4, a reactor structure α provided with a case 7 that houses a braid 10 will be described with reference to FIG. 9 . Case 7 is part of reactor 1 .

The case 7 includes a resin portion 70 in which at least a portion with which the bus bar 4 contacts is made of an insulating material. The case 7 of this example includes a bottom plate portion 71 on which the braid 10 is placed, and a side wall portion 72 that covers the side surface of the braid 10 . In the case of this example, the entire side wall portion 72 is constituted by the resin portion 70 .

The side wall portion 72 of this example is higher than the end portion of the braid 10 in the Z1 direction. Therefore, the braid 10 as a whole is housed in the case 7 . The side wall portion 72 is provided with a slit 72 s for guiding the winding end portion 21 of the braid 10 housed in the case 7 to the outside of the case 7 . In the configuration of this example, the pin 5 , the terminal block 61 and the fixing portion 8 are provided on the outer peripheral surface of the side wall portion 72 . The configurations of the pin 5, the terminal block 61, and the fixing portion 8 are the same as those of the first embodiment.

The bottom plate portion 71 may be made of an insulating material, or may be made of metal. The bottom plate portion 71 made of metal is excellent in rigidity and thermal conductivity. An insulating sheet is preferably arranged between the metal bottom plate portion 71 and the braid 10 . The bottom plate portion 71 is provided with a plurality of mounting portions 76 . The mounting portion 76 of the bottom plate portion 71 is for fixing the case 7 to an installation target. The mounting portion 76 is provided with a through hole 76h. The axis of the through hole 76h is aligned with the Z direction. A screw for fixing the case 7 to an installation target is arranged in the through hole 76h.

The busbar 4 is stably attached to the reactor 1 also by the structure of this example. There is no need to fix the intermediate portion of the busbar 4 with a screw.

<Embodiment 5>
≪Converter / power converter≫
The reactor structure α according to the embodiment can be used for applications that satisfy the following energization conditions. Current conditions include, for example, a maximum DC current of approximately 100 A to 1000 A, an average voltage of approximately 100 V to 1000 V, and a working frequency of approximately 5 kHz to 100 kHz. The reactor structure α according to the embodiment can be typically used as a component of a converter installed in a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device including this converter.

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 as shown in FIG. and a motor 1220 that Motor 1220 is typically a three-phase AC motor, drives wheels 1250 during running, and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes engine 1300 in addition to motor 1220 . In FIG. 10, an inlet is shown as the charging point of vehicle 1200, but a plug may be provided.

The power conversion device 1100 has a converter 1110 connected to a main battery 1210 and an inverter 1120 connected to the converter 1110 for mutual conversion between direct current and alternating current. Converter 1110 shown in this example boosts the input voltage of main battery 1210 from approximately 200 V to 300 V to approximately 400 V to 700 V and supplies power to inverter 1120 when vehicle 1200 is running. During regeneration, converter 1110 steps down the input voltage output from motor 1220 via inverter 1120 to a DC voltage suitable for main battery 1210 to charge main battery 1210 . The input voltage is a DC voltage. Inverter 1120 converts the direct current boosted by converter 1110 into a predetermined alternating current and supplies power to motor 1220 when vehicle 1200 is running, and converts the alternating current output from motor 1220 into direct current during regeneration and outputs the direct current to converter 1110. is doing.

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 structure 1115 as shown in FIG. 11, and converts the input voltage by repeating ON/OFF. . Conversion of the input voltage means stepping up and down in this case. A power device such as a field effect transistor or an insulated gate bipolar transistor is used for the switching element 1111 . The reactor structure 1115 has a function of smoothing the change when the current increases or decreases due to the switching operation by using the property of the coil that prevents the change of the current to flow in the circuit. As the reactor structure 1115, the reactor structure α according to any one of the first to fourth embodiments is provided. Power conversion device 1100 and converter 1110 are excellent in productivity by including reactor structure α and the like, which are excellent in productivity.

