JP5267240B2 - Reactor and converter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a small reactor with excellent manufacturability, and a coil compact used for the reactor. <P>SOLUTION: The reactor 1 includes an annular magnetic core 11, a coil 12 arranged on an outer circumference of the magnetic core 11, an outer side resin portion 13 for covering the outer circumference of an assembly 10 of the magnetic core 11 and the coil 12, and a sensor hole 13h in which a sensor such as a thermistor is inserted. The reactor 1 can be small by omitting a case. Because the sensor hole 13h is formed by resin molding of the outer side resin portion 13, positioning of the sensor hole 13h becomes easy, and the sensor can be arranged in a predetermined position easily, resulting in excellent manufacturability of the reactor 1. In addition, damage on the coil 12 or the like in forming the sensor hole 13h can be prevented, and damage on the sensor during resin molding is also prevented. <P>COPYRIGHT: (C)2010,JPO&amp;INPIT

Description

  The present invention relates to a reactor used for a component of an in-vehicle DC-DC converter such as a hybrid vehicle, and a coil molded body used for the reactor. In particular, the present invention relates to a small reactor that is excellent in manufacturability.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. For example, Patent Document 1 discloses a reactor used for a circuit component of a converter mounted on a vehicle such as a hybrid vehicle. The reactor includes an annular magnetic core, a coil having a pair of coil elements arranged side by side on the outer periphery of the core, a case for housing a combination of the magnetic core and the coil, and a case. And a resin that is filled to seal the combination.

  In the reactor, the coil generates heat and the temperature changes with energization. Therefore, a temperature sensor may be arranged to grasp the temperature of the reactor (particularly the temperature of the coil). For example, the temperature sensor is arranged in the vicinity of the coil before filling with the resin, filled with the resin in this state, and fixed to the reactor by curing of the resin.

JP 2008-028290 A

However, further miniaturization is difficult with a conventional reactor having a case.
Recently, in-vehicle components such as hybrid vehicles are desired to be smaller and lighter. Therefore, it is conceivable to omit the case, but if the case is omitted, the magnetic core and coil will be exposed, so it is desirable to protect from the external environment such as dust and corrosion and mechanical protection. .

  Moreover, when fixing a temperature sensor with resin with which a case is filled, there exists a possibility of damaging a temperature sensor by the shrinkage | contraction at the time of the said resin hardening. Furthermore, when the resin is filled, the temperature sensor may flow through the resin and shift from a predetermined position, and it is difficult to position the temperature sensor at the predetermined position. In order to position the temperature sensor, it is necessary to temporarily fix the temperature sensor, and the number of processes increases, thereby reducing the manufacturability of the reactor.

  As a configuration that satisfies the above requirements, the case is omitted, the outer periphery of the combination of the magnetic core and the coil is covered with an external resin, and after the resin is cured, a hole is provided for placing the temperature sensor in the external resin with a drill or the like. The configuration was examined. However, in this case, there is a risk of damaging the coil or the like when drilling. In addition, in a state where the combination is covered with resin, it is difficult to provide a hole at a predetermined position with high accuracy.

  For example, the heat of the coil can be accurately measured by providing a hole for the sensor at a location covering the coil elements in the external resin. However, it is difficult to grasp the inside of the resin, for example, between the coil elements, by being covered with the external resin. In particular, when downsizing is desired, it is difficult to provide sensor holes at predetermined positions between the coil elements because the gap between the coil elements is narrow. Therefore, in this method, a process for providing a sensor hole is required, and the number of processes is increased. In addition, it takes time to position the hole, and improvement in workability is desired.

  Therefore, an object of the present invention is to provide a reactor that is small in size and excellent in manufacturability. Moreover, it is providing the coil molded object suitable for this reactor.

  The present invention proposes to omit the case and cover the outer periphery of the combination of the magnetic core and the coil with a resin mainly for the purpose of reducing the size and weight, and protecting from the external environment and mechanical protection. . And this invention proposes simultaneously manufacturing the location for arrange | positioning the sensor which measures the physical quantity of a reactor, such as a temperature sensor, at the time of the shaping | molding of the said resin.

The reactor of the present invention includes a magnetic core and a coil disposed on the outer periphery of the magnetic core. Further, the reactor includes an outer resin portion that covers the outer periphery of the combination of the magnetic core and the coil, and a sensor hole in which a sensor that measures a physical quantity of the reactor is disposed. In particular, the sensor hole is one which we provided a resin molding of the external resin portion.

  The reactor of the present invention having the above-described configuration can be reduced in size and weight by not having a case, but can protect the magnetic core and the coil from the external environment by having an outer resin portion. Can be mechanically protected. And by providing the sensor hole formed by resin molding of this external resin part, it can arrange | position to this invention reactor simply by inserting sensors, such as a temperature sensor, in the sensor hole. Further, when positioning in forming the sensor hole, since the coil or the like is exposed without being covered with the outer resin portion, it can be easily positioned, and another process such as cutting for providing the sensor hole is required. It is unnecessary and the reactor of the present invention is excellent in manufacturability. Furthermore, according to the reactor of the present invention, the coil or the like is not damaged when forming the sensor hole, and the sensor is not substantially damaged when the reactor including the sensor is formed.

