JP5861940B2 - Reactor, converter, and power converter - Google Patents

Description

  The present invention relates to a reactor used for a component part of a power conversion device such as a vehicle-mounted DC-DC converter mounted on a vehicle such as a hybrid vehicle. In particular, the present invention relates to a small reactor that can appropriately measure physical quantities (temperature, current value, etc.) during operation of the reactor.

  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 in a converter mounted on a vehicle such as a hybrid vehicle. The reactor includes a coil having a pair of coil elements, an annular magnetic core in which the coil is disposed, and a case that houses a combination of the coil and the magnetic core, and a seal that is filled in the case. What has a stop resin (secondary resin part, potting resin) is disclosed.

  When the coil generates heat with energization, the loss of the reactor increases due to this heat generation. Therefore, the reactor is generally used by being fixed to an installation target such as a cooling base so that the coil can be cooled. In addition, when a reactor is used, it is considered that a sensor for measuring a physical quantity such as a coil temperature or current is arranged in the vicinity of the reactor to control the current to the coil according to the measured temperature or current. . Patent Document 1 discloses a reactor in which sensors are arranged between coil elements in a direction orthogonal to both the side-by-side direction of both coil elements and the axial direction of the coil elements.

JP 2010-245458 A

  In the reactor of Patent Document 1, it is necessary to provide at least a gap corresponding to the thickness of the sensor between both coil elements. When the size of the gap and the thickness of the sensor are substantially equal, the coil element that has thermally expanded due to heat generation may press the sensor and damage the sensor. In particular, the region sandwiched between the inner core portions between the two coil elements has substantially no space for absorbing the thermal expansion of the coil element, and the pressing force due to the thermal expansion of the coil element is likely to be loaded on the sensor. Therefore, it is necessary to reduce the stress applied to the sensor (pressing force from the coil element), preferably to further prevent the stress from being applied, and to reduce the size of the reactor. difficult.

  Accordingly, one of the objects of the present invention is to provide a small reactor that can appropriately measure a physical quantity during operation of the reactor. Moreover, the other object of this invention is to provide the converter which provides the said reactor, and the power converter device which provides this converter.

  The present invention aims to achieve the above object by setting the shape of each coil element to a specific shape and setting the position of the sensor for measuring the physical quantity (coil temperature, current, etc.) during operation of the reactor as a specific position. Achieve.

  A reactor according to the present invention includes a coil including a pair of coil elements connected to each other, a pair of inner core portions disposed in each of the coil elements, and an outer core portion that connects these inner core portions to form a closed magnetic circuit. And a magnetic core. Further, the reactor includes a heat radiating plate on which the coil is placed, and a sensor that measures a physical quantity during operation of the reactor. Each of the coil elements is a cylindrical body formed by winding a winding in a spiral shape, and the end surface shape has a corner R portion with rounded corners so that the axes of the coil elements are parallel to each other. Are arranged in parallel. The sensor is disposed in a trapezoidal space formed by the corner R portion and the heat radiating plate disposed to face each other in each coil element.

  The reactor according to the present invention has a sufficient trapezoidal space according to the rounding radius of the corner R portion even when the coil elements are arranged side by side in the vicinity of the region sandwiched between the inner core portions of the pair of coil elements. Since the space can be large, the sensor can be sufficiently installed. That is, when the sensor is arranged in the trapezoidal space, the gap between the two coil elements can be made smaller than the thickness of the sensor, and thus the reactor can be miniaturized. In addition, the trapezoidal space is a so-called dead space formed by winding a winding so as to provide a corner R portion. However, the dead space can be effectively used by arranging a sensor in the space. For this reason, the reactor is not substantially enlarged.

  In addition, the reactor according to the present invention has a large part of the trapezoidal space sandwiched between the corners R, which deviates from the region sandwiched between both inner cores. It is possible to reduce the stress caused by the coil element to be applied, and preferably not to be applied substantially.

In the state where the reactor is placed on the heat sink, the trapezoidal space is formed on the upper side and the lower side of the reactor when the placement side when placed is the lower side and the opposite side is the upper side. . When the sensor is arranged in the trapezoidal space sandwiched between the corners R of each coil element on the upper side of the reactor, there is room for improvement in the following points.
(1) When the reactor includes a sealing resin, it is possible to store a combination of a coil and a magnetic core in a case, fill the case with the sealing resin, and cure the resin. In that case, when the sealing resin is filled, the sensor floats due to the resin, and the sensor cannot be fixed at a predetermined position.
(2) If the reactor does not contain sealing resin, the outer periphery of the sensor (especially in the case of a temperature sensor) will be uncovered and exposed to the atmosphere, and the sensor will be in a state other than the coil that is the measurement target (atmosphere). Physical quantities may be measured.

  The reactor of the present invention can be sandwiched between the corner R portion and the heat sink by arranging the sensor in a trapezoidal space sandwiched by the corner R portion of each coil element on the lower side of the reactor. When the reactor includes the sealing resin, the sensor can be prevented from being lifted by the resin. (2) When the reactor does not include the sealing resin, the sensor can be prevented from being exposed to the atmosphere.

  As one form of the reactor of this invention, the said heat sink has a joining layer which fixes the said coil, and the form in which the said sensor is being fixed by the said joining layer is mentioned.

  Since the sensor is fixed by the bonding layer, the sensor can be held more firmly. With the bonding layer, the coil can be fixed to the heat radiating plate and the sensor can be fixed at the same time. Therefore, the bonding process for individually bonding the coils can be simplified, and the assembly workability is excellent.

  As one form of the reactor of this invention, the sensor holder which hold | maintains the said sensor, and the insulator interposed between the said coil and the said magnetic core are provided, and the said sensor holder is integrally formed with the said insulator. A form is mentioned.

  By providing the sensor holder, the sensor can be held more firmly. Since the sensor holder is formed integrally with the insulator, when the sensor is assembled to the sensor holder, the assembly of the assembly and the insulator can be fixed to the heat sink and the sensor can be fixed at the same time. Excellent. Further, since the assembly and the sensor can be fixed to the heat radiating plate as an integrated body, the sensor can be easily positioned with respect to the coil, and the displacement of the sensor can be prevented.

  As one form of the reactor of this invention, the said sensor holder has the form comprised by the member independent of the said insulator.

  Since the sensor holder and the insulator are formed of independent members, the sensor can be easily arranged because the sensor can be assembled to the sensor holder after being assembled to the sensor holder.

  As one form of the reactor of the present invention in which the sensor holder and the insulator are independent members, the sensor holder includes a form including an engaging portion that engages with the insulator.

  When the sensor holder and the insulator are engaged, the positioning of the sensor holder can be facilitated. Further, the sensor holder can be more firmly fixed to the assembly, the sensor can be prevented from being displaced, and the assembly workability is excellent.

  The converter of the present invention includes the reactor of the present invention. The power converter of the present invention includes the converter of the present invention.

  The converter of this invention is small by providing the reactor of this invention which is small. Moreover, the power converter device of this invention is small by providing the converter of this invention which is small.

  The reactor of the present invention can be appropriately measured for physical quantities (coil temperature, etc.) during operation of the reactor, and is small in size.

