JP6016034B2 - Reactor - 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 reactor that can suppress movement of a coil accompanying vibration during operation while improving heat dissipation.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. The reactor is used in a converter mounted on a vehicle such as a hybrid vehicle. As the reactor, for example, there is one shown in Patent Document 1.

  The reactor of Patent Document 1 is configured such that an assembly of a coil molded body obtained by integrally molding a coil and a part of an annular core with an inner resin portion and the remaining portion of the core is covered with an outer resin portion. As the coil, a coated rectangular wire obtained by enamelling a copper rectangular wire is used. The reactor is housed and fixed in a housing part through which liquid refrigerant is circulated. And a reactor is cooled by distribute | circulating a liquid refrigerant in this accommodating part, and making a reactor into an immersion state.

JP 2011-049494 A

  In the reactor described in Patent Document 1, the entire circumference of the coil is covered with an inner resin portion and an outer resin portion that are integral with the core, and the coil and the liquid refrigerant are not in direct contact with each other. Therefore, it is desired to further enhance the heat dissipation effect by the liquid refrigerant with respect to the reactor. If the inner resin portion and the outer resin portion are omitted, heat dissipation can be improved, but the coil and the core are in an unfixed state. Then, the coil moves in the coil axial direction and the circumferential direction due to the vibration of the coil and the core during the reactor operation or the influence from the external environment. Along with this movement, the coil and the core collide or rub, and adjacent turns forming the coil collide or rub against each other, increasing noise. In particular, when the coil is composed of a coated wire, there is a risk that the enamel coating of the coil may be damaged due to the collision and rubbing between the coil and the core and the collision or rubbing between the turns.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor capable of suppressing the movement of a coil accompanying vibration during operation while improving heat dissipation.

  The reactor according to the present invention includes a coil formed by winding a coil, an inner core portion disposed inside the coil, and a magnetic member having an outer core portion that is connected to the inner core portion and forms a closed magnetic circuit together with the inner core portion. A core. The outer core portion includes a side main body portion serving as a magnetic path. The side main body portion has a facing surface including an inner core facing region facing the inner core portion and a coil facing region facing the end surface of the coil. The reactor includes an end adhesive layer that is interposed between the end face of the coil and the coil facing region and fixes the coil and the outer core portion.

  The reactor of this invention can suppress the movement of the coil accompanying the vibration at the time of operation | movement, etc., improving heat dissipation.

1 is a schematic perspective view showing a reactor according to Embodiment 1. FIG. It is a disassembled perspective view which shows the outline of the union body with which the reactor which concerns on Embodiment 1 is equipped. It is a schematic explanatory drawing explaining the coil opposing area | region of the outer core part with which the reactor which concerns on Embodiment 1 is equipped. It is a schematic explanatory drawing which shows the use condition of the reactor which concerns on Embodiment 1. FIG. It is a longitudinal cross-sectional view which shows the reactor which concerns on Embodiment 2. FIG. It is a schematic perspective view which shows the reactor which concerns on Embodiment 3. FIG. It is a schematic perspective view which shows the outer core part with which the reactor which concerns on Embodiment 4 is equipped. It is a schematic perspective view which shows the reactor which concerns on Embodiment 6. FIG. 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 a power converter device provided with a converter.

<< Description of Embodiments of the Present Invention >>
First, embodiments of the present invention will be listed and described.

  (1) The first reactor according to the embodiment forms a closed magnetic circuit together with the inner core portion connected to the coil formed by winding the winding, the inner core portion disposed inside the coil, and the inner core portion. And a magnetic core having an outer core portion. The outer core portion includes a side main body portion serving as a magnetic path. The side main body portion has a facing surface including an inner core facing region facing the inner core portion and a coil facing region facing the end surface of the coil. The reactor includes an end adhesive layer that is interposed between the end face of the coil and the coil facing region and fixes the coil and the outer core portion. Being interposed between the end face of the coil and the coil facing area means that the end adhesive layer is provided in a part between the end face of the coil and the coil facing area, and is provided over the entire area between them. Including the case where

  According to the first reactor, the coil and the outer core portion are not fixed with the resin that covers the entire circumference of the coil integrally with the magnetic core as in the prior art, but between the end face of the coil and the outer core portion. It is performed by an end adhesive layer interposed therebetween. Therefore, the outer peripheral surface of a coil can be exposed and the heat dissipation of a reactor can be improved. In particular, when the reactor is disposed at a location where the liquid refrigerant is circulated, the liquid refrigerant and the coil can be brought into direct contact with each other. Therefore, the heat dissipation of the coil, and thus the heat dissipation of the reactor can be improved more effectively.