  As one form of the reactor of the present invention, the coil includes a pair of coil elements, and the coil elements are arranged side by side so that the respective axial directions are parallel to each other. In this case, the sensor hole may be provided at a location covering the coil element in the outer resin portion.

  For example, when the sensor is a temperature sensor, it is desirable to dispose the temperature sensor in the vicinity of a coil that tends to become hot when the reactor is used. In particular, when the coil elements are arranged side by side as described above, the temperature between the coil elements becomes the highest. Therefore, according to the said structure, sensors, such as a temperature sensor, can be easily arrange | positioned between the coil elements which become high temperature easily. Further, even when the space between the coil elements is narrow, the sensor hole can be easily formed only by arranging an appropriate core when molding the outer resin portion.

  As one form of this invention reactor, the form provided with the following this invention coil molded object is mentioned. The coil molded body of the present invention is used for a reactor in which a coil formed by winding a winding in a spiral shape is disposed on a magnetic core, and an inner resin portion that retains the shape of the coil and a physical quantity of the reactor. And a sensor inner hole in which a sensor to be measured is arranged. The sensor inner hole is provided by resin molding of the inner resin portion. The reactor according to the present invention including the coil molded body includes the coil molded body, a magnetic core on which the coil molded body is disposed, and an outer resin portion that covers an outer periphery of an assembly of the coil molded body and the magnetic core. Have. The reactor includes a sensor outer hole that communicates with the sensor inner hole of the inner resin portion and is formed by resin molding of the outer resin portion.

  The reactor of the present invention including the coil molded body of the present invention is also small and lightweight by omitting the case, and by providing the outer resin portion and the inner resin portion, the magnetic core and the coil are protected from the external environment. And mechanical protection can be achieved. And since the shape of a coil is hold | maintained at the time of the assembly of a reactor and it does not expand-contract by utilizing this coil molded object of this invention, it is easy to handle a coil and is excellent in the manufacturability of a reactor. In particular, if the inner resin portion is configured to be held in a state compressed more than the free length of the coil, the coil can be shortened in the axial direction as compared with the case where the coil is extended by a springback. The magnetic core to be disposed can be made smaller, and the reactor can be made smaller. Further, by utilizing the coil molded body of the present invention, an insulator (inner bobbin / outer bobbin in Patent Document 1) that insulates between the magnetic core and the coil used in a conventional reactor, or a state in which the coil is compressed The middle case (refer to Patent Document 1) for holding the cover can be omitted. Therefore, the reactor of the present invention including the coil formed body of the present invention can reduce the number of parts and the assembly process, and is excellent in manufacturability from this point. Furthermore, the reactor of the present invention includes a sensor outer hole communicating with the sensor inner hole, so that the sensor can be easily arranged. In particular, when positioning the inner hole for the sensor, the coil is exposed without being covered with the inner resin portion, so that it can be easily positioned, and when positioning the outer hole for the sensor, Since the inner hole is exposed without being covered with the outer resin portion, it can be easily positioned. In addition, since both the inner hole for sensor and the outer hole for sensor are formed by resin molding, the reactor of the present invention is excellent in manufacturability as compared with the case where it is formed by a drill or the like. In forming the inner hole for the sensor and the outer hole for the sensor, there is almost no possibility of damaging the coil or the like. Further, the sensor is hardly damaged when the reactor is provided with the sensor.

  As one form of the coil molded body of the present invention, the coil includes a pair of coil elements, and the coil elements are arranged side by side so that the respective axial directions are parallel to each other. In this case, the said sensor inner hole can be made into the form provided in the location which covers between coil elements in the said inner side resin part.

  As described above, by providing the sensor inner holes between the coil elements that generate a large amount of heat, a sensor such as a temperature sensor can be easily disposed between the coil elements.

  As one form of this invention coil molded object, the said inner side resin part has the form comprised with resin containing the ceramic filler.

  Since the inner resin portion comes into contact with the coil having a large calorific value, the heat dissipation can be improved by using a resin containing ceramics having excellent thermal conductivity as the constituent resin. Further, since the ceramic filler is usually an insulating material, it is possible to maintain insulation between the ceramic filler.

  The reactor of the present invention is small in size because the case is omitted, and is excellent in manufacturability. The coil molded body of the present invention is easy to handle the coil when the reactor is assembled, and can contribute to the improvement of the manufacturability of the reactor.