FIG. 2 shows a reactor according to the first embodiment, where (A) is a perspective view and (B) is a cross-sectional view taken along line BB in FIG. FIG. 3 is an exploded perspective view schematically showing a combination of a coil and a magnetic core provided in the reactor of the first embodiment. FIG. 4 shows an insulator provided in the reactor of Embodiment 2, wherein (A) is a cross-sectional perspective view, and (B) is a cross-sectional view of FIG. 3 (A). FIG. 5 shows an insulator and a sensor holder included in the reactor of Embodiment 3, wherein (A) is a cross-sectional perspective view, and (B) is a cross-sectional view of FIG. 4 (A). FIG. 6 is an exploded perspective view showing an outline of a reactor according to a fourth embodiment. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of the power converter device of this invention provided with the converter of this invention.

  Embodiments of the present invention will be described below with reference to the drawings. In the drawings, the same reference numerals denote the same members. In the following description, the installation side when the reactor is installed will be described as the lower side, and the opposite side as the upper side.

<Embodiment 1>
A first embodiment of the present invention will be described with reference to FIGS.

≪Reactor overall structure≫
The reactor 1 connects a coil 2 having a pair of coil elements 2a and 2b connected to each other, a pair of inner core portions 31 (FIG. 2) disposed in the coil elements 2a and 2b, and the inner core portions 31, respectively. And a combination 10 with the magnetic core 3 having the outer core portion 32 forming a closed magnetic path. Furthermore, a bottom plate portion 40 (heat radiating plate) on which the coil 2 is placed and a sensor 7 for measuring a physical quantity during operation of the reactor 1 are provided. In addition, the reactor 1 of this example includes an insulator 5 interposed between the coil 2 and the magnetic core 3, and a bonding layer 42 at a position where the surface on the installation side of the coil 2 contacts in the bottom plate portion 40. . The main features of the reactor 1 are the shape of each coil element 2a, 2b and the position where the sensor 7 is arranged. Hereinafter, the characteristic part will be described first, and then other configurations will be described in more detail.

[coil]
The coil 2 will be described with reference mainly to FIG. 1 (B) and FIG. In FIG. 1B, for easy understanding, the coil 2, the sensor 7, and the bonding layer 42 are mainly shown, and the insulator 5 and the like are omitted.

  The coil 2 includes a pair of coil elements 2a and 2b formed by spirally winding a single continuous winding 2w having no joint part, and a coil connecting part 2r for connecting both the coil elements 2a and 2b. . Each coil element 2a, 2b is a hollow cylindrical body having the same number of turns, arranged in parallel (side by side) so that the respective axial directions are parallel, and wound on the other end side of coil 2 (right side in FIG. 2) A part of 2w is bent into a U shape to form a coil coupling portion 2r. With this configuration, the winding directions of both coil elements 2a and 2b are the same.

  In addition, it can be set as the coil which produced each coil element by a separate coil | winding, and joined one end part of the coil | winding of each coil element by welding, soldering, crimping | compression-bonding, etc.

  As the winding 2w, a coated wire having an insulating coating made of an insulating material can be suitably used on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof. The thickness of the insulating coating is preferably 20 μm or more and 100 μm or less, and the thicker the pinholes can be reduced and the electrical insulation can be improved. The conductor is typically a rectangular wire, and various other cross-sectional shapes such as a circular shape, an elliptical shape, and a polygonal shape can be used. The rectangular wire has the advantage that it is easy to form a coil having a higher space factor than when a round wire having a circular cross section is used, and it is easy to ensure a wide contact area with the bonding layer. Here, the conductor is made of a copper rectangular wire, and the insulation coating is made of a coated rectangular wire made of enamel (typically polyamideimide). Edgewise coil.

  Both end portions 2e of the winding forming the coil 2 are appropriately extended from the turn forming portion on one end side (left side in FIG. 2) of the coil 2 (FIG. 1 (A)). A terminal member (not shown) made of a conductive material is connected to the conductor portion exposed by peeling off the insulation coating at both ends 2e of the winding, and power is supplied to the coil 2 through this terminal member. An external device (not shown) such as a power source is connected.

  Each of the coil elements 2a and 2b has an end face shape viewed from the axial direction (= a shape cut by a plane perpendicular to the axial direction), a rounded rectangular corner, and four corner R portions 21, A long linear portion 22 and a short linear portion 23 connecting the corner R portions 21 are formed. Accordingly, the outline of each coil element 2a, 2b is a figure composed of a curve forming the corner R portion 21 and a straight line forming the linear portions 22, 23, as shown in FIG. is there.

  The end face shape of each coil element 2a, 2b can be a shape obtained by rounding the corners of a polygon other than the rectangle. However, the above-mentioned shape with rounded corners of the rectangle is (1) easy to wind the winding 2w and excellent in manufacturability of the coil. (2) The inner peripheral shape is simple and similar to the inner peripheral shape of the coil element. There is an advantage that it is easy to form an inner core portion having a simple outer peripheral shape, and (3) a small size with little dead space.

  The rounding radius of the corner R portion 21 can be selected as appropriate. The rounding radius may be selected in consideration of the size of the coil 2 and the size of the winding 2w to be used (width and thickness in the case of a flat wire). In particular, when the coil 2 is an edgewise coil, it is easy to increase the rounding radius on the outer peripheral side in the winding 2w that constitutes the corner R portion 21, and between the adjacent coil elements 2a and 2b, the storage location of the sensor 7 It is easy to take a large trapezoidal space.

  In each of the coil elements 2a and 2b, a slight gap g is provided between the linear portions 22 as shown in FIG. 1B to enhance the insulation between the coil elements 2a and 2b. However, the gap g is smaller than the thickness (for example, about 3 mm) of the sensor 7 described later and larger than the wiring 71 connected to the sensor 7 (for example, about 2 mm). In this example, the gap g is secured by partition pieces 53a and 53b (FIG. 2) of the insulator 5 described later. In this gap g, a wiring 71 connected to the sensor 7 described later is interposed.

The coil 2 having the corner R portion 21 on the lower side of the reactor 1 is formed by the corner R portion 21 and the bottom plate portion 40 arranged to face each other in the coil elements 2a and 2b, as shown in FIG. A trapezoidal space. The trapezoidal space is formed on the upper side and the lower side of the reactor 1, but the lower trapezoidal space is used in the present invention. Specifically, this trapezoidal space is the intersection of the lower corner R portion 21 of one coil element 2a and the long linear portion 22 connected to the corner R portion 21, and the lower corner R of the other coil element 2b. A straight line l _r connecting the intersection of the section 21 and the long linear section 22 connected to the corner R section 21, a curve constituting the corner R section 21 of both coil elements 2a and 2b, and a bottom plate section 40 (both coil elements 2a, a space surrounded by the lower surface 2d of 2b). The present invention is characterized in that a trapezoidal space formed by the lower corner R portion 21 and the bottom plate portion 40 of both the coil elements 2a and 2b is used as a space for arranging the sensor 7.

  The size of the trapezoidal space can be adjusted by the rounding radius of the corner R portion 21. If the rounding radius is large, the storage space for the sensor 7 is likely to be large, and if the rounding radius is small, a small coil is likely to be obtained.