  Further, by fixing the coil and the outer core portion with the end adhesive layer, the coil axis caused by the influence of the vibration of the coil or the core during the operation of the reactor or the external environment (for example, the liquid refrigerant). The movement in the direction and the circumferential direction can be suppressed. Therefore, the collision and rubbing between the coil and the magnetic core and the collision and rubbing between the turns of the coil can be suppressed. Therefore, it is possible to reduce noise accompanying the collision and rubbing and damage to the coil insulation coating.

  Furthermore, the application | coating operation | work of the constituent material of an edge part adhesive layer is simple by making the formation location of an edge part adhesive layer into at least one part of the said opposing surface.

  (2) The second reactor according to the embodiment forms a closed magnetic circuit together with the inner core portion connected to the coil formed by winding the winding, the inner core portion disposed inside the coil, and the inner core portion. And a magnetic core having an outer core portion. The outer core portion includes a side main body portion serving as a magnetic path. The side main body portion has a facing surface including an inner core facing region facing the inner core portion and a coil facing region facing the end surface of the coil. The reactor includes a heat radiating plate disposed on the installation surface of the coil, and an end adhesive layer that is interposed between the end surface of the coil and the coil facing region and fixes the coil and the outer core portion.

  According to the second reactor, in addition to achieving the same effect as the first reactor described above, a heat radiating plate interposed between the coil installation surface and the reactor installation target is used for the coil heat dissipation path. By doing so, heat dissipation can be improved.

  (3) As one form of said 1st and 2nd reactor, interposing between a coil and an inner core part and providing an inner side adhesive layer which fixes a coil and an inner core part are mentioned. In this case, the inner adhesive layer is provided in a part of the coil in the circumferential direction.

  According to said structure, since the turn part and inner core part of a coil can be fixed in addition to fixation of the end surface and outer core part of a coil, the motion of a coil can be suppressed further.

  (4) As one form of said 1st and 2nd reactor, it forms along at least one part of the axial direction of a coil in a part of the circumferential direction in the outer peripheral surface of a coil, and fixes the space | interval of the turns of a coil. And providing a fixed covering layer.

  According to said structure, the space | interval between turns of a coil can be fixed, increasing the exposed area of the outer peripheral surface of a coil, and the collision and rubbing of turns can be suppressed further.

  (5) As one form of said 1st and 2nd reactor, it is mentioned that the edge part adhesive layer is comprised with the ultraviolet curable adhesive.

  According to said structure, since an ultraviolet curable adhesive is hardened | cured by irradiating an ultraviolet-ray, it is not necessary to heat at high temperature compared with a thermosetting adhesive at the time of formation of an contact bonding layer. Further, since the ultraviolet curable adhesive does not cure unless it is irradiated with ultraviolet rays, there are few restrictions on the time until curing, for example, when the adhesive layer is formed. Furthermore, since the curing speed is relatively fast, it is easy to shorten the formation time of the adhesive layer, and hence the production time of the reactor.

  (6) As one form of said 1st and 2nd reactor, an outer core part is provided with the side resin mold part which covers at least one part of the outer periphery of a side main body part, and insulates between a side main body part and a coil. Can be mentioned. In this case, the side resin mold portion has an intervening region interposed between the side main body portion and the end adhesive layer.

  According to said structure, the insulation between a side main-body part and a coil is securable by providing the side resin mold part which has the said interposition area | region. Further, since the side main body portion can be protected from the external environment, the side main body portion is hardly damaged by a physical impact. Furthermore, when this reactor is arrange | positioned in the location where a liquid refrigerant is distribute | circulated, the rust prevention property with respect to a liquid refrigerant can be improved.

  (7) As one form of the first and second reactors, when the side resin mold portion has an intervening area, the surface facing the coil in the intervening area is configured with an inclined surface corresponding to the form of the end face of the coil. Can be mentioned. At this time, the thickness of the intervening region is increased along the inclination of the end surface of the coil as the end surface of the coil is separated from the coil facing region.

  According to said structure, the thickness of an edge part adhesive layer can be made uniform over the whole region. Therefore, it is easy to make the adhesive strength between the coil and the outer core portion uniform over the entire end adhesive layer, and it is easy to firmly fix the coil and the outer core portion.

  (8) As one form of said 1st and 2nd reactor, an inner core part covers the middle main-body part used as a magnetic path, and at least one part of the outer periphery of a middle main-body part, and between a middle main-body part and a coil. And a middle resin mold part that insulates.