FIG. 1 (I) is a schematic perspective view showing a state in which the reactor of Embodiment 1 is placed on a fixed object, and FIG. 1 (II) is a schematic cross-sectional view showing an XX cross section of the reactor. FIG. 2 is a schematic perspective view showing a state where the reactor of the second embodiment is placed on a fixed object. FIG. 3 (I) is a schematic perspective view of a coil molded body provided in the reactor of Embodiment 2, FIG. 3 (II) is a schematic perspective view of a coil provided in this coil molded body, and FIG. 3 (III) is It is a schematic sectional drawing which shows the YY cross section of this coil molded object. FIG. 4 is an exploded perspective view for explaining an assembly procedure of a combination of a magnetic core and a coil molded body, which is provided in the reactor of the second embodiment.

(Embodiment 1)
Hereinafter, the reactor 1 of the first embodiment will be described with reference to FIG. In the drawings, the same reference numerals denote the same items. The reactor 1 is used by being directly attached to a fixed object such as a metal (typically aluminum) cooling base (not shown) having a refrigerant circulation path therein, and an annular magnetic core 11 A combination 10 in which the coil 12 is disposed on the outer periphery of the combination and an outer resin portion 13 covering the outer periphery of the combination 10 are provided. The feature of the reactor 1 is that the outer resin portion 13 is provided with a sensor hole 13h. Hereinafter, each configuration will be described in more detail.

<Union body>
[Magnetic core]
The magnetic core 11 will be described with reference to FIG. 4 described later as appropriate. The magnetic core 11 includes a pair of rectangular parallelepiped coil winding portions 11c in which the coil 12 is disposed, and a pair of end cores 11e that are exposed without the coil 12 being disposed, and are disposed apart from each other. The end core 11e is disposed so as to sandwich the coil winding portion 11c, and is formed in a closed loop shape (annular shape). The coil winding portion 11c is configured by alternately laminating core pieces 11m made of a soft magnetic material containing iron such as iron or steel and gap members 11g made of a nonmagnetic material such as alumina, and an end core 11e is a core piece made of the soft magnetic material. Each core piece can be a soft magnetic powder compact or a laminate of a plurality of electromagnetic steel plates. The gap material 11g is a plate-like material disposed in a gap provided between the core pieces 11m for adjusting the inductance (it may be an air gap). The core piece and the gap material are integrally joined with an adhesive or the like. The number of core pieces and gap members can be appropriately selected so that the reactor 1 has a desired inductance. Moreover, the shape of a core piece or a gap material can be selected suitably.

  The outer peripheral surface of the coil winding portion 11c and the outer peripheral surface of the end core 11e are not flush with each other, but the surface on the cooling base side of the end core 11e (hereinafter referred to as the core base surface; the lower side in FIGS. ) Projecting from the coil winding portion 11c. The end base 11e has a core base surface that is flush with a cooling base side surface (hereinafter referred to as a coil base surface 12d in FIG. 1) of the coil 12, which will be described later. The height of the core 11e (the length in the direction perpendicular to the surface of the cooling base (in this case, the direction equal to the direction orthogonal to the axial direction of the coil 12) when the reactor 1 is placed on the cooling base) It is adjusted. Note that the outer peripheral surface of the coil winding portion and the outer peripheral surface of the end core may be flush with each other.

[coil]
As shown in FIG. 1, the coil 12 includes a pair of coil elements 12a and 12b formed by spirally winding a winding 12w. Both coil elements 12a and 12b are arranged side by side so that the respective axial directions are parallel to each other. Each coil element 12a, 12b is formed by a separate winding 12w, and ends of the windings forming each coil element 12a, 12b are joined together by welding or the like to form an integrated coil 12. The winding 12w is preferably a coated wire having an insulating coating layer on the outer periphery of the conductor. Here, a coated rectangular wire is used in which the conductor is made of a copper rectangular wire and the insulating coating layer is made of enamel. Each of the coil elements 12a, 12b is formed by edgewise winding the covered rectangular wire. The windings can be used in various shapes such as a circular shape and a polygonal shape in addition to the conductor made of a flat wire. Both coil elements 22a and 22b are formed by one continuous winding 22w as in a coil 22 (see FIG. 3 (II) ) included in the reactor of the second embodiment described later, and a part of the winding 22w is folded back. It is good also as a structure connected by the winding | turning-back part 22r formed.

  Both ends of the winding 12w forming the coil 12 are appropriately extended from the turn forming portion and pulled out of the outer resin portion 13, and the conductive portion is exposed to the conductive portion exposed by peeling off the insulating coating layer. A terminal member (not shown) is connected. An external device (not shown) such as a power source for supplying power is connected to the coil 12 through this terminal member. Welding such as TIG welding can be used to connect the ends of the windings of the coil elements 12a and 12b and to connect the conductor portion of the winding 12w and the terminal member.