In the trapezoidal space, the sensor 7 is preferably arranged in a region not sandwiched by the inner core portion 31. In this example, the inner core portion 31 having an outer peripheral shape similar to the inner peripheral shape of the coil elements 2a and 2b is accommodated coaxially in each of the coil elements 2a and 2b, and connects the lower surfaces of these inner core portions 31. When a straight line (tangent) l _c is taken, a region below the tangent l _c is a region not sandwiched by the inner core portion 31. In this example, as shown in FIG. 1 (B), a region of the trapezoidal space that is not sandwiched between the inner core portions 31 (the tangent line l _c and the lower corner R portion 21 of each coil element 2a, 2b The sensor 7 is arranged in a region surrounded by the curve to be formed.

  The trapezoidal space is formed from one end surface of the coil 2 to the other end surface, and the sensor 7 can be disposed at this arbitrary location. However, in the trapezoidal space, it is preferable that an intermediate region including the center of the coil 2 in the axial direction is an arrangement region of the sensor 7. The intermediate region is, for example, a region from the center to one end side or the other end side of the coil 2 up to 30% of the axial length of the coil 2, that is, the axial length of the coil 2 including the center. An area of 60% is mentioned.

[Sensor]
Here, the sensor 7 is a temperature sensor, and includes a rod-like body including a thermal element 7a such as a thermistor and a protective portion 7b that protects the thermal element 7a. Examples of the protective part 7b include tubes made of resin. Connected to the sensor 7 is a wiring 71 (FIG. 1B) for transmitting sensed information to an external device such as a control device. Examples of the sensor include a sensor for measuring a physical quantity during operation of the reactor, such as a current sensor, a voltage sensor, and an acceleration sensor capable of measuring the vibration of the reactor, in addition to the temperature sensor.

  In a state where the reactor 1 is installed on the cooling base (not shown), the surface on the installation side of the coil 2 (the lower surface 2d (FIG. 1 (B))) to the opposite surface (the upper surface 2u (FIG. 1 (B))) When the temperature distribution between the coil elements 2a and 2b was examined, the intermediate portion in the height direction between the coil elements 2a and 2b is the highest temperature location, and the temperature decreases as the distance from the highest temperature location increases. The lower surface 2d and the area in the vicinity thereof are the lowest temperature places because they are cooled by the cooling base. Therefore, by measuring the temperature distribution between the temperature and the maximum temperature in the lower trapezoidal space in advance, when the temperature is measured in the trapezoidal space, the correlation of the reactor at that time is determined from the correlation due to this temperature distribution. The maximum temperature is required. Therefore, it is possible to control the current to the coil 2 according to the measured temperature.

(Bottom plate (heat sink))
The bottom plate portion 40 (heat radiating plate) is typically a plate material fixed in contact with the installation target when the reactor 1 is installed on the installation target (FIG. 1). Since the bottom plate portion 40 is used for the heat dissipation path of the coil 2, it is generally made of a metal that is a material having high thermal conductivity. Specific examples of the metal include aluminum and its alloys, magnesium and its alloys, copper and its alloys, silver and its alloys, iron and austenitic stainless steel. Aluminum, magnesium and their alloys are lightweight and can be a lightweight reactor. The thickness of the bottom plate portion 40 is, for example, about 2 mm to 5 mm in consideration of strength, shielding properties, heat dissipation properties, noise characteristics, and the like. Here, the bottom plate portion 40 is made of an aluminum alloy. The bottom plate portion 40 has a bonding layer 42 formed on the entire surface where the surface on the installation side of the coil 2 contacts.

  The bottom plate portion 40 may form a protrusion along the two-axis direction of the coil when the combined body 10 is placed on the bottom plate portion 40 at a location facing the trapezoidal space. By this protrusion, when the sensor 7 is placed on the bottom plate portion 40, the sensor 7 is easily positioned and placed. By disposing the sensor 7 on the ridge, the sensor 7 can be brought close to the coil 2 side, and the sensor 7 can be easily brought into contact with the corner R portion 21 of the coil 2. Further, the amount of adhesive for the bonding layer 42 formed in the trapezoidal space can be reduced.

  The outer shape of the bottom plate portion 40 can be selected as appropriate. Here, the bottom plate portion 40 has a rectangular shape as shown in FIG. 1 (A), and has mounting portions 400 protruding from the four corners. Here, an installation state in which the bottom plate portion 40 is downward is shown, but there may be an installation state in which the bottom plate portion 40 is upward or lateral.

(Bonding layer)
The bottom plate portion 40 includes a bonding layer 42 at a location where at least a surface on the installation side of the coil 2 (the lower surface 2d (FIG. 1B)) contacts. In the present invention, the sensor 7 is disposed on the bonding layer 42 and the sensor 7 disposed in the trapezoidal space described above is held in contact with the coil 2.

  The bonding layer 42 can be easily formed by a single layer structure made of an insulating material, and can insulate the coil 2 and the bottom plate portion 40 even if the bottom plate portion 40 is made of metal. Insulating properties can be further improved by using a multilayer structure made of an insulating material. When a multilayer structure of the same material is used, the thickness per layer can be reduced. Even if a pinhole exists by making it thin, insulation can be ensured by closing the pinhole with another adjacent layer. On the other hand, when the multi-layer structure is made of different materials, a plurality of characteristics such as insulation between the coil 2 and the bottom plate 40, adhesion between the two, and heat dissipation from the coil 2 to the bottom plate 40 can be provided. In this case, at least one constituent material is an insulating material.

  The shape of the bonding layer 42 is not particularly limited as long as at least the surface (lower surface 2d) on the installation side of the coil 2 has a sufficient contact area. Here, the bonding layer 42 has a shape along the shape formed by the surface on the installation side of the combined body 10, that is, the surfaces on the installation side of both the coil 2 and the outer core portion 32. Therefore, both the coil 2 and the outer core portion 32 can sufficiently contact the bonding layer 42.

  In particular, the bonding layer 42 is a multilayer including an adhesive layer made of an insulating material on the surface side where the installation side surface of the coil 2 contacts, and a heat dissipation layer made of a material having excellent thermal conductivity on the side contacting the bottom plate portion 40. A structure is preferred. Here, the bonding layer 42 includes an adhesive layer and a heat dissipation layer.

  For the adhesive layer, a material having excellent adhesive strength can be suitably used. For example, the adhesive layer can be composed of an insulating adhesive, specifically, an epoxy adhesive, an acrylic adhesive, or the like. For example, the adhesive layer may be formed on the heat dissipation layer or screen printing may be used. A sheet-like adhesive may be used for the adhesive layer. Here, the adhesive layer has a single-layer structure of an insulating adhesive.

  For the heat dissipation layer, a material having excellent heat dissipation, preferably a material having a thermal conductivity of more than 2 W / m · K can be suitably used. The heat dissipation layer preferably has a higher thermal conductivity, and should be composed of a material of 3 W / m · K or higher, particularly 10 W / m · K or higher, more preferably 20 W / m · K or higher, especially 30 W / m · K or higher. preferable.