In addition to converter 1110, vehicle 1200 is connected to power feed device converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary equipment 1240, and main battery 1210 to supply the high voltage of main battery 1210. An accessory power supply converter 1160 for converting to low voltage is provided. Converter 1110 typically performs DC-DC conversion, but power supply device converter 1150 and auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply converters 1150 perform DC-DC conversion. The reactor structure 1115 of the power supply device converter 1150 and the auxiliary power converter 1160 has the same configuration as the reactor structure α of any one of the first to fourth embodiments, and the size, shape, etc. are appropriately changed. You can use a reactor structure with Further, the reactor structure α of any one of Embodiments 1 to 4 can also be used for a converter that converts input power and that only boosts or only steps down.

α Reactor structure 1 Reactor 10 Braid 2 Coil 20 Winding part 21, 22 Winding end part 3 Core 3A, 3B Split core 31 Inner core part 32 Outer core part 4 Bus bar 40 Body piece R1 First region R2 second region 40s elastic deformation portion 41 first piece 42 second piece 42h terminal hole 4h pin hole 5 pin 6 resin mold portion 6a first surface 60 base portion 61 terminal block 61h screw hole 7 case 70 resin portion 71 bottom plate portion 72 side wall portion 72s slit 76 mounting portion 76h through hole 8 fixing portion 81, 82 rod 83 groove 9 insulating member 1100 power converter 1110 converter 1111 switching element 1112 drive circuit 1115 reactor structure 1120 Inverter 1150 Power supply device converter 1160 Auxiliary power supply converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub-battery 1240 Auxiliary equipment 1250 Wheel 1300 Engine

Claims (12)

a reactor having a coil and a core;
A reactor structure comprising a bus bar that electrically connects the coil to an external device,
The busbar is
a first piece connected to the winding end portion of the coil in an overlapping state;
a second piece arranged at a position separated from the first piece in the X direction and connected to the external device;
a body piece connecting the first piece and the second piece;
a pin hole provided in the body piece or the second piece,
The main body piece is elastically deformed in a direction away from the reactor in the Y direction,
The reactor is
a fixing portion that determines the position of the busbar so that the first piece is in contact with the winding end;
a pin protruding in the Y direction or the Z direction and penetrating the pin hole;
The body piece is
a first region held by the fixing portion;
a second region that presses a portion of the reactor spaced apart from the fixed portion in the X direction;
The X direction is a direction in which the winding end portion and the first piece are arranged in parallel,
The Y direction is a direction that intersects the X direction and is along the extending direction of the winding ends,
The Z direction is a direction that intersects the X direction and the Y direction,
Reactor structure. 2. The reactor structure according to claim 1, wherein an axis of said pin hole extends in said Y direction. The reactor has a through hole through which a screw for fixing the reactor to an installation target is passed,
3. The reactor structure according to claim 1, wherein an axis of said through hole coincides with said Z direction. The reactor includes a pedestal provided at the base of the pin,
The reactor structure according to any one of claims 1 to 3, wherein the pedestal portion abuts on the second region of the busbar. The reactor structure according to any one of claims 1 to 4, wherein the busbar includes an elastically deformable portion formed by bending a portion of the body piece. The reactor structure according to claim 5, wherein the elastically deformable portion has a shape bent in an S shape when viewed from the Z direction. The fixed part includes a rod extending in the Z direction,
7. The reactor structure according to claim 6, wherein the S-shaped bent portion of the elastic deformation portion is hooked on the rod. The reactor includes an insulating member that determines the relative position of the coil and the core,
The reactor structure according to any one of claims 1 to 7, wherein the pin and the fixing portion are provided on the insulating member. 9. The reactor structure according to claim 8, wherein the insulating member is a resin molded portion that integrates the coil and the core. The reactor includes a case that houses the assembly of the core and the coil,
The case includes a resin portion made of an insulating material,
The reactor structure according to any one of claims 1 to 9, wherein the pin and the fixing portion are provided in the resin portion. Equipped with the reactor structure according to any one of claims 1 to 10,
converter. comprising a converter according to claim 11,
Power converter.

Images