JP5234422B2 - Reactor coil member, manufacturing method thereof, and reactor - Google Patents

Description

  The present invention relates to a reactor used for in-vehicle components such as an electric vehicle and a hybrid vehicle, a coil member for a reactor that is a component of the reactor, and a method for manufacturing the coil member for the reactor.

  Conventionally, a reactor including a pair of coils arranged in parallel and an annular core inserted through these coils is known. Each coil is formed by spirally winding a winding with a linear conductor coated with an insulation coating, and by supplying current from the outside through the lead-out end of the coil, the inside of the core A magnetic field passing through is generated. In such a reactor, it has been proposed to use a reactor coil member in which a pair of coils is formed by a single winding (see, for example, Patent Document 1).

  Patent Document 1 includes a configuration in which a first coil element and a second coil element are electrically connected via a connecting portion, and these members are one rectangular wire (winding). A formed coil component (reactor coil member) is disclosed (see FIG. 1 and FIGS. 7 to 8 of Patent Document 1). The relationship between these coil elements will be described in detail. The leading ends of both coil elements are arranged on the same side in the coil axis direction. That is, the traveling direction of the spiral (the direction along the winding axis of the coil element in each coil element and the direction from the leading end side toward the connecting portion side) is the same direction in both coil elements. Further, the connecting portion that connects both the coil elements is folded back in a hairpin curve shape of approximately 180 ° from the first coil element toward the second coil element.

  As shown in FIGS. 4 and 5 of Patent Document 1, each coil element and the connecting portion have the above-described configuration. The two coil elements are different in one end and the other end of one winding. This is because the coil member for the reactor is produced by folding the connecting portion in half after being formed into a shape.

JP 2004-55920 A

  However, in the conventional reactor coil member described in Patent Document 1, since the connecting portion is folded in two, the bending radius of the bent portion is very small, and there is a possibility that the conductor of the winding and the insulation coating may be damaged. is there. In particular, in recent years, there is a tendency to increase the diameter of the winding in order to use the reactor with a large current, and there is concern about damage to the winding at the bent portion.

  The present invention has been made in view of the above circumstances, and its main object is to form a reactor that does not have a bent portion with a small bending radius like a conventional coil member for a reactor while being formed by a single winding. It is providing the coil member for manufacturing, and its manufacturing method. Another object of the present invention is to provide a reactor using the coil member for a reactor of the present invention.

  The reactor coil member according to the present invention includes a first coil and a second coil arranged in parallel with each other, and a connecting portion that connects the two coils, and these members are coil members for a reactor formed of a single winding. Concerning. In each coil, the direction along the coil winding axis from the coil drawing end toward the connecting portion is defined as the spiral traveling direction of the coil, and is orthogonal to both the parallel direction of both coils and the coil axis direction of both coils. When the direction of the coil is the height direction of the coil, the traveling directions of the spirals of both coils are opposite to each other, and the connecting portion is arranged without protruding from both coils in the height direction. It is characterized by.

The traveling direction of the spirals of both coils is arranged opposite to each other so that the connecting portion connecting both coils extends in the coil axis direction, and the connecting portion does not protrude from both coils in the height direction of the coil. Thus, the bending radius of the bent portion generated in the connecting portion can be made larger than before. As a result, the insulation coating of the winding in the connecting portion is difficult to be damaged, and even if the diameter of the winding is increased, the insulation coating of the winding is difficult to be damaged.

  In the reactor coil member of the present invention, there are the following two typical configurations in which the connecting portion connecting both coils extends in the coil axis direction so as not to protrude in the coil height direction.

  The first configuration is a configuration in which a connecting portion that connects the two coils is arranged between the first coil and the second coil.

  The second configuration is a configuration in which a connecting portion that connects the two coils is arranged so as to go around the side of the first coil or the second coil.