  According to said structure, the insulation between a middle main-body part and a coil is securable by providing a middle resin mold part. Further, since the middle main body can be protected from the external environment, the middle main body is hardly damaged by a physical impact. Furthermore, when this reactor is arrange | positioned in the location where a liquid refrigerant is distribute | circulated, the rust prevention property with respect to a liquid refrigerant can be improved.

  (9) As one form of said 1st and 2nd reactor, providing the case where a liquid refrigerant is supplied and discharged | emitted while accommodating the assembly of a coil and a magnetic core inside is mentioned.

  According to said structure, since the perimeter of a coil is not covered with resin like the past, and a coil can be directly contacted with a liquid refrigerant and can be cooled, the heat dissipation of a reactor can be improved. In particular, the case can control the flow of the liquid refrigerant that cools the combination by supplying and discharging the liquid refrigerant, and can effectively cool the combination.

  In addition, since the coil and the core are fixed by the above-described adhesive layer, movement and deformation of the coil in the axial direction and the circumferential direction can be suppressed even when liquid refrigerant is applied to the coil. Therefore, the collision and rubbing between the coil and the core, the collision and rubbing between the turns of the coil can be suppressed, and noise can be reduced. When the coil is composed of a covered wire, damage to the covered wire can be suppressed.

<< Details of Embodiment of the Present Invention >>
Details of embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
[Overall structure of the reactor]
With reference to FIGS. 1-4, the reactor 1A of Embodiment 1 is demonstrated. The reactor 1A will be described in detail in the state of use of the reactor 1A, which will be described later. 1 A of reactors are provided with the combination 10 of the coil 2 and the magnetic core 3 which is arrange | positioned inside and outside the coil 2 and forms a closed magnetic circuit. The main feature of the reactor 1A is that it includes an end adhesive layer 4e that fixes the coil 2 and the outer core portion 32 of the magnetic core 3 disposed outside the coil 2. Hereinafter, the characteristic part of reactor 1A, the structure of related parts, and main effects will be described in order, and then each structure will be described in detail. Here, the installation target side of the combined body 10 is the installation side (lower side), and the opposite side is the opposite side (upper side). The same reference numerals in the figure indicate the same names.

[Composition of main features and related parts]
[Union]
(coil)
As shown in FIGS. 1 and 2, the coil 2 connects a pair of coil elements 2 a and 2 b formed by spirally winding a single continuous winding 2 w without a joint portion, and both coil elements 2 a and 2 b. Connecting portion 2r. For the winding 2w, a coated flat wire in which an outer periphery of a conductor made of a flat wire is coated with an insulating coating is used, and the coil elements 2a and 2b are constituted by edgewise coils in which the coated flat wire is edgewise wound. The coil elements 2a and 2b are arranged in parallel (side by side) so that the axial directions are parallel to each other. The length along the parallel direction of the coil elements 2a and 2b of the coil 2 is longer than the length along the same direction of the outer core portion 32 (FIG. 3). The connecting portion 2r is formed by bending a part of the winding in a U shape on one end side of the coil 2 (the right side in FIGS. 1 and 2).

  The shape of the coil elements 2a and 2b is a hollow cylindrical body (square cylinder) having the same number of turns. The end face shape of the coil elements 2a and 2b is a shape obtained by rounding the corners of the rectangular frame. The end surfaces of the coil elements 2a and 2b are inclined surfaces that are inclined with respect to the axial direction of the coil elements 2a and 2b in accordance with the winding pitch of the winding 2w. The inner and outer peripheral surfaces of the coil elements 2a and 2b are composed of four planes and four curved surfaces connecting adjacent planes.

  The facing region (outer core facing region 2f) with the outer core portion 32 on the end faces of the coil elements 2a and 2b can be appropriately selected depending on the size (width and height) of the outer core portion 32 described later. Here, the outer core facing region 2f is an L-shaped region indicated by the hatched portion in FIG. 2, and the inner end surface on the adjacent side of the coil elements 2a and 2b and the lower lower end surface of the entire coil end surface. And a curved end surface connecting both end surfaces.

  Both end portions 2e of the winding 2w of the coil elements 2a and 2b are extended from the turn forming portion. The lead-out part of the end 2e is located on the upper side (upper side in FIG. 2) in the coil circumferential direction on the side opposite to the coil axial direction connecting part 2r side. A conductive member (here, terminal fitting 5) that supplies power to the coil 2 from an external device (not shown) such as a power source is connected to both ends 2e. When the reactor 1A includes a case 8 described later, the terminal fitting 5 is pulled out to the outside of the case 8 (FIG. 4).