[Insulator]
The assembly 10 including the magnetic core 11 and the coil 12 is also provided with an insulator 14. The insulator 14 includes a cylindrical bobbin 14b that covers the outer periphery of the coil winding portion 11c, and a pair of flange portions 14f that are in contact with the end face of the coil 12. The cylindrical bobbin 14b can easily cover the outer periphery of the coil winding portion 11c if the half-cut square tube pieces are engaged with each other. Each flange 14f is a rectangular frame arranged at one end of the bobbin. For the insulator, an insulating resin such as a polyphenylene sulfide (PPS) resin, a liquid crystal polymer (LCP), or a polytetrafluoroethylene (PTFE) resin can be used.

<Outside resin part>
The outer periphery of the combined body 10 is covered with the outer resin portion l3. Here, the outer resin portion l3 is formed so that the outer resin portion 13 has a rectangular parallelepiped shape by casting the epoxy resin after the assembly 10 is manufactured. The end of the winding 12w is exposed from the outer resin portion 13 as shown in FIG. In the reactor 1, a sensor hole 13h is provided at a portion of the outer resin portion 13 that covers between the coil elements 12a and 12b.

  Here, the sensor hole 13h is a bottomed cylindrical shape in which a thermistor (not shown) for measuring the temperature when the reactor 1 is used (mainly the temperature of the coil 12) can be arranged, and the bottom of the opening is formed from the opening. It has a uniform size (diameter). The sensor hole 13h is provided at the same time as the outer resin portion 13 is molded. The diameter and depth of the sensor hole can be appropriately selected.

  In addition, in the reactor 1, the core base surface of the end core 11e and the coil base surface 12d of the coil 12 are exposed from the outer resin portion 13, and these both base surfaces are on the cooling base side in the outer resin portion 13. It is flush with the surface (hereinafter referred to as resin base surface 13d). Therefore, when the reactor 1 is placed on the cooling base, the core base surface, the coil base surface 12d, and the resin base surface 13d are in contact with the cooling base.

  Further, the reactor 1 includes bolt holes 13b in which bolts 100 for fixing the reactor 1 to the cooling base are attached to the four corners of the rectangular parallelepiped outer side resin portion 13 where the combined body 10 does not exist. The reactor can be fixed to the cooling base by appropriately using, for example, a] -shaped fixing member without providing the bolt hole 13b.

<Reactor assembly procedure>
The reactor 1 having the above configuration can be formed as follows.

  First, the core piece 11m (FIG. 4) and the gap member 11g (FIG. 4) are fixed with an adhesive or the like to form the coil winding portion 11c, and the cylindrical bobbin 14b of the insulator 14 is disposed on the outer periphery thereof. Separately, the coil elements 12a and 12b of the prepared coil 12 are respectively arranged in the coil winding portion 11c where the cylindrical bobbin 14b is arranged, and the insulator 14 is attached to both end faces of the coil elements 12a and 12b. The part 14f and the end core 11e are brought into contact with each other, the flange part 14f and the end core 11e are arranged so as to sandwich the coil 12, and the end core 11e and the coil winding part 11c are joined with an adhesive or the like. By this step, the combined body 10 of the magnetic core 11 and the coil 12 is obtained.

  In the obtained combination 10, the outer resin portion 13 is molded so that the core base surface of the end core 11e, the coil base surface 12d of the coil 12, and the end of the winding 12w are exposed. At the same time, a cylindrical core is appropriately disposed between the coil elements 12a and 12b and the sensor hole 13h and the bolt hole 13b are formed. By the above process, the reactor 1 is obtained.

  The obtained reactor 1 is placed on the cooling base so that the core base surface of the end core 11e and the coil base surface 12d of the coil 12 are on the cooling base side, and is fixed to the cooling base by screwing in the bolt 100. be able to. In addition, by disposing a sensor for measuring a physical quantity such as a thermistor in the sensor hole 13h, a predetermined physical quantity can be appropriately measured when the reactor 1 is used. Note that if an adhesive or the like is applied to the core base surface of the end core 11e very thinly (about several tens of μm), the end core 11e and the cooling base are easily brought into close contact.

<Effect>
Reactor 1 having the above configuration is small and light because it does not have a case, but by providing outer resin part 13, it can protect union 10 from the external environment or mechanically protect it. can do. In addition, the reactor 1 includes a sensor hole 13h for arranging a sensor for measuring the physical quantity of the reactor, and a desired sensor (for example, a thermistor for measuring temperature) is inserted into the sensor hole 13h. The desired sensor can be easily positioned. In particular, in the reactor 1, the sensor hole 13h is formed at the same time as the outer resin portion 13 is molded, and the sensor is disposed after molding. There is almost no risk of damaging the sensor in forming the reactor. In addition, by forming the sensor hole 13h when the outer resin portion 13 is molded, the sensor hole can be easily positioned and the sensor hole can be easily formed, so that the productivity of the reactor is excellent.