Specific examples of the constituent material of the heat dissipation layer include a metal material. A metal material is generally a conductive material having a high thermal conductivity, and it is desired to improve the insulating properties of the adhesive layer. Moreover, the heat dissipation layer made of a metal material tends to be heavy. On the other hand, if a non-metallic inorganic material such as ceramics such as a material selected from oxides, carbides, and nitrides of metal elements, B, and Si is used as a constituent material of the heat dissipation layer, heat dissipation is excellent. It is also preferable because of its excellent electrical insulation. More specific ceramics are silicon nitride (Si ₃ N ₄ ): about 20 W / m · K to 150 W / m · K, alumina (Al ₂ O ₃ ): about 20 W / m · K to about 30 W / m · K, Aluminum nitride (AlN): 200W / m ・ K ~ 250W / m ・ K, Boron nitride (BN): 50W / m ・ K ~ 65W / m ・ K, Silicon carbide (SiC): 50W / m ・ K About 130W / m · K. In order to form the heat dissipation layer with the ceramic, for example, a vapor deposition method such as PVD method or CVD method is used, or a sintered plate of the ceramic is prepared and bonded to the bottom plate portion 40 with an appropriate adhesive. Can be mentioned.

  Alternatively, the constituent material of the heat dissipation layer includes an insulating resin (for example, an epoxy resin or an acrylic resin) containing a filler made of the above ceramics. This material provides a heat dissipation layer that is excellent in both heat dissipation and electrical insulation. In this case, since both the heat dissipation layer and the adhesive layer are made of an insulating material, that is, the whole bonding layer is made of an insulating material, the bonding layer is further excellent in insulation. When the insulating resin is an adhesive, the adhesiveness between the heat dissipation layer and the adhesive layer is excellent, and the bonding layer including the heat dissipation layer can firmly bond the coil 2 and the bottom plate portion 40. The adhesives constituting the adhesive layer and the heat dissipation layer may be different, but if they are the same type, the adhesive layer is excellent and the bonding layer can be easily formed. You may form the whole joining layer with the said insulating adhesive containing a filler. In this case, the bonding layer has a single layer structure made of a single kind of material.

  In order to form the heat dissipation layer with the filler-containing resin, it can be easily formed by, for example, applying to the bottom plate portion 40 or screen printing.

  The heat dissipation layer may be a single layer structure or a multilayer structure. In the case of a multi-layer structure, at least one layer of materials may be different. For example, the heat dissipation layer can have a multilayer structure made of materials having different thermal conductivities.

  The thickness of the bonding layer 42 is 0.2 mm or more, more preferably 1 mm or more. When the thickness of the bonding layer 42 is 3 mm or more, the sensor 7 can be disposed in the bonding layer 42 and held more firmly. The thickness of the bonding layer 42 is the thickness before the combined body 10 is placed. As for the thickness of the bonding layer 42, a region where the sensor 7 is disposed may be partially thickened. The sensor 7 can be disposed in the bonding layer 42 or can be in contact with the coil 2.

[Magnetic core]
The magnetic core 3 will be described with reference to FIG. The magnetic core 3 has a pair of inner core portions 31 covered with the coil elements 2a and 2b, and a pair of outer core portions 32 that are not disposed on the coil 2 and are exposed from the coil 2. Here, each inner core portion 31 is a columnar body having an outer shape obtained by rounding the corners of a rectangular parallelepiped along the inner peripheral shape of each coil element 2a, 2b as described above, and each outer core portion 32 is Each is a columnar body having a pair of trapezoidal surfaces. The magnetic core 3 has an outer core portion 32 disposed so as to sandwich the inner core portion 31 that is spaced apart, and the end surface 31e of each inner core portion 31 and the inner end surface 32e of the outer core portion 32 are in contact with each other to form an annular shape. Formed. The inner core portion 31 and the outer core portion 32 form a closed magnetic path when the coil 2 is excited.

  As shown in FIG. 2, the inner core portion 31 is a laminate in which a plurality of core pieces 31m made of a soft magnetic material and gap members 31g made of a material having a relative permeability smaller than that of the core pieces 31m are alternately stacked. It is a thing. When the core piece 31m and the gap material 31g are integrated with an adhesive, it is easy to handle and it is expected that noise can be reduced by firmly fixing the core piece 31m and the gap material 31g. In addition, when the core piece 31m and the gap material 31g are integrated with an adhesive tape or the like, it is easy to handle. The outer core portion 32 is a core piece made of a soft magnetic material.

  The core pieces constituting the inner core portion 31 and the outer core portion 32 have a molded body using a soft magnetic powder typified by an iron group metal such as iron or an alloy thereof, an oxide containing iron, or an insulating coating. A laminated plate body in which a plurality of magnetic thin plates (for example, an electromagnetic steel plate typified by a silicon steel plate) is laminated may be mentioned. Examples of the molded body include a compacted body, a sintered body, and a composite material obtained by injection molding or cast molding a mixture including soft magnetic powder and resin. Here, each core piece is a powder compact of soft magnetic metal powder containing iron such as iron or steel.

  The specific material of the gap material 31g is a mixture containing a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as polyphenylene sulfide (PPS) resin, and magnetic powder (for example, soft magnetic powder such as iron powder). Etc. Here, a known material can be used as the gap material 31g.

  Here, each core piece constituting the magnetic core 3 has the same specification (compact compact) made of a uniform material, but the inner core portion 31 and the outer core portion 32 are magnetic. Characteristics and specifications can be varied. For example, it is possible to adopt a form in which a green compact and a composite material are combined, or a form in which composite materials having different materials and mixed amounts of soft magnetic powder are combined.

  In addition, in the magnetic core 3 shown in this example, the installation side surface of the inner core portion 31 and the installation side surface of the outer core portion 32 are not flush with each other, and the installation side surface of the outer core portion 32 is It protrudes from the inner core portion 31 and is flush with the surface on the installation side of the coil 2 (the lower surface 2d in FIG. 1 (B)). Therefore, the surface on the installation side of the combination 10 of the coil 2 and the magnetic core 3 is composed of the lower surface 2d of both the coil elements 2a and 2b and the surface on the installation side of the outer core portion 32, and the coil 2 and the magnetic core Since both 3 can contact the bonding layer 42, the reactor 1 is excellent in heat dissipation. Further, since the surface on the installation side of the combined body 10 is composed of both the coil 2 and the magnetic core 3, the contact area with the fixed object is sufficiently large, and the reactor 1 is excellent in stability when installed. Furthermore, by configuring the core piece with a compacted body, a portion of the outer core portion 32 that protrudes from the inner core portion 31 can be used as a magnetic flux passage.

[Insulator]
The insulator 5 will be described with reference to FIG. The insulator 5 includes a cylindrical portion 51 that houses the inner core portion 31, and a frame plate portion 52 that is interposed between the end surfaces of the coil elements 2a and 2b and the inner end surface 32e of the outer core portion 32. The cylindrical part 51 insulates the coil elements 2a, 2b and the inner core part 31, and the frame plate part 52 insulates the end faces of the coil elements 2a, 2b and the inner end face 32e of the outer core part 32.

  The cylindrical portion 51 is configured by cylindrical divided pieces 50a and 50b along the outer peripheral shape of the inner core portion 31, and the pair of divided pieces 50a and 50b are combined and integrated. The shapes of the split pieces 50a and 50b can be selected as appropriate. Here, when the divided pieces 50a and 50b are arranged on the outer peripheral surface of the inner core portion 31, a part of the inner core portion 31 is exposed. Therefore, when the sealing resin is provided, it is easy to deaerate when filled with the sealing resin, and it is excellent in manufacturability, and the contact area between the inner core portion 31 and the sealing resin can be increased, and noise is suppressed. It is expected to be possible.