(Magnetic core)
As shown in FIG. 2, the magnetic core 3 includes a pair of inner core portions 31 disposed inside the coil elements 2 a and 2 b and a pair of protrusions (exposed) protruding from the coil 2 without the coil 2 being disposed. And an outer core portion 32. 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 is formed in an annular shape by bringing the end surface of the inner core portion 31 and the inner end surface 32e of the outer core portion 32 into contact with each other. Is done. The inner core portion 31 and the outer core portion 32 form a closed magnetic circuit when the coil 2 is excited. A specific connection / separation form between the inner core portion 31 and the outer core portion 32 will be described later. The upper surfaces of the outer core portion 32 and the inner core portion 31 are substantially flush. On the other hand, the size of the outer core portion 32 is adjusted so that the lower surface of the outer core portion 32 protrudes from the lower surface of the inner core portion 31 and is substantially flush with the lower surface of the coil 2. The lower surface of the combined body 10 is mainly composed of the lower surfaces of the two outer core portions 32 and the lower surface of the coil 2.

<Outer core part>
The shape of the outer core portion 32 can be selected as appropriate. Here, the upper and lower surfaces are dome-shaped (deformed trapezoidal shape in which the cross-sectional area decreases outwardly from the inner end surface 32e) as columnar bodies. As shown in FIGS. 2 and 3, the outer core portion 32 is opposed to the inner core facing region (inner end surface 32e) facing the inner core portion 31, and the coil facing facing the coil elements 2a and 2b (outer core facing region 2f). It has a facing surface including a region 32f (shaded portion in the figure). The facing surface is configured by a plane orthogonal to the upper surface (lower surface) of the outer core portion 32. That is, the surface constituting the coil facing region 32f is not parallel to the surface constituting the outer core facing region 2f described above. Here, the coil facing region 32f is an L-shaped region similar to the outer core facing region 2f of the coil elements 2a and 2b described above, as shown by hatched portions in FIGS. It is formed along the periphery of the end surface 32e (between the inner end surface 32e and a partition portion 34 (described later) and below the inner end surface 32e).

[End adhesive layer]
The end adhesive layer 4 e fixes the coil 2 and the outer core portion 32. Examples of the location where the end adhesive layer 4e is formed include a core-coil facing region between the outer core facing region 2f and the coil facing region 32f of the outer core portion 32 at least at one end of each coil element 2a, 2b.

  The end 2 e of the coil 2 is fixed to the terminal fitting 5, but when the end adhesive layer 4 e is not provided, the turn forming portion is not fixed to the magnetic core 3. When the coil 2 or the magnetic core 3 vibrates, the end 2e does not move, but the turn forming portion moves in the axial direction and the circumferential direction of the coil 2. This movement of the turn forming portion causes a stress in the lead portion extending from the turn forming portion to the end 2e of the winding 2w, and the generation of the stress causes a poor connection between the end 2e of the winding 2w and the terminal fitting 5. There may be a cause. Therefore, by forming the end adhesive layer 4e at least one of the core-coil facing regions, it is possible to suppress the influence of vibration of the turn forming portion from extending to the lead portion of the winding 2w, and Generation can be reduced as much as possible.

  If the portion where the end adhesive layer 4e is formed is the core-coil facing region on the connecting portion side, the movement of the coil elements 2a and 2b can be easily suppressed. In addition, it is easy to suppress the above-described bonding failure as compared with the case where the above-described end adhesive layer 4e is not provided. On the other hand, if the portion where the end adhesive layer 4e is formed is the core-coil facing region on the end 2e side, the movement of the coil elements 2a and 2b can be easily suppressed. In addition, it is easy to suppress the above-described bonding failure as compared with the case where the end portion adhesive layer 4e is formed as a core-coil facing region on the connection portion side. In particular, the end adhesive layer 4e is preferably formed in the core-coil facing region on both the end 2e side and the connecting portion side. Here, the end adhesive layer 4e is provided in the core-coil opposing regions on both the coil axial direction end side and the connecting portion side.

  The region where the end adhesive layer 4e is formed includes at least a part of the core-coil facing region. For example, the region where the end adhesive layer 4e is formed is preferably the side close to the end 2e of the winding 2w in the core-coil facing region. If it does so, it will be easy to suppress the movement of the edge part 2e in coil element 2a, 2b vicinity of the said joining location, and it will be easy to suppress the said joining defect. The region where the end adhesive layer 4e is formed preferably covers 50% or more of the total length of the core-coil facing region from the side close to the end 2e, more preferably 75% or more, and particularly preferably the entire length.