  In addition, the reactor 1 has a configuration in which the core base surface of the end core 11e and the coil base surface 12d of the coil 12 are exposed from the outer resin portion 13 and come into contact with the cooling base. It is directly transmitted to the cooling base and has excellent heat dissipation. In addition, the reactor 1 has a shape in which the end core 11e protrudes from the coil winding portion 11c, so that when the end core and the coil winding portion have the same volume as the magnetic core, the reactor 1 Since the axial length of the coil 12 can be shortened, the coil 12 can be made smaller.

(Modification 1)
In the first embodiment, the configuration in which the sensor hole 13h has a uniform size (diameter) from the opening portion to the bottom surface has been described. However, for example, a stepped hole having a large diameter on the opening portion side may be used. . In this case, if the sensor is covered with resin or the like and molded into a T shape and the protruding portion is stopped by the step, the sensor can be prevented from falling out of the sensor hole. Furthermore, if the projecting portion is provided with a screw hole and is fixed to the outer resin portion with a screw or the like, the sensor can be firmly fixed to the reactor, and falling off can be more reliably prevented. Alternatively, the sensor may be fixed to the sensor hole with an adhesive or the like.

(Embodiment 2)
Hereinafter, the reactor 2 according to the second embodiment will be described with reference to FIGS. In FIG. 2, a part of the outer resin portion is cut away so that the magnetic core and the coil molded body existing inside the outer resin portion can be seen. The reactor 2 includes a combined body 20 in which a coil molded body 22A is disposed on the outer periphery of an annular magnetic core 11, and an outer resin portion 23 that covers the outer periphery of the combined body 20. The main difference between the reactor 2 and the reactor 1 of the first embodiment is that the coil 22 is a coil molded body 22A covered with an inner resin portion 22c. Hereinafter, this difference will be mainly described, and the other points are substantially the same as the reactor 1 of the first embodiment, and thus the description thereof will be omitted.

[Coil molding]
As shown in FIG. 3 (II), the coil molded body 22A includes a coil 22 having a pair of coil elements 22a and 22b formed by spirally winding one continuous winding 22w, and an outer periphery of the coil 22. And an inner resin portion 22c for covering.

{coil}
The coil 22 is formed by winding one continuous winding 22w as described above. Both ends of the winding 22w are appropriately extended from the turn forming portion and pulled out to the outside of the inner resin portion 22c and the outside of the outer resin portion 23 (FIG. 2), in the same manner as the reactor 1 of the first embodiment, A terminal member (not shown) is connected.

{Inner resin part}
An inner resin portion 22c is provided so as to maintain the shape of each coil element 22a, 22b. Here, in particular, the inner resin portion 22c is provided so as to hold each of the coil elements 22a and 22b in a compressed state. Further, here, the inner resin portion 22c covers substantially along the outer shape of the coil 22 as shown in FIGS. 3 (I) and (II), and both ends of the winding 22w and the coil elements 22a and 22b. A part of the outer peripheral surface of the turn forming portion is exposed without being covered with the constituent resin of the inner resin portion 22c. That is, the outer peripheral surface of the inner resin portion 22c has an uneven shape. In the inner resin portion 22c, the thickness of the portion covering the turn forming portions of the coil elements 22a and 22b is substantially uniform as shown in FIG. 3 (III), and the portion covering the winding portion 22r is as shown in FIG. As shown in (I) and (II), the shape protrudes in the axial direction of the coil. The surface of the inner resin portion 22c and the exposed turn forming portion are brought into contact with the inner surface of the outer resin portion 23 when the reactor 2 is assembled.

  The inner periphery of each coil element 22a, 22b is also covered with the constituent resin of the inner resin portion 22c, and has a hollow hole 220 formed by this constituent resin. In each hollow hole 220, a coil winding portion 11c (FIG. 4) of the magnetic core 11 (FIG. 4) is inserted and arranged. The thickness of the constituent resin of the inner resin portion 22c is adjusted so that each coil winding portion 11c is disposed at an appropriate position on the inner circumference of the coil elements 22a and 22b, and the shape of the hollow hole 220 is changed to coil winding. The outer shape of the turning portion 11c (here, a rectangular parallelepiped shape) is used. Therefore, the constituent resin of the inner resin portion 22c existing on the inner circumference of each coil element 22a, 22b functions as a positioning portion for the coil winding portion 11c.

  The coil molded body 22A includes a sensor inner hole 22h at a location covering the coil elements 22a and 22b in the constituent resin of the inner resin portion 22c. Here, the sensor inner hole 22h is a bottomed cylindrical shape in which a thermistor (not shown) for measuring the temperature at the time of use of the reactor 2 (mainly the temperature of the coil 22) can be arranged. It has a uniform size (diameter). The sensor inner hole 22h is provided at the same time as the inner resin portion 22c is molded. The diameter and depth of the sensor inner hole can be appropriately selected.