  Moreover, this invention reactor is equipped with the coil member for this invention reactor, and the core comprised by the 1st coil of this coil member, and the 2nd coil, and was comprised cyclically | annularly.

  The reactor of the present invention operates stably even when used with a large current because the windings constituting the reactor coil member to be used are hardly damaged.

On the other hand, the manufacturing method of the coil member for reactor of this invention has the 1st coil and 2nd coil which are arrange | positioned in parallel mutually, and the connection part which connects both coils, These members are from one coil | winding. The present invention relates to a method of manufacturing a reactor coil member. And the manufacturing method of the coil member for reactors of this invention makes each coil the direction along the coil winding axis which goes to the said connection part from the drawing end of a coil as the advancing direction of the spiral of the coil, and the parallel direction of both coils When the direction orthogonal to both the coil axis direction is the coil height direction, the following steps are provided.
A step of preparing one winding.
A step of forming the first coil by winding the winding on one end side of the winding.
A step of forming a second coil by winding a winding on the other end side of the winding so as to satisfy the following requirements, with an interval of a length corresponding to the connecting portion from the first coil.
(1) The axial direction of the second coil is made substantially parallel to the axial direction of the first coil.
(2) The height direction position of the second coil with respect to the first coil is substantially aligned.
The step of bending the connecting portion so that the connecting portion does not protrude in the height direction of both coils, and arranging both coils in parallel so that the traveling directions of the spirals of both coils are opposite to each other.

According to the method for manufacturing a reactor coil member of the present invention, the reactor coil member of the present invention can be manufactured. At the time of production, since the bending radius of the winding wire in the connecting portion is larger than the conventional one, the conducting wire and the insulation coating provided in the winding wire are hardly damaged.

As one form of the manufacturing method of the coil member for reactors of this invention, you may perform the process of forming a 2nd coil so that the following requirements may be satisfy | filled.
(1) The position of the second coil in the axial direction of the second coil is set on the side opposite to the position of the first coil with respect to the connecting portion.
(2) The traveling direction of the spiral of the second coil is opposite to the traveling direction of the spiral of the first coil.
When the second coil is formed so as to satisfy the above requirements, the step of arranging both coils in parallel is preferably performed so that the connecting portion is arranged between the two coils.

  According to the manufacturing method of the said coil member, the coil member for reactors which distribute | arranged the connection part which connects between both coils mentioned above between the 1st coil and the 2nd coil can be manufactured.

Moreover, you may perform the process of forming a said 2nd coil as one form of the manufacturing method of the coil member for reactors of this invention so that the following requirements may be satisfy | filled.
(1) The position of the second coil in the axial direction of the second coil is set on the same side as the position of the first coil with respect to the connecting portion.
(2) The traveling direction of the spiral of the second coil is made the same as the traveling direction of the first coil spiral.
When the second coil is formed so as to satisfy the above requirements, the step of arranging both coils in parallel may be performed so that the connecting portion wraps around the side of one of the coils.

  According to the manufacturing method of the said coil member, the coil member for reactors which distribute | arranged the connection part which connects between the both coils mentioned above so that it may wrap around to the side of a 1st coil or a 2nd coil can be manufactured.

The coil member for a reactor according to the present invention has a larger bending radius of the bent portion generated in the connecting portion than in the prior art, and therefore, there is almost no cracking of the conducting wire or damage to the insulating coating in the bent portion. Therefore, when it uses for the component of the reactor premised on use with a large current, it contributes to the stable operation | movement of a reactor.