The thickness of the end portion adhesive layer 4e is secured coil elements 2a, 2b and an outer core portion 32 can be fixed, and a coil element 2a by the end adhesive layer 4e, 2b and the outer core portion 3 2 are sufficient insulation It is mentioned that it can be made as much as possible.

  Here, the shape of the end adhesive layer 4e is L-shaped, and the region where the end adhesive layer 4e is formed extends over the entire length of the core-coil facing region (FIGS. 2 and 3). The thickness of the end adhesive layer 4e is increased along the inclined surface of the outer core facing region 2f of the coil elements 2a and 2b as the end surfaces of the coil elements 2a and 2b move away from the coil facing region 32f of the outer core portion 32. ing. That is, the facing surface of the end adhesive layer 4e facing the coil 2 is inclined along the inclined surface of the core facing surface 2f of the coil elements 2a and 2b.

The constituent material of the end adhesive layer 4e preferably has insulating properties and heat resistance. The heat resistance means that the reactor 1A is not softened with respect to the highest temperature achieved during use. That way, it is possible to reliably fix the coil 2 and the outer side core part 3 2 during operation of the reactor 1A.

  The constituent material of the end adhesive layer 4e is, for example, a thermosetting insulating adhesive such as an epoxy resin, a silicone resin, or an unsaturated polyester, a thermoplastic insulation such as a polyphenylene sulfide (PPS) resin, or a liquid crystal polymer (LCP). An ultraviolet (light) curable insulating adhesive such as an adhesive, urethane acrylate, acrylic resin acrylate, and epoxy acrylate can be suitably used. In particular, an ultraviolet curable insulating adhesive can be suitably used. This is because the ultraviolet curable insulating adhesive can be cured by irradiating with ultraviolet rays and does not need to be heated to a higher temperature than the thermosetting adhesive when forming the end adhesive layer 4e. Moreover, since it does not harden | cure unless it irradiates with an ultraviolet-ray, when forming the edge part contact bonding layer 4e, there are few restrictions, such as time to hardening, for example. Furthermore, since the curing speed is relatively fast, it is easy to shorten the time for forming the end adhesive layer 4e, and hence the time for manufacturing the reactor 1A.

  The end adhesive layer 4e is formed by applying an end adhesive to at least one of the outer core facing region 2f of each coil element 2a, 2b and the coil facing region 32f of the outer core portion 32, and then the outer core portion 32 and the coil. This can be done by curing the end adhesive while the elements 2a, 2b and the end adhesive are in contact with each other.

[Effects of the main features of the reactor]
According to the reactor 1A, the end surface of the coil elements 2a and 2b and the outer core portion 32 are fixed to each other by the end adhesive layer 4e between the end surfaces of the coil elements 2a and 2b and the outer core portion 32. The core 3 can be fixed. Therefore, since it is not necessary to provide the resin which covers the whole surface of the coil 2 like the past, a liquid refrigerant and a coil can be made to contact directly and the heat dissipation of a reactor can be improved. Further, it is possible to suppress the movement of the coil 2 in the axial direction and the circumferential direction due to the influence of the liquid refrigerant and the like from the external environment and the vibration of the coil and the core during the operation of the reactor. Therefore, the collision and rubbing between the coil 2 and the magnetic core 3 and the collision and rubbing between the turns of the coil 2 can be suppressed, noise can be reduced, and damage to the insulation coating of the coil 2 can be reduced.

[Description of each configuration including other features]
[coil]
Examples of the constituent material of the conductor of the winding 2w include conductive materials such as copper, aluminum, and alloys thereof, and examples of the constituent material of the insulating coating include insulating materials such as enamel (typically polyamideimide). The shape of the conductor may be a round wire or the like. The end face shape of the coil elements 2a and 2b can be changed as appropriate, such as a circular shape. The coil may be configured to include a pair of coil elements formed by spirally winding two independent windings, and a connecting member that connects both coil elements by a member independent of both coil elements.

[Magnetic core]
As described above, the magnetic core 3 includes the pair of inner core portions 31 and the pair of outer core portions 32. Here, the form of the magnetic core 3 is, one outer core portion 32 and the core molded bodies 3b and of U-shaped integrated both the inner core portion 31 (toward the right side in FIG. 2), the other of the outer core portion 32 (The left side in FIG. 2). The U-shaped core molded body 3b and the other outer core portion 32 can be joined via an adhesive.