  In addition, in this coil molded body 22A, a recess 221 is provided at a location covering a gap having a triangular cross section formed between the coil elements 22a and 22b on the cooling base side of the inner resin portion 22c. Here, the recess 221 has a trapezoidal cross section, and is provided in the entire region from one end surface 22e to the other end surface 22e of the coil molded body 22A along the axial direction of the coil. The shape, formation region, depth, and the like of the recess 221 can be selected as appropriate, and need not be provided.

  The resin component of the inner resin part 22c has heat resistance that does not soften against the maximum temperature of the coil or magnetic core when using the reactor 2 including the coil molded body 22A. Transfer molding or injection molding Can be suitably used. In particular, a material having excellent insulating properties is preferable. Specifically, a thermosetting resin such as epoxy, or a thermoplastic resin such as PPS resin or LCP can be suitably used. Here, an epoxy resin is used. In addition, when the resin is mixed with a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide, the insulating property is excellent and the heat dissipation is further improved.

{Manufacture of coil moldings}
The coil molded body 22A can be manufactured using a molding die as described below. As the molding die, one constituted by a pair of first and second molds that can be opened and closed can be used. The first mold has a rectangular parallelepiped shape inserted into the end plate located on one end side of the coil 22 (the side from which the end of the winding 22w is pulled out in FIG. 3) and the inner circumference of each of the coil elements 22a and 22b. The second mold includes an end plate located on the other end side of the coil (on the winding portion 22r side in FIG. 3) and a peripheral side wall that covers the periphery of the coil 22. The first mold and the second mold include a plurality of rod-shaped bodies that can be moved back and forth inside the mold by a drive mechanism. The coil elements 22a and 22b are compressed by appropriately pressing the visible surface). The rod-shaped body has sufficient strength against compression of the coil 22 and heat resistance against heat during molding of the inner resin part 22c, and reduces the number of portions of the coil 22 that are not covered with the inner resin part 22c. Furthermore, it is preferable to make it as thin as possible. The second mold includes a cylindrical core that can be moved back and forth between the coil element from the peripheral side wall. This core is used to form a sensor hole.

  The coil 22 is spirally wound to form the coil 22, and the coil 22 is accommodated in the molding die so that a certain gap is formed between the surface of the molding die and the coil 22. At this time, the coil 22 is not yet compressed.

  Next, the molding die is closed, and the core of the first die is inserted into the inner periphery of each coil element 22a, 22b. At this time, the interval between the inner circumference of the core and the coil elements 22a and 22b is made substantially uniform over the entire circumference of the core.

  Subsequently, the rod-shaped body is advanced into the molding die to compress the coil elements 22a and 22b. By this compression, the gap between adjacent turns constituting each coil element 22a, 22b is reduced, and the coil 22 is held in a state compressed more than its free length. In this state, a cylindrical core is inserted between the coil elements.

  While maintaining the compression state, the resin is filled into the molding die from the resin injection port and cured, and then the molding die is opened, and the coil molded body in which the compression state is held by the resin is taken out. The obtained coil molded body 22A includes a sensor inner hole 22h at a location covering the space between the coil elements 22a and 22b. Note that the plurality of small holes formed in the portion pressed by the rod-like body are filled with the outer resin portion 13, and may be left as they are, or may be filled with an appropriate insulating material or the like. Further, when the recess 221 is formed, a mold having a protrusion for forming the recess 221 is used.

<Outside resin part>
The combined body 20 formed by combining the magnetic core 11 and the coil molded body 22A is covered with the outer resin portion 23 as shown in FIG. The outer resin portion 23 includes a sensor outer hole 23h communicating with a sensor inner hole 22h included in the coil molded body 22A. The sensor outer hole 23h is formed at the same time as the outer resin portion 23 is molded. Here, the sensor outer hole 23h has a cylindrical shape having the same size (diameter) as the sensor inner hole 22h of the coil molded body 22A, and has a uniform size from the opening to the sensor inner hole 22h. (Diameter). The sensor outer hole 23h is inserted with a cylindrical material having a size (diameter) that fits into the sensor inner hole 22h of the coil molded body 22A before the outer resin portion 23 is molded. It can be easily formed by molding the external resin portion 23 in the state. The cylindrical member may be of a sufficient length so that one end protrudes from the surface of the external resin portion 23 when inserted into the sensor inner hole 22h of the coil molded body 22A. Pull out.

  Here, the outer resin portion 23 is formed substantially along the outer shape of the assembly 20 by casting the epoxy resin after producing the assembly 20. An end portion of the winding 22w is exposed from the outer resin portion 23. Further, both the base surface of the end core 11e of the magnetic core 11 and the surface on the cooling base side of the coil molded body 22A (hereinafter referred to as the molded body base surface 22d (FIG. 3 (III))) are outside. The resin part 23 is exposed. Further, the core base surface and the molded body base surface 22d are flush with the resin base surface of the outer resin portion 23. Therefore, when the reactor 2 is placed on the cooling base, the core base surface, the molded body base surface 22d, and the resin base surface are in contact with the cooling base.