1 is a perspective view of a reactor according to Embodiment 1. FIG. 3 is a perspective view of a reactor coil member according to Embodiment 1. FIG. It is a four-plane figure of the coil member for reactors shown in FIG. 2, Comprising: (A) is a front view (Y2 direction arrow view of FIG. 2), (B) is a left view, (C) is a top view, (D) FIG. It is a perspective view which shows the state in the middle of manufacture of the coil member for reactors which concerns on Embodiment 1. FIG. 4A and 4B are four-side views of the coil member for reactor shown in FIG. 4, in which FIG. 4A is a front view (a view taken in the direction of arrow Y2 in FIG. 4), FIG. 4B is a left side view, and FIG. (D) is a rear view. 6 is a perspective view of a reactor coil member according to Embodiment 2. FIG. It is a four-plane figure of the coil member for reactors shown in FIG. 6, Comprising: (A) is a front view (Y2 direction arrow view of FIG. 6), (B) is a left view, (C) is a top view, (D) FIG. It is a perspective view which shows the state in the middle of manufacture of the coil member for reactors which concerns on Embodiment 2. FIG. It is a four-plane figure of the coil member for reactors in the middle of manufacture shown in Drawing 8, (A) is a front view (Y2 direction arrow view of Drawing 8), (B) is a left side view, (C) is a top view, (D) is a rear view.

  Hereinafter, with reference to drawings, an embodiment of a coil member for a reactor of the present invention and a reactor using this coil member will be described.

<Embodiment 1>
≪Reactor overall structure≫
A reactor 10 shown in FIG. 1 includes a reactor coil member 1 including a first coil 11 and a second coil 12, and an annular core 3 fitted into both the coils 11 and 12. The reactor 10 may be provided with an insulator (not shown) that is interposed between the core 3 and the coils 11 and 12 to ensure insulation between the core 3 and the coils 11 and 12. For the insulator, for example, a PPS resin, a PTFE resin, a liquid crystal polymer, or the like can be used. The reactor 10 may be housed in, for example, an aluminum or aluminum alloy case having an opening and sealed with a resin such as an epoxy resin or a urethane resin.

≪Reactor coil member≫
As shown in FIGS. 2 and 3, the reactor coil member 1 includes a first coil 11, a second coil 12, and a connecting portion 13 that connects both the coils 11 and 12. The shape of each of the coils 11 and 12 viewed from the axial direction of the winding is substantially rectangular, and the overall three-dimensional shape of the coils 11 and 12 is a rectangular tube. Further, the end portions of the coils 11 and 12 (the first lead-out end 11A and the second lead-out end 12A) are drawn away from the coils 11 and 12, and the terminal blocks for supplying power to the coils 11 and 12 are provided. It is connected to a terminal fitting (not shown). These members 11, 12, and 13 included in the coil member 1 are formed of a single rectangular copper wire (winding) having an insulating coating such as enamel.

  Hereinafter, each structure of the coil member 1 is demonstrated in detail.

  In the description of the reactor coil member 1, the direction orthogonal to both the parallel direction (X1-X2 direction) of the coils 11, 12 and the coil axial direction (Y1-Y2 direction) of the coils 11, 12 orthogonal to the parallel direction ( (Z1-Z2 direction) is defined as the coil height direction. Further, the direction of the coils 11 and 12 along the winding axis of the coils 11 and 12 and the direction from the lead-out ends 11A and 12A toward the connecting portion 13 is set in the spiral of the coils 11 and 12. The direction of travel.

  The first coil 11 is formed by winding a rectangular copper wire in an edgewise manner, the spiral traveling direction is the Y1 direction, and the winding direction is counterclockwise. Further, the first lead-out end 11A is formed by being bent in a flatwise shape in the Y2 direction of the winding axis of the winding at the upper end of the coil 11 and being drawn out in the Y2 direction. However, the first leading end 11 </ b> A may be pulled out in the X <b> 1 direction or X <b> 2 direction that is the side of the coil 11, or the Z <b> 1 direction that is above the coil 11.

  The second coil 12 is formed by winding a rectangular copper wire in an edgewise manner, and the spiral traveling direction is the Y2 direction opposite to the first coil 11, and the winding direction is clockwise. It is. The second lead-out end 12A provided in the coil 12 is formed by being bent in a flatwise shape in the Y1 direction of the winding shaft at the upper end of the coil 12, and being drawn out in the Y1 direction. However, the second lead end 12 </ b> A may be drawn to the side or the upper side of the coil 12.