  The frame plate portion 52 is a B-shaped flat plate portion having a pair of openings (through holes) into which the two inner core portions 31 can be inserted. The frame plate portion 52 is arranged between the partition pieces 53a and 53b arranged so as to be interposed between the coil elements 2a and 2b, and the coil connecting portion 2r and the outer core portion 32 when assembled to the coil 2. And a flat pedestal 52p. The partition pieces 53a and 53b protrude from the one surface of the frame plate portion 52 toward the coil side, and the pedestal 52p protrudes from the other surface of the frame plate portion 52 toward the outer core portion 32 side. The partition pieces 53a and 53b and the base 52p may be omitted.

  As the constituent material of the insulator 5, insulating materials such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, and liquid crystal polymer (LCP) can be used.

≪Manufacture of reactors≫
Typically, the reactor 1 having the above-described configuration can be manufactured by a process of preparing an assembly, preparing a bottom plate, fixing a sensor, and fixing the assembly.

[Preparation of union]
First, a procedure for producing the combination 10 of the coil 2 and the magnetic core 3 will be described. Specifically, as shown in FIG. 2, the inner core portion 31 in which the core pieces 31m and the gap material 31g are laminated and one divided piece 50a of the insulator 5 are inserted into the coil elements 2a and 2b. Here, the inner core portion 31 is formed in a columnar shape by connecting the outer peripheral surfaces of the laminated body of the core piece 31m and the gap material 31g with an adhesive tape. Next, the other split piece 50b of the insulator 5 is inserted into the other end face of the coil elements 2a and 2b. The core piece 31m and the gap member 31g may be separated from each other without being integrated with an adhesive tape or an adhesive. In this case, a part of the core pieces 31m and the gap material 31g are supported by the one divided piece 50a, and the other core pieces 31m and the gap material 31g are supported by the other divided piece 50b, whereby the coil elements 2a, 2b are supported. It is good to insert in.

  Next, the frame plate portion 52 and the outer side of the coil 2 are sandwiched between the end surface 31e of both the coil elements 2a and 2b and the end surface 31e of the inner core portion 31 between the frame plate portion 52 of the insulator 5 and the inner end surface 32e of the outer core portion 32. The core part 32 is arrange | positioned and the assembly 10 is formed. At this time, the end surface 31e of the inner core portion 31 is exposed from the opening of the frame plate portion 52 and contacts the inner end surface 32e of the outer core portion 32. Partition pieces 53a and 53b of the insulator 5 are interposed between the two coil elements 2a and 2b, and a gap g corresponding to the thickness of the partition pieces 53a and 53b can be provided between the two elements 2a and 2b.

[Preparing the bottom plate]
An aluminum plate is punched into a predetermined shape to form a bottom plate portion 40, and a bonding layer 42 having a predetermined shape is formed on one surface so as to have a thickness of 0.2 mm or more (here 1 mm). A bottom plate portion 40 is prepared.

[Fix sensor and assembly]
The sensor 7 is placed at a predetermined position on the bonding layer 42. At this time, when the combination 10 is disposed, the sensor 7 is placed so as to be positioned in the central region of the coil 2 in the axial direction. Then, the assembled assembly 10 is placed on the bonding layer 42 so that the sensor 7 is disposed in a trapezoidal space formed below the two coil elements 2a and 2b. At this time, the wiring 71 connected to the sensor 7 is drawn from the upper side of the coil 2 through the gap g from the lower side between the coil elements 2a and 2b. Thereafter, the bonding layer 42 is appropriately cured to fix the combined body 10 and the sensor 7 to the bottom plate portion 40.

≪Usage≫
The reactor 1 described above is used in applications where the energization conditions are, for example, maximum current (DC): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, and operating frequency: about 5 kHz to 100 kHz, typically an electric vehicle or a hybrid It can be suitably used for a component part of an in-vehicle power converter such as an automobile.

≪Effect≫
The reactor 1 of the present invention is applied to the sensor 7 by arranging the sensor 2 in a trapezoidal space formed by a specific region: the corner R portion 21 having the coil 2 having a specific shape. The stress (stress caused by the thermally expanded coil 2) can be reduced or no stress is applied. Therefore, the sensor 7 is not damaged by the stress, and the reactor 1 can appropriately measure the temperature of the coil 2. And trapezoidal space reactor 1, so-called a dead space, less susceptible to the stress, or substantially disposed in the sensor 7 a (lower region than the tangent l _c in the trapezoidal region) region where the stress is not loaded This is an area. Therefore, the reactor 1 is small without causing an increase in size due to the arrangement of the sensor 7 or an increase in size for protection of the sensor 7.

  The reactor 1 of the present invention employs a space sandwiched between the corner R portions 21 of the coil elements 2a and 2b on the lower side of the reactor 1 as the trapezoidal space, so that the sensor 7 includes the corner R portion 21 and the bottom plate. Can be enclosed with part 40. Therefore, when the reactor includes the sealing resin, the sensor can be prevented from floating by the resin, and when the reactor does not include the sealing resin, the sensor can be prevented from being exposed to the atmosphere. The sensor 7 can be bonded more firmly by being fixed by the bonding layer 42 formed on the bottom plate portion 40. Although the sensor 7 may not be in contact with the coil 2, if the sensor 7 is in contact with the coil 2, the reliability of the measured value is considered high. In addition, the coil 2 can be fixed to the bottom plate portion 40 by the bonding layer 42, and the sensor 7 can be fixed at the same time, so that the assembly workability is excellent.

<Embodiment 2>
In the first embodiment described above, the sensor 7 is fixed by the bonding layer 42 formed on the bottom plate portion 40. In addition, as shown in FIG. 3, the sensor 7 can be held by the sensor holding portion 54 (sensor holder). The sensor holding portion 54 is formed integrally with the insulator 5. Hereinafter, this difference will be mainly described with reference to FIG. 1 (B) as appropriate, and the other configuration is the same as the configuration of Embodiment 1, and thus the description thereof will be omitted. First, the insulator which is the difference will be described, and then the method for manufacturing the reactor of the second embodiment will be described.

[Insulator]
The frame plate portion 52 of the insulator 5 includes a sensor holding portion 54 on the lower side. The sensor holding part 54 may be a rod-like body provided so as to protrude toward the trapezoidal space of the coil 2 when the divided piece 50b is assembled to the coil 2. The protruding length of the sensor holding portion 54 may be appropriately selected as long as the sensor 7 can be held in contact with the coil 2 side and the sensor 7 can be assembled to the sensor holding portion 54. Here, the sensor holding portion 54 has a protruding length such that about 1/2 of the axial length of the sensor 7 (left and right length in FIG. 3B) is in contact with the sensor holding portion 54. Yes.

  The frame plate portion 52 of the split piece 50b includes an L-shaped partition piece 53b disposed so as to be interposed between the coil elements 2a and 2b when assembled to the coil 2, and has an L-shaped short side. A portion is provided below the frame plate portion 52. The short side portion of the partition piece 53b serves as a connection portion between the sensor holding portion 54 and the frame plate portion 52, and the end surface of the short side portion serves as a stopper for the sensor 7, as shown in FIG. Therefore, the sensor 7 can be held by the sensor holding portion 54 and can be positioned in the axial direction with respect to the coil 2 by the position of the end face of the partition piece 53b. At this time, the protruding length is adjusted so that the sensor 7 can be held in a state where the sensor 7 is positioned in the central region of the coil 2 in the axial direction. Here, the sensor 7 is held in contact with the coil 2 side.