  Further, in the reactor 2, the constituent resin of the outer resin portion 23 is also present at the location where the combination 20 is not present so that the outer shape of the cooling base side of the outer resin portion 23 is rectangular. The four corners of the flange portion 23f constituting the rectangular portion are provided with bolt holes 23b to which bolts (not shown) for fixing the reactor 2 to the cooling base are attached. Here, each bolt hole 23b is formed of a reinforcing metal tube, but may be formed of resin itself. Examples of the metal tube include those made of brass, steel, stainless steel, and the like. The thickness of the flange portion 23f, the number of bolt holes 23b, and the like can be selected as appropriate.

  The portion of the outer resin portion 23 excluding the flange portion 23f has a uniform average thickness of 1 to 2 mm, and the thickness of the outer resin portion 23 at the portion and the covering region for the assembly 20 can be selected as appropriate. . For example, not only the core base surface of the end core 11e and the molded body base surface 22d of the coil molded body 22A, but also a part of the end core 11e and a part of the coil molded body 22A are covered with the constituent resin of the outer resin portion. Instead, it can be in an exposed form.

  As the constituent resin of the outer resin portion 23, the same resin as the outer resin portion 13 of the reactor 1 of the first embodiment described above can be used. The constituent resin of the outer resin portion 23 may be the same as or different from the constituent resin of the inner resin portion 22c of the coil molded body 22A. Further, the above-described ceramic filler may also be included in the outer resin portion 23 to enhance heat dissipation.

<Reactor assembly procedure>
The reactor 2 having the above configuration can be assembled as follows.

  First, the coil molded body 22A is prepared as described above. Further, as shown in FIG. 4, the coiled portion 11c is formed by fixing the core piece 11m and the gap material 11g with an adhesive or the like. Then, the coil winding portion 11c is inserted and disposed in the hollow hole 220 of the coil molded body 22A. Each coil winding portion 11c inserted into the hollow hole 220 is disposed at an appropriate position with respect to the coil elements 22a and 22b (FIG. 3). Next, the end core 11e is arranged so that both end faces 22e of the coil molded body 22A are sandwiched between the pair of end cores 11e, and the end core 11e and the coil winding part 11c are joined with an adhesive or the like. . By this process, the combined body 20 is obtained.

In the obtained combined body 20, the outer periphery of the combined body 20 is covered with resin so that the core base surface of the end core 11e, the formed body base surface 22d of the coil formed body 22A, and the end of the winding 22w are exposed. Thus, the outer resin portion 23 is formed. At the same time, the sensor outer hole 23h is formed in the outer resin portion 23 so as to communicate with the sensor inner hole 22h of the coil molded body 22A as described above at a portion covering the coil elements 22a and 22b. Further, the flange portion 23f and the bolt hole 23b are molded on the base side of the outer resin portion 23 . By the above process, the reactor 2 is obtained. In the obtained reactor 2, the core base surface of the end core 11e, the molded body base surface 22d of the coil molded body 22A, and the resin base surface of the outer resin portion 23 are flush with each other. The reactor 2 can be fixed to the cooling base by placing the reactor 2 on the cooling base and tightening the bolt into the bolt hole 23b and the bolt hole provided in the cooling base. Further, by disposing a sensor such as a thermistor in the sensor outer hole 23h and the sensor inner hole 22h, the physical quantity can be appropriately measured when the reactor 2 is used.

<Effect>
Reactor 2 having the above configuration is not provided with a case like reactor 1 of the first embodiment, and is small and light, but has outer resin portion 23 and inner resin portion 22c, thereby providing a magnetic core. 11 and the coil 22 can be protected from the external environment and mechanically protected. And reactor 2, the use of the coil molded product 22 A, during assembly, since the coil 22 is easy to handle without the coil 22 is elastic, excellent manufacturability. Further, by using the coil molded 22 A, can be omitted and the insulator, reducing the number of parts, and it is possible to reduce the step of placing these components, it is excellent in productivity from this viewpoint. Further, similarly to the reactor 1 of the first embodiment, the reactor 2 includes a sensor inner hole 22h and a sensor outer hole 23h that are simultaneously formed when the outer resin portion 23 and the inner resin portion 22c are molded. The positioning of the sensor can be easily performed, and there is almost no risk of damaging the coil 22 or the sensor in forming the holes 22h and 23h or the reactor including the sensor. In addition, it is easy to form the sensor inner hole 22h and the sensor outer hole 23h.

  In addition, in the reactor 2, like the reactor 1 of the first embodiment, the core base surface of the end core 11e and the molded body base surface 22d of the coil molded body 22A are exposed from the outer resin portion 23 and contact the cooling base. Since it is a structure, it is excellent in heat dissipation. Further, the reactor 2 can be made smaller because the end core 11e has a shape protruding from the coil winding portion 11c.