  The connecting part 13 is arranged at the lower end of the coils 11 and 12 so as to connect the coil 11 and the coil 12. More specifically, the winding constituting the connecting portion 13 is once bent edgewise in the direction of the second coil 12 (X1 direction) from the end surface in the Y1 direction on the first coil 11 side. The first coil 11 is bent flatwise in the coil axis direction (Y2 direction) and extends between the first coil 11 and the second coil 12. Further, the winding is bent in a flat-wise manner in the direction of the second coil 12 (X1 direction) in the vicinity of the end surface of the second coil 12 in the Y2 direction, and is directly connected to the second coil 12. As described above, although the connecting portion 13 is bent in a flatwise shape, the bending angle is about 90 ° to 120 °, and it is not folded in half at an angle close to 180 ° as in the conventional case. As a result, there is no problem with the windings constituting the connecting portion 13.

  In the reactor coil member 1 having the above-described configuration, the connecting portion 13 does not protrude in any of the coil height directions, and therefore the height of the reactor 10 is not increased due to the connecting portion 13. Further, since the connecting portion 13 is on the lower end side of the coils 11 and 12 and is at the same height over the entire length, the thermistor can be disposed between the coils 11 and 12 from the upper end side of the coils 11 and 12. Between the coils 11 and 12, when the reactor is used, the heat radiation area of both the coils 11 and 12 overlaps and is a part where the temperature becomes the highest. Therefore, in order to achieve a stable operation of the reactor 10, the reactor 10 It is suitable as a part for monitoring the temperature.

≪Core≫
The core 3 includes coil winding portions 31 and 32 in which the coils 11 and 12 are disposed, and exposed portions 33 and 34 that are exposed without being covered by the coils 11 and 12. The coil winding portions 31 and 32 are provided in parallel, and one end portions of the coil winding portions 31 and 32 are connected by one exposed portion 33, and the other end portions of the coil winding portions 31 and 32 are separately exposed. They are connected by the unit 34. That is, the core 3 is formed by connecting the two coil winding portions 31 and 32 and the two exposed portions 33 and 34 in a ring shape.

  The exposed portions 33 and 34 of the core 3 protrude to the lower end side in the height direction of the coils 11 and 12 from the coil winding portion, and are flush with the lower surfaces of the coils 11 and 12. By setting it as such a structure, since the exposed parts 33 and 34 of the core 3 can be made to contact with the mounting surface of the reactor 10, the heat | fever generated with the reactor 10 can be thermally radiated efficiently. Moreover, even if the length of the exposed portions 33 and 34 in the coil axis direction is shortened in order to reduce the size of the reactor 10 by projecting the exposed portions 33 and 34 to the lower end side of the coils 11 and 12, the magnetic path area is reduced. Can be secured.

≪Method for manufacturing reactor coil member≫
Next, the manufacturing method of the coil member 1 for reactors mentioned above is demonstrated based on FIG. 4, FIG. The definition of the direction in FIGS. 4 and 5 is the same as that in FIGS. Hereafter, each process of a manufacturing method is demonstrated in detail.

  First, one rectangular copper wire having a length sufficient to form the first coil 11, the second coil 12, and the connecting portion 13 is prepared.

  The first coil 11 is formed by spirally edgewise winding one end of the flat copper wire. The winding direction of the first coil 11 is counterclockwise, and the traveling direction of the spiral is the Y1 direction.

  Next, the other end of the rectangular copper wire is spirally edgewise wound to form the second coil 12 at a predetermined interval from the first coil 11. The winding direction of the second coil 12 is clockwise, and the traveling direction of the spiral is the Y2 direction. The number of turns of the second coil 12 is set to be substantially the same as that of the first coil 11.