(Core molding)
The U-shaped core molded body 3b includes a core part having one side main body part 32b to be a magnetic path and a pair of middle main body parts 31b to be a magnetic path, and covers both the main body parts 31b and 32b. A connecting resin mold part that integrates the core part and the coil 2 is provided. Specifically, the connection resin mold part includes a middle resin mold part 31c that covers at least a part of the middle body part 31b, and a side resin mold part 32c that covers at least a part of the side body part 32b. The inner core portion 31 includes a middle main body portion 31b and a middle resin mold portion 31c, and the outer core portion 32 includes a side main body portion 32b and a side resin mold portion 32c. Here, the middle resin mold part 31c and the side resin mold part 32c are formed in series (integral) with the same constituent material.

<Core parts>
{Middle body}
The middle main body 31b is a laminated body in which a plurality of core pieces 31m mainly composed 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 laminated ( Figure 2). The integration of the core piece 31m and the gap material 31g is particularly easy to handle when an adhesive is used. In addition, even when the core piece 31m is made of a material that vibrates due to magnetostriction and the gap material 31g is made of a highly rigid material such as alumina, the core piece 31m and the gap material 31g are brought into contact or non-contact. It is expected that noise can be reduced. In addition, an adhesive tape or the like can be used to integrate the core piece 31m and the gap material 31g. Here, the core piece 31m and the gap material 31g are integrated by an adhesive. The middle main body 31b (magnetic core 3) can have a form that does not include the gap material 31g or a form that includes an air gap.

  The shape of the middle main body 31b is preferably a shape that matches the shape of the coil 2 (the internal space of the coil 2). Here, as shown in FIG. 2, the shape of the middle main body 31b is a rectangular parallelepiped, and the corners (regions facing the curved surfaces of the coil elements 2a and 2b) are formed on the curved surfaces of the coil elements 2a and 2b. It is rounded along. That is, the end surface shape of the middle main body 31b is a rectangular shape with rounded corners, and the side surface (the surface along the circumferential direction of the coil elements 2a and 2b) of the middle main body 31b is adjacent to the four planes. It consists of four curved surfaces that connect the planes.

{Side body part}
One side main body 32b is a core piece mainly composed of a soft magnetic material, like the middle main body 31b. The shape of the outer core part 32 can also be a prismatic body, for example.

  A pair of middle main-body part 31b and one side main-body part 32b can be joined by an adhesive agent. The pair of middle main body portions 31b and the side main body portions 32b can be joined by being integrally covered with the connecting resin mold portion without being joined by the adhesive.

<Connected resin mold part>
{Middle resin mold part}
Middle resin mold part 31c insulates between middle body part 31b and coil elements 2a and 2b. The covering region of the middle resin mold portion 31c may be at least a part of the surfaces (upper and lower surfaces and both side surfaces) along the circumferential direction of the coil elements 2a and 2b in the middle main body portion 31b. As the covering area of the middle resin mold portion 31c is wider, it is easier to ensure insulation from the coil elements 2a and 2b, and, for example, when the combination 10 is disposed at a location in contact with the liquid refrigerant C, the middle body portion 31b is prevented. Rust can be improved.

The covering region of the middle resin mold portion 31c may or may not include a surface facing the outer core portion 32 side in the middle main body portion 31b. Since the constituent material of the middle resin mold portion 31c is generally a non-magnetic material, it functions as a gap material when covering the facing surface. Middle resin mold portion 31c in cover the opposing surfaces (exposed not covered) case, the side body portion 32 b of the inner end surface 32e is exposed from the side resin mold portion 32 c of the (side resin mold portion 32c of the outer core portion 32 Cover and do not expose). If only one of the opposing surface of the middle main body 31b and the inner end surface 32e of the other side main body 32b is covered with a resin and both are fixed with an adhesive, a dimensional error associated with the resin molding can be reduced. It is easy to adjust the gap length accurately.

  Here, the covering region of the middle resin mold portion 31c is the entire surface excluding the connection portion with the one side main body portion 32b in the middle main body portion 31b. That is, the above-described facing surface of the middle main body 31b is also covered with the middle resin mold portion 31c, and the end surface of the inner core portion 31 that is a connection portion with the outer core portion 32 is made of a constituent material of the middle resin mold portion 31c. . The outer peripheral surface near the other side main body portion 32b in the middle resin mold portion 31c is formed with an annular thin portion 31t having a thickness smaller than that of the other outer peripheral surface. This thin portion 31t is fitted with a cylindrical portion 32t of the other side resin mold portion 32c described later. Thus, the core molded body 3b and the other outer core portion 32 are easily combined.