≪Manufacture of reactors≫
Typically, a reactor having the above-described configuration can be manufactured by a process of preparing an assembly, fixing a sensor to the assembly, preparing a bottom plate, and fixing the assembly with a sensor to the bottom plate. Since the preparation process of the combined body and the bottom plate portion is the same as that of the first embodiment, here, the step of fixing the sensor to the combined body and the step of fixing the combined body with the sensor to the bottom plate portion will be described.

[Fix the sensor to the union]
First, the sensor 7 is assembled to the sensor holding portion 54. The sensor 7 is inserted into a space sandwiched between the corner R portion 21 of both the coil elements 2a and 2b and the sensor holding portion 54 of the insulator 5. At this time, the sensor 7 is inserted so that the axial direction of the sensor 7 is along the axial direction of the coil elements 2a and 2b, with the end face of the partition piece 53b of the split piece 50b of the insulator 5 being a stopper. When the sensor 71 is inserted into the sensor holding portion 54, the wiring 71 connected to the sensor 7 passes through the gap g between the coil elements 2a and 2b from the side opposite to the side where the sensor 7 is disposed. Pull it out. By doing so, the sensor 7 can be held in a state of being sandwiched between the corner R portion 21 and the sensor holding portion 54 of both the coil elements 2a and 2b and in contact with the coil 2 side. This sensor assembly work is facilitated when the lower surface of the coil 2 is faced up.

[Fixed assembly with sensor on bottom plate]
On the bonding layer 42 formed on the bottom plate part 40, the assembly 10 (assembly) in which the sensor 7 is assembled is placed. At this time, the sensor 7 is mounted so that the side on which the sensor 7 is assembled faces the bonding layer 42. Thereafter, the bonding layer 42 is appropriately cured to fix the combined body 10 with the sensor 7 to the bottom plate portion 40.

≪Effect≫
According to the configuration of the second embodiment, the sensor 7 is fixed to the assembly of the combined body 10 and the insulator 5, and then the assembly and the sensor 7 are fixed to the bottom plate portion as an integrated body. It is easy to position the sensor 7. Since the positioning state can be held by the sensor holding portion 54, the displacement of the sensor 7 can also be prevented. Further, the assembly can be fixed to the bottom plate portion 40 and the sensor 7 can be fixed at the same time, so that the assembly workability is excellent.

<Embodiment 3>
In Embodiment 2 described above, the form in which the sensor holding portion 54 (sensor holder) is integrally formed with the insulator 5 has been described. In addition, as shown in FIG. 4, the sensor holder 8 may be a member independent of the insulator 5. Hereinafter, this difference will be mainly described with reference to FIG. 1 (B) as appropriate, and the other configuration is the same as the configuration of Embodiment 1, and thus the description thereof will be omitted. First, a sensor holder which is a difference will be described, and then a method for manufacturing the reactor according to the third embodiment will be described.

[Sensor holder]
The sensor holder 8 is a strip-shaped mounting portion 8a on which the sensor 7 is mounted, and a holding portion 8b that is arranged by forming a lateral side of an L-shaped slit between the mounting portion 8a, The holding part 8b includes a plate-like partition part 8c extending on the opposite side of the mounting part 8a, and a drawer part 8h arranged to form the vertical side of the L-shaped slit. Here, the placement portion 8a, the holding portion 8b, and the partition portion 8c. The drawer portion 8h is integrally formed. The horizontal side of the slit is a storage space for the sensor 7. When the sensor 7 is stored in the slit, the upper and lower sides of the sensor 7 are sandwiched between the holding portion 8b and the mounting portion 8a, and the left and right sides are opened. Yes. The vertical side of the slit is a storage space for the wiring 71 connected to the sensor 7, and one end of the wiring 71 is drawn out of the reactor 1.

  The mounting portion 8a is a rod-like body having one end side integrated with the holding portion 8b and the other end side connected to the drawer portion 8h. The placement portion 8a includes a sensor stop 8i so that the sensor 7 does not fall off in a state where the sensor 7 is placed. The sensor stops 8i are preferably provided at both ends of the sensor 7 so as not to damage the thermal element 7a of the sensor 7 when the sensor 7 is placed. The surface of the mounting portion 8a that contacts the sensor 7 is an arcuate curved surface similar to the outer shape of the sensor 7.

  The partition portion 8c is a plate-like body disposed in the gap g provided between the linear portions 22 in each of the coil elements 2a and 2b, and is a rectangular plate-like body here. The thickness of the partition portion 8c is equal to or less than the gap g between the coil elements 2a and 2b and is smaller than the thickness of the sensor 7. The partition portion 8c includes a main body portion 8d that extends in the axial direction of the coil 2, and an engagement portion 8e that contacts the frame plate portion 52 of the insulator 5 and engages with the engagement portion 53e formed on the frame plate portion 52. Prepare. The main body portion 8d is tapered such that both side surfaces on the distal end side in the direction in which the sensor holder 8 is inserted into the gap g are reduced in width toward the distal end. The engaging portion 8e has a hook 8f protruding toward the frame plate portion 52 at the end on the tip side. The shape of the hook 8f is tapered so as to become thinner toward the tip.

  The lead portion 8h is rounded so that the wire 71 is not damaged by hitting the corner of the sensor holder 8 when the wire 71 is pulled out.

  When the sensor holder 8 is inserted into the gap g, the hook 8f of the engaging portion 8e is engaged and positioned with the engaging portion 53e of the frame plate portion 52, and the sensor holder 8 can be prevented from falling off. In the present embodiment, a gap 8g is provided between the hook 8f and the engaging portion 53e. With this gap 8g, even if the sensor holder 8 is once inserted, the sensor holder 8 can be pulled out until the hook 8f is stopped against the engaging portion 53e, and the sensor 7 can be easily taken in and out at any time. .

  In a state where the sensor holder 8 is inserted into the gap g, the sensor 7 is in contact with the corner R portion 21 of each of the coil elements 2a and 2b at a portion exposed from the sensor holder 8.

  As the constituent material of the sensor holder 8, the same insulating material as the insulator 5 such as polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, polybutylene terephthalate (PBT) resin, liquid crystal polymer (LCP) is used. it can. In this case, even when the sensor holder 8 is arranged in contact with the coil 2, the insulation between them is excellent. Further, when at least a part of the sensor holder 8 is made of metal, an improvement in heat dissipation can be expected.

≪Manufacture of reactors≫
Typically, a reactor having the above-described configuration can be manufactured by a process of preparing an assembly, fixing a sensor to the assembly, preparing a bottom plate, and fixing the assembly with a sensor to the bottom plate. Since the preparation process of the combined body and the bottom plate portion is the same as that of the first embodiment, here, the step of fixing the sensor to the combined body and the step of fixing the combined body with the sensor to the bottom plate portion will be described.