  At the stage where the formation of the second coil 12 is completed, the first coil 11 and the second coil 12 are disposed in a state where a straight portion serving as the connecting portion 13 of the coil member 1 is sandwiched. In addition, the coil 11 and the coil 12 are aligned in the height direction, the coil axis direction is parallel, and the coil 11 is displaced in the coil axis direction (the second coil 12 in the axial direction of the second coil 12). Is in a state opposite to the position of the first coil 11 with respect to the connecting portion 13).

  Finally, the first coil 11 side and the second coil 12 side of the connecting portion 13 are bent in a flat-wise manner at an angle of about 90 °, and the first coil 11 and the second coil 12 are parallel to each other. (See FIG. 2 and FIG. 3).

  As described above, in the method for manufacturing the reactor coil member 1 according to the first embodiment, since the flat copper wire is not bent so as to be folded back, the flat copper wire is hardly damaged. Therefore, if this coil member 1 is used, a highly reliable reactor 10 can be produced even when a large current is used.

<Embodiment 2>
In the second embodiment, a coil member for a reactor of the present invention having a shape different from that of the first embodiment will be described with reference to FIGS. The definition of the direction described in these drawings is the same as that in the first embodiment. Hereinafter, the coil member of Embodiment 2 and the manufacturing method thereof will be described.

  As shown in FIGS. 6 and 7, the reactor coil member 2 of the present embodiment is formed of a single rectangular copper wire as in the first embodiment, and includes a first coil 21 and a second coil 22. And a connecting portion 23 that connects both the coils 21 and 22. The first coil 21 is formed by winding a rectangular copper wire in an edgewise manner, the spiral traveling direction is the Y2 direction, and the winding direction is counterclockwise. The second coil 22 is also formed by winding a rectangular copper wire in an edgewise manner, and the spiral traveling direction is the Y1 direction opposite to the first coil 21, and the winding direction is Counterclockwise.

  In addition, the winding constituting the connecting portion 23 that connects the first coil 21 and the second coil 22 is edgewise in the direction opposite to the second coil 22 (X2 direction) from the end surface of the first coil 21 in the Y2 direction. Immediately after being bent into a flat-wise shape in the coil axial direction (Y1 direction) and wrapping around the side of the first coil 21. Further, this winding is bent in a flat-wise manner in the direction of the second coil 22 (X1 direction) in the vicinity of the end surface of the first coil 21 on the first lead-out end 21A side, and is connected to the second coil 22 as it is. .

<Manufacturing method of coil member for reactor>
Next, the formation method of the coil member 2 for reactors provided with the said structure is demonstrated below based on FIG. 8, FIG.

  First, a single rectangular copper wire having a length sufficient to form the first coil 21, the second coil 22, and the connecting portion 23 is prepared.

  The first coil 21 is formed by spirally winding one end of a flat copper wire edgewise. The spiral direction of the first coil 21 is the Y1 direction, and the winding direction is counterclockwise.

  Next, the other end of the rectangular copper wire is spirally edgewise wound to form the second coil 22 at a predetermined interval from the first coil 21. The traveling direction of the spiral of the second coil 22 is the Y1 direction, and the winding direction is counterclockwise.

  At the stage where the formation of the second coil 22 is completed, the first coil 21 and the second coil 22 are arranged in a state of being connected with a straight portion serving as the connecting portion 23 of the coil member 2 interposed therebetween. In addition, the coil 21 and the coil 22 are aligned in the height direction, are parallel in the coil axis direction, and are arranged at substantially the same position in the coil axis direction (the axial direction of the second coil 22). The position of the second coil 22 is in the same side as the position of the first coil 21 with respect to the connecting portion 23).

  Finally, the connecting portion 23 is bent so that the first coil 21 is wound around the connecting portion 23 so that the connecting portion 23 wraps around the side of the first coil 21, and the first coil 21 and the second coil 22 are Are in parallel with each other (see FIGS. 6 and 7).