{Side resin mold part}
One side resin mold portion 32c insulates between the side main body portion 32b and the coil elements 2a and 2b. The covering region of the side resin mold portion 32c covers at least the portion facing the coil elements 2a and 2b in the side main body portion 32b. Specifically, the side resin mold portion 32c preferably has an intervening region 32i interposed between the side main body portion 32b and the end adhesive layer 4e. Here, the intervening region 32 i constitutes a coil facing region 32 f that faces the coil elements 2 a and 2 b in the outer core portion 32. In other words, the intervening region 32 i is formed in the above-described L-shaped region and is configured by a plane orthogonal to the upper surface (lower surface) of the outer core portion 32. The thickness of the intervening region 32i is uniform over the entire region.

  Moreover, it is preferable that the side resin mold part 32c also covers the location facing the connection part 2r on the upper surface of the side main body part 32b. As the covering area of the side resin mold portion 32c is wider, the side main body portion 32b can be protected, and in addition, for example, when the assembly 10 is disposed at a location in contact with the liquid refrigerant C, the rust prevention property of the side main body portion 32b can be improved. . Since the side main body 32b protrudes (exposes) from the coil 2 and the side main body 32b is formed of a compacted body as will be described later, if the side main body 32b is covered with the side resin mold 32c, an insulating property is provided. In addition to rust prevention, it is also effective in preventing soft magnetic powder from falling off.

  Here, the covering region of the side resin mold portion 32c is the entire region excluding the contact portion of the side main body portion 32b with the pair of middle main body portions 31b. That is, the entire surface of the core molded body 3b is covered with the connecting resin mold portion.

  As for the thickness of the resin mold parts 31c and 32c, 0.1 mm or more and 3 mm or less are mentioned. By setting the thickness of the resin mold portions 31c and 32c to 0.1 mm or more, the insulation against the coil elements 2a and 2b can be improved, and the rust of the magnetic core 3 due to the liquid refrigerant C can be prevented. On the other hand, by setting the thickness of the resin mold portions 31c and 32c to 3 mm or less, the resin mold portions 31c and 32c do not become too thick.

(The other outer core)
The other outer core portion 32 includes a side main body portion 32b and a side resin mold portion 32c similar to the one outer core portion 32 described above. The covering region of the other side resin mold portion 32c is at least a portion facing the coil elements 2a and 2b in the side main body portion 32b. The wider the covering region of the other side resin mold part 32c is, the more preferable it is for the same reason as the one outer core part 32 described above.

  Here, only the inner core facing region (inner end surface 32e) with the end surface of the inner core portion 31 in the other side main body portion 32b is exposed, and the other portions including the above-described intervening region 32i are covered. A cylindrical portion 32t that protrudes toward the inner core portion 31 side and surrounds the thin portion 31t is formed on the periphery of the inner core facing region of the side main body portion 32b in the side resin mold portion 32c. The outer peripheral surface of the cylindrical portion 32t is substantially flush with the outer peripheral surface of the middle resin mold portion 31c over the entire periphery when the cylindrical portion 32t and the thin portion 31t are fitted together.

<Constituent materials for each main body, gap material, and resin mold part>
Examples of the soft magnetic material that is the main component of each core piece constituting the middle main body portion and the side main body portion include nonmetals such as iron, iron alloy, and ferrite. As the core piece, a molded body using the soft magnetic powder made of the soft magnetic material or a laminated body in which a plurality of magnetic thin plates having an insulating coating (for example, an electromagnetic steel plate typified by a silicon steel plate) are stacked can be used. As for the said molded object, the composite material containing a sintered compact, soft magnetic powder, and resin other than a compacting body (powder magnetic core) is mentioned. Even if the composite material has a complicated three-dimensional shape by using injection molding or the like, it can be easily molded. As a resin serving as a binder in the composite material, a thermosetting resin such as an epoxy resin or a thermoplastic resin such as a PPS resin can be used. The content of the soft magnetic powder in the composite material may be 20 volume% or more and 75 volume% or less when the composite material is 100 volume%. The balance is a non-magnetic material such as a non-metallic organic material such as a resin, ceramics such as alumina or silica, or a non-metallic inorganic material. Here, each core piece is a green compact.