[Fix the sensor to the union]
First, the sensor 7 is assembled to the sensor holder 8. The sensor 7 is placed on the placement portion 8a of the sensor holder 8, and the sensor 7 is held by the placement portion 8a, the holding portion 8b, and the sensor stopper 8i, whereby the sensor 7 is held by the sensor holder 8. At this time, the sensor 7 is held at an intermediate position in the width direction of the sensor holder 8. The wiring 71 connected to the sensor 7 is arranged along the lead portion 8h, and one end is drawn to the outside. Next, the sensor holder 8 holding the sensor 7 is arranged in a trapezoidal space formed below the two coil elements 2a and 2b. Here, the partition portion 8c of the sensor holder 8 is inserted into the gap g provided between the coil elements 2a and 2b, and the hook 8f of the sensor holder 8 and the engagement portion 53e of the frame plate portion 52 are engaged. Integrate both. By doing so, the sensor 7 is fixed at the corner R portion 21 of the two coil elements 2a and 2b and the sensor holder 8, and the two coils are exposed at the positions exposed from the placement portion 8a and the holding portion 8b of the sensor holder 8. The state is in contact with the coil 2 at the corner R portion 21 of the elements 2a and 2b.

  Here, after assembling the sensor 7 to the sensor holder 8, the placement portion 8a and the holding portion 8b of the sensor holder 8 are arranged in the trapezoidal space, but the placement portion 8a and the holding portion 8b of the sensor holder 8 are trapezoidal. The sensor 7 may be assembled to the sensor holder 8 after being arranged in the space. At this time, the partition portion 8c of the sensor holder 8 is inserted into the gap g and integrated with the frame plate portion 52. However, since there is a gap 8g between the hook 8f and the engagement portion 53e, the hook 8f is engaged with the engagement portion. The sensor holder 8 can be pulled out until it is stopped by 53e, and the sensor 7 can be assembled in this state.

[Fixed assembly with sensor on bottom plate]
On the bonding layer 42 formed on the bottom plate portion 40, the combined body 10 in which the sensor 7 is assembled is placed. At this time, the sensor 7 is mounted so that the side on which the sensor 7 is assembled faces the bonding layer 42. Thereafter, the bonding layer 42 is appropriately cured to fix the combined body 10 with the sensor 7 to the bottom plate portion 40.

≪Effect≫
According to the configuration of the third embodiment, since the sensor holder 8 and the insulator 5 are configured by independent members, the sensor 7 is assembled to the sensor holder 8 and then assembled to the assembly of the combined body 10 and the insulator 5. Since it can be arranged, the sensor 7 is easy to arrange. Further, when the sensor holder 8 and the insulator 5 (frame plate portion 52) are provided with engaging portions, the sensor holder 8 can be easily positioned by engaging both. In addition, the sensor holder 8 can be more firmly fixed to the assembly, the positional deviation of the sensor 7 can be prevented, and the assembly workability is excellent.

<Embodiment 4>
In Embodiments 1 to 3 described above, the form in which the outer periphery of the combined body 10 is not covered and exposed to the atmosphere has been described. In addition, the outer periphery of the combined body 10 can be formed by coating with resin by injection molding or the like. In this embodiment, since the outer periphery of the combined body 10 is covered with resin, the combined body 10 can be protected from the external environment such as dust and corrosion, and mechanical characteristics such as strength can be ensured. Examples of the resin include epoxy resin, unsaturated polyester, urethane resin, PPS resin, PBT resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like. When this resin contains the filler made of the above-mentioned ceramic, the heat dissipation can be enhanced.

<Embodiment 5>
In Embodiments 1 to 4 described above, the form in which the case is omitted has been described. In addition, it can be set as the form which provides a case. The reactors of Embodiments 1 to 4 can be used as they are, but by storing them in a case, it is possible to secure mechanical properties such as protection from the external environment such as dust and corrosion and strength. Hereinafter, this difference will be mainly described, and the other configuration is the same as the configuration of the above-described embodiment, and thus the description thereof will be omitted. First, a case that is a difference will be described, and then a method for housing the reactor in the case will be described.

[Case]
Case 4 will be described with reference to FIG. The case 4 in which the combined body 10 of the coil 2 and the magnetic core 3 is housed includes the bottom plate portion 40 described in the first embodiment and a frame-like side wall portion 41 standing on the bottom plate portion 40. In the case 4 of the reactor 1, the bottom plate portion 40 and the side wall portion 41 are not integrally formed, but are independent members, and are integrated by a fixing material. Since the bottom plate portion 40 is the same as the configuration of the first embodiment, the description thereof is omitted.

(Sidewall)
The side wall portion 41 is a frame-like body (here, rectangular shape), and when the case 4 is assembled by closing one opening portion with the bottom plate portion 40, the side wall portion 41 is arranged so as to surround the periphery of the combination body 10, and the other side The opening is opened. Here, the side wall portion 41 has a rectangular shape along the outer shape of the bottom plate portion 40 when the reactor 1 is installed on a fixed object, and the open side region is magnetic with the coil 2. It is a curved surface shape along the outer peripheral surface of the combination 10 with the core 3.

  The side wall portion 41 is made of an insulating resin. Therefore, even when the coil 2 and the side wall 41 are arranged close to each other as shown in FIG. 1 (for example, the distance between the outer peripheral surface of the coil 2 and the inner surface of the side wall 41 is about 0 mm to 1.0 mm) Excellent. Moreover, the reactor 1 can be reduced in size by reducing the said space | interval. Examples of the insulating resin include PBT resin, urethane resin, PPS resin, acrylonitrile-butadiene-styrene (ABS) resin, and the like.

  If at least a part of the side wall portion 41 is made of metal (particularly nonmagnetic metal such as aluminum or magnesium), an improvement in heat dissipation and a shielding function can be expected. If all of the side wall 41 is made of an insulating resin as in this example, (1) excellent insulation between the coil 2 and the case 4 will be obtained. (2) Even complicated shapes will be easily manufactured by injection molding. It has the advantage that (3) weight reduction can be achieved.

  The side wall portion 41 also has an attachment portion 411. When the case 4 is formed by assembling the bottom plate portion 40 and the side wall portion 41, the attachment portion 400 of the bottom plate portion 40 and the attachment portion 411 of the side wall portion 41 overlap. Bolt holes 400h and 411h are provided in the attachment portions 400 and 411 so as to communicate with each other. Bolts (not shown) for fixing the case 4 to the installation target are inserted into the bolt holes 400h and 411h. The shape, the number, etc. of the attachment parts 400, 411 can be selected as appropriate. If the bolt hole 411h of the side wall portion 41 is made of a metal tube, the strength is excellent even if the side wall portion 41 is made of resin as will be described later.

(Consolidation method)
Here, the bottom plate portion 40 and the side wall portion 41 are integrated by the bolt as described above, but an adhesive may be used together with the bolt. Or you may connect the baseplate part 40 and the side wall part 41 only using an adhesive agent. In this case, for example, both the adhesive layer used for the bonding layer 42 and the adhesive layer that bonds the bottom plate portion 40 and the side wall portion 41 can be formed. In this embodiment, the curing step of the bonding layer 42 and the curing step of the adhesive layer that bonds the bottom plate portion 40 and the side wall portion 41 can be performed simultaneously, and the curing step can be reduced. Therefore, this form can improve productivity.