  In addition, this invention is not necessarily limited to embodiment mentioned above, In the range which does not deviate from the summary of this invention, it can change suitably. For example, in Embodiments 1 and 2, a rectangular copper wire having a rectangular cross-sectional shape is used as the winding, but the coil member may be manufactured using a winding having a circular, elliptical, or polygonal cross-sectional shape. .

  The reactor using the coil member for a reactor of the present invention can be suitably used as a component part of a converter mounted on a moving body such as a hybrid automobile.

DESCRIPTION OF SYMBOLS 10 Reactor 1, 2 Reactor coil member 11, 21 1st coil 11A, 21A 1st extraction end 12, 22 2nd coil 12A, 22A 2nd extraction end 13, 23 Connection part 3 Core 31, 32 Coil winding part 33 , 34 Exposed part

Claims (7)

A first coil and a second coil arranged in parallel with each other, and a connecting portion that connects the two coils, and these members are coil members for a reactor including a single winding,
In each coil, the direction along the coil winding axis from the coil drawing end toward the connecting portion is defined as the spiral traveling direction of the coil, and the direction orthogonal to both the parallel direction of both coils and the coil axis direction of both coils. Is the height direction of the coil,
Each lead-out end of the first coil and the lead-out end of the second coil, that is disposed in one end and the other end of the coil axis direction, the traveling direction of the helix of the coils has become opposite to each other,
The reactor coil member, wherein the connecting portion is arranged in the height direction without protruding from both coils. The reactor according to claim 1, wherein the connecting portion is arranged to extend from one end side to the other end side in the coil axis direction at a position between the first coil and the second coil. Coil member.   2. The reactor coil member according to claim 1, wherein the communication portion is arranged so as to wrap around the side of the first coil or the second coil. The coil member for reactors as described in any one of Claims 1-3,
A core that is inserted into the first coil and the second coil and configured in an annular shape;
The reactor characterized by providing. A first coil and a second coil arranged in parallel with each other, and a connecting portion that connects the two coils, and a method for manufacturing a reactor coil member in which these members are formed of one winding,
In each coil, the direction along the coil winding axis from the end of the coil toward the connecting portion is the traveling direction of the spiral of the coil, and the direction orthogonal to both the parallel direction of the coils and the coil axis direction is the direction of the coil. When the height direction
Preparing a single winding;
Winding the winding at one end of the winding to form a first coil;
A step of forming a second coil by winding a winding on the other end side of the winding so as to satisfy the following requirements, with an interval of a length corresponding to the connecting portion from the first coil;
(1) The axial direction of the second coil is made substantially parallel to the axial direction of the first coil. (2) The position of the second coil in the height direction with respect to the first coil is substantially aligned. The connecting portion is bent so as not to protrude in the height direction, and both the coils are arranged in parallel so that the leading end of the first coil and the leading end of the second coil are arranged on one end side and the other end side in the coil axial direction, respectively. And making the traveling directions of the spirals of both coils opposite to each other ,
The manufacturing method of the coil member for reactors characterized by including these. The step of forming the second coil is performed so as to satisfy the following requirements:
(1) The position of the second coil in the axial direction of the second coil is opposite to the position of the first coil with respect to the connecting portion. (2) The traveling direction of the spiral of the second coil is the spiral of the first coil. The step of arranging the two coils in parallel is performed so that the connecting portion extends from one end side to the other end side in the coil axis direction at a position between the two coils. A method for manufacturing the reactor coil member according to claim 5. The step of forming the second coil is performed so as to satisfy the following requirements:
(1) The position of the second coil in the axial direction of the second coil is set to the same side as the position of the first coil with respect to the connecting portion. (2) The traveling direction of the spiral of the second coil is the first coil spiral. 6. The method of manufacturing a reactor coil member according to claim 5, wherein the step of arranging the two coils in parallel is performed so that the connecting portion wraps around a side of one of the coils.

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