  Furthermore, the reactor 2 is provided with the flange portion 23f as a formation portion of the bolt hole 23b, so that the magnetic core 11 and the coil molded body 22A are excessively covered by the constituent resin of the outer resin portion 23, and the heat dissipation is reduced. Can be suppressed. In addition, in the reactor 2, by providing the recess 221 on the installation side of the coil molded body 22A, the surface area of the inner resin portion 22c can be increased, and the heat dissipation can be improved. Furthermore, in the reactor 2, since the outer peripheral surface of the coil molded body 22A is uneven, the contact area between the coil molded body 22A and the outer resin portion 23 is increased, and the adhesion between the two is enhanced.

(Modification 2)
In the second embodiment, the form in which the size (diameter) from the opening of the sensor outer hole 23h of the outer resin portion 23 to the bottom surface of the sensor inner hole 22h of the coil molded body 22A is uniform has been described. For example, the size of the sensor outer hole 23h of the outer resin portion 23 may be different from the size of the sensor inner hole 22h of the coil molded body 22A. More specifically, the sensor outer hole of the outer resin portion may be made larger than the sensor inner hole of the coil molded body to form a stepped hole having a large diameter on the opening side as a whole. In this case, a stepped material having a large diameter portion and a small diameter portion may be used as the columnar material inserted into the sensor inner hole of the coil molded body when the outer resin portion is molded. Then, as described in the first modification, if the sensor is formed in a T shape with resin or the like and is configured to stop against the step, the sensor can be prevented from falling out of the stepped hole. it can.

  The above-described embodiment can be appropriately changed without departing from the gist of the present invention, and is not limited to the above-described configuration.

  The reactor of this invention can be utilized suitably for the components of vehicle-mounted components, such as a vehicle-mounted converter mounted in vehicles, such as a hybrid vehicle, an electric vehicle, and a fuel cell vehicle, for example. The coil molded object of this invention can be utilized suitably for the component of the said reactor of this invention.

1,2 Reactor 10,20 Combined body 11 Magnetic core 11e End core 11c Coil winding part
11m core piece 11g gap material 12,22 coil 12a, 12b, 22a, 22b coil element
12w, 22w Winding 12d Coil base surface 13,23 Outer resin part 13h Sensor hole
13d Resin base surface 13b, 23b Bolt hole 14 Insulator 14b Cylindrical bobbin
14f Isobe
22A Coiled product 22c Inner resin part 22r Rewinding part 22h Sensor inner hole
22e End surface 22d Molded body base surface 23h Sensor outer hole 23f Flange
100 bolt 220 hollow hole 221 dent

Claims (6)

A reactor comprising a magnetic core and a coil disposed on the outer periphery of the magnetic core,
An outer resin portion covering the outer periphery of the combination of the magnetic core and the coil;
Comprising a sensor hole in which a sensor for measuring the physical quantity of the reactor is disposed ;
The coil includes a pair of coil elements, and both the coil elements are arranged so that the respective axial directions are parallel to each other,
Of the magnetic core, the surface on the cooling base side in the exposed portion where the coil is not disposed and the surface on the cooling base side in the coil are flush with each other,
The sensor hole is provided by resin molding of the outer resin portion at a location covering the coil elements in the outer resin portion ,
The cooling base side surface of the exposed portion of the magnetic core and the cooling base side surface of the coil are exposed from the outer resin portion,
A reactor characterized by having no case . A coil molded body comprising a coil formed by spirally winding a winding, and an inner resin portion that retains the shape of the coil;
A magnetic core on which the coil molded body is disposed;
An outer resin portion covering the outer periphery of the combined body of the coil molded body and the magnetic core;
Comprising a sensor inner hole and a sensor outer hole in which a sensor for measuring the physical quantity of the reactor is disposed;
The coil includes a pair of coil elements, and both the coil elements are arranged so that the respective axial directions are parallel to each other,
Of the magnetic core, the surface on the cooling base side in the exposed portion where the coil molded body is not disposed and the surface on the cooling base side in the coil molded body are flush with each other,
The sensor inner hole is provided by resin molding of the inner resin portion at a location covering the coil elements in the inner resin portion,
Outside the hole for the sensor communicates with the sensor hole of the internal resin portion, and is provided by the resin molding of the external resin portion,
The cooling base side surface of the exposed portion of the magnetic core and the cooling base side surface of the coil molded body are exposed from the outer resin portion,
A reactor characterized by having no case . 3. The reactor according to claim 2 , wherein the inner resin portion is made of a resin containing a ceramic filler. 4. The reactor according to claim 1, wherein the outer resin portion includes a bolt hole to which a bolt for fixing the reactor to a cooling base is attached . 5. The reactor according to claim 4, wherein the bolt hole is formed of a metal pipe . A converter comprising the reactor according to any one of claims 1 to 5 .

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