[Sealing resin]
The case 4 may be filled with a sealing resin (not shown). The sealing resin fixes the position of the assembly 10 stored in the case 4, mechanical protection of the assembly 10 and protection from the external environment (improved corrosion resistance), improved heat dissipation depending on the material, insulation Can be improved. In this embodiment, for example, when the end of the winding 2w is exposed from the sealing resin, the end of the winding 2w and the terminal fitting (not shown) can be easily joined. After joining the end portion of the winding 2w and the terminal metal fitting, it is also possible to have a form in which the joining portion is embedded in the sealing resin.

  Examples of the sealing resin include insulating resins such as an epoxy resin, a urethane resin, and a silicone resin. Further, a sealing resin containing a filler having excellent insulation and thermal conductivity, for example, a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, mullite, and silicon carbide; Then, the heat dissipation can be further enhanced.

  When the case 4 is filled with sealing resin, if a packing (not shown) is provided between the bottom plate portion 40 and the side wall portion 41, uncured resin is removed from the gap between the bottom plate portion 40 and the side wall portion 41. It can prevent leakage. When the bottom plate portion 40 and the side wall portion 41 are integrated with an adhesive, the adhesive can be sealed between the two to prevent leakage of uncured resin, so that packing can be omitted.

≪Manufacture of reactors≫
The reactor including the case 4 can be manufactured by a storage process of storing the reactors of the first to fourth embodiments in the case 4. This storing step typically includes a case assembling step by attaching the side wall portion 41 to the bottom plate portion 40.

[Assembly of the case]
The side wall portion 41 is placed from above the reactor so as to surround the outer periphery of the sensor-attached assembly 10 (reactor) fixed to the bottom plate portion 40, and is disposed on the bottom plate portion 40. The bottom plate portion 40 and the side wall portion 41 are integrated with a separately prepared bolt (not shown). Through this process, the box-shaped case 4 is assembled and the reactor can be stored in the case 4.

<Embodiment 6>
In the fifth embodiment described above, the embodiment in which the bottom plate portion 40 and the side wall portion 41 are independent members has been described. In addition, it can be set as the form which provides the case which consists of a box body in which the baseplate part and the side wall part were shape | molded integrally. In this form, when the whole case is comprised with metals, such as the above-mentioned aluminum, the whole case can be utilized for a thermal radiation path | route and heat dissipation is improved.

<Embodiment 7>
The reactor of Embodiments 1-6 can be utilized for the component of the converter mounted in a vehicle etc., and the component of the power converter device which provides this converter, for example.

  For example, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is used for traveling by being driven by a main battery 1210, a power converter 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. Motor (load) 1220. The motor 1220 is typically a three-phase AC motor, which drives the wheel 1250 when traveling and functions as a generator during regeneration. In the case of a hybrid vehicle, the vehicle 1200 includes an engine in addition to the motor 1220. In FIG. 6, although an inlet is shown as a charging point of the vehicle 1200, a form including a plug may be adopted.

  The power conversion device 1100 includes a converter 1110 connected to the main battery 1210 and an inverter 1120 connected to the converter 1110 and performing mutual conversion between direct current and alternating current. Converter 1110 shown in this example boosts the DC voltage (input voltage) of main battery 1210 of about 200 V to 300 V to about 400 V to 700 V and feeds power to inverter 1120 when vehicle 1200 is traveling. In addition, converter 1110 steps down DC voltage (input voltage) output from motor 1220 via inverter 1120 to DC voltage suitable for main battery 1210 during regeneration, and causes main battery 1210 to be charged. The inverter 1120 converts the direct current boosted by the converter 1110 into a predetermined alternating current when the vehicle 1200 is running and supplies power to the motor 1220. During regeneration, the alternating current output from the motor 1220 is converted into direct current and output to the converter 1110. doing.

  As shown in FIG. 7, 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 L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. For the switching element 1111, a power device such as FET or IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that tends to prevent the change of the current to flow through the circuit. As this reactor L, the reactor of the said Embodiment 1-6 is provided. By providing a small reactor 1 and the like, the power conversion device 1100 and the converter 1110 are also small.

  Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting high voltage to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some converters 1150 for power feeding devices perform DC-DC conversion. The reactors of the power supply device converter 1150 and the auxiliary power supply converter 1160 have the same configuration as the reactors of the first to sixth embodiments, and a reactor whose size and shape are appropriately changed can be used. Further, the reactors of the first to sixth embodiments described above can be used for a converter that performs conversion of input power and that only performs step-up or a step-down operation.

  Note that the present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the gist of the present invention.

  The reactor of the present invention includes various converters such as an in-vehicle converter (typically a DC-DC converter) and an air conditioner converter mounted on a vehicle such as a hybrid vehicle, a plug-in hybrid vehicle, an electric vehicle, and a fuel cell vehicle. It can be suitably used as a component part of a power converter.

1 Reactor 10 Union
2 Coil 2a, 2b Coil element 2r Coil connection part 2w Winding
2e Winding end 2d Bottom 2u Top 21 Corner R 22,22 Linear
3 Magnetic core 31 Inner core 31e End face 31m Core piece
31g Gap material
32 Outer core part 32e Inner end face
4 Case 40 Bottom plate (heat sink) 41 Side wall 42 Bonding layer
400,411 Mounting part 400h, 411h Bolt hole
5 Insulator 50a, 50b Split piece 51 Cylindrical part
52 Frame plate part 52p Base 53a, 53b Partition piece 53e Engagement part
54 Sensor holder
7 Sensor 7a Thermal element 7b Protection part 71 Wiring
8 Sensor holder 8a Placement part 8b Holding part
8c Partition 8d Body 8e Engagement 8f Hook 8g Clearance
8h Drawer 8i Sensor stop
1100 Power converter 1110 Converter 1111 Switching element
1112 Drive circuit L Reactor 1120 Inverter
1150 Power supply converter 1160 Auxiliary power converter
1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery
1240 Auxiliary 1250 Wheel

Claims (7)

A coil having a pair of coil elements connected to each other, a pair of inner core portions disposed in each of the coil elements, and a magnetic core having an outer core portion that connects these inner core portions to form a closed magnetic path. A reactor that has
A heat sink on which the coil is placed;
Comprising a sensor for measuring a physical quantity during operation of the reactor,
Each of the coil elements is a cylindrical body formed by winding a winding in a spiral shape, and the end face shape has a shape having a corner R portion with rounded corners so that the axes of the coil elements are parallel to each other. Placed in parallel,
The sensor is a reactor arranged in a trapezoidal space formed by the corner R portion and the heat radiating plate arranged to face each other in each coil element. The heat sink includes a bonding layer that fixes the coil,
2. The reactor according to claim 1, wherein the sensor is fixed by the bonding layer. A sensor holder for holding the sensor;
Comprising an insulator interposed between the coil and the magnetic core;
3. The reactor according to claim 1, wherein the sensor holder is formed integrally with the insulator. A sensor holder for holding the sensor;
Comprising an insulator interposed between the coil and the magnetic core;
3. The reactor according to claim 1, wherein the sensor holder is configured by a member independent of the insulator.   5. The reactor according to claim 4, wherein the sensor holder includes an engaging portion that engages with the insulator.   A converter comprising the reactor according to any one of claims 1 to 5.   A power converter comprising the converter according to claim 6.

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