  Specific materials for the gap material 31g include a nonmagnetic material such as alumina or unsaturated polyester, a nonmagnetic material such as PPS resin, and a magnetic material (an example of a magnetic material is a soft magnetic powder such as iron powder). Etc.

  The constituent material of the resin mold portions 31c and 32c is preferably a material excellent in insulation, and particularly preferably a material excellent in rust prevention and thermal conductivity in addition to insulation. Examples of such a material include PPS resin. The resin mold portions 31c and 32c can be formed by insert molding or dipping in a constituent resin.

  When each core piece is comprised with the above-mentioned composite material, it can also be set as the structure which does not coat | cover each main-body part with a resin mold part. That is, the inner core portion and the outer core portion are respectively composed of a middle main body portion and a side main body portion made of a composite material. The surface of the composite material is in a state where the soft magnetic powder is hardly exposed from the resin. Therefore, the coil elements 2a and 2b can be insulated from each other, and the corrosion of the soft magnetic powder contained in the composite material can be suppressed. Of course, each of the main body portions may be covered with the above-described resin mold portion. In this case, the constituent material of the resin mold portion is a material that does not soften or damage the resin of the composite material when the resin mold portion is formed. Is selected.

  The magnetic core 3 can also be configured to include a pair of L-shaped core molded bodies in which one outer core portion 32 and one inner core portion 31 are integrated. In this case, each L-shaped core molded body includes the one side main body portion 32b and the one middle main body portion 31b, and a connecting resin mold portion that integrally holds both the main body portions 32b and 31b. Furthermore, the magnetic core 3 can also be configured to include a pair of inner core portions 31 and a pair of outer core portions 32 each formed of independent members. In this case, each inner core portion 31 includes the middle main body portion 31b and the middle resin mold portion 31c, and each outer core portion 32 includes the side main body portion 32b and the side resin mold portion 32c. The L-shaped core molded bodies or the inner core portion 31 and the outer core portion 32 can be joined with an adhesive.

[Other configuration of magnetic core]
(Mounting part)
Both side resin mold parts 32c preferably include an attachment part 33 for fixing the combined body 10 to an installation target (FIGS. 1 and 2). The attachment portion 33 may be formed integrally with the side resin mold portion 32c using the constituent material of the side resin mold portion 32c. The attachment portion 33 is provided in a flange shape that projects in the parallel direction of the coil elements 2a and 2b in the side main body portion 32b. The formation location of the attachment portion 33 may be selected as appropriate in accordance with the height of the fixing location (the boss 82 of the case 8 described later) on which the reactor 1A is to be installed. Here, the outer core portion 32 is provided at a substantially intermediate position in the height direction.

  A collar 35 for receiving a tightening force by the bolt 36 through which the bolt 36 (FIG. 4) used when the assembly 10 is fixed to the installation target is penetrated is embedded in the mounting portion 33. Examples of the material of the collar 35 include a rigid material such as a metal. If it does so, damage to the side resin mold part 32c which comprises the attachment part 33 can be suppressed, and the assembly 10 can be fixed to the boss | hub 82 firmly.

(Partition)
Both side resin mold portions 32c preferably include a partition portion 34 that ensures insulation between the coil elements 2a and 2b (FIGS. 2 and 3). The partition part 34 is provided so as to be interposed between the coil elements 2a and 2b. The partition part 34 may be formed integrally with the side resin mold part 32c using the constituent material of the side resin mold part 32c.

[Reactor usage status]
The usage state of the reactor 1A will be described with reference to FIG.

[Case]
The reactor 1A can also include a case 8 that houses and fixes the combined body 10 (FIG. 4). The case 8 is a box-shaped member into which the liquid refrigerant C is supplied and discharged. The supply port 80i for supplying the liquid refrigerant C into the case 8 and the liquid refrigerant C in the case 8 are discharged out of the case 8. And a discharge port 80o. Is supplied from the supply port 80i into the casing 8 liquid refrigerant C, which is discharged from the outlet 80o to the case 8 outside is cooled to a predetermined temperature by such a cooler (not shown), casing 8 again from the supply port 80i Supplied in. In this way, the liquid refrigerant C is circulated and supplied into the case 8.

The supply port 80i is provided above the combined body 10, and the discharge port 80o is provided at a position substantially the same as the height of a boss 82 described later. The diameter φ _o of the discharge port 80 _o is smaller than the diameter φ _i of the supply port 80 _i . Then, the combined body 10 is always immersed in the liquid refrigerant C so that the upper surface of the coil 2 is located below the liquid surface of the liquid refrigerant C as shown in FIG.

  The case 8 preferably includes an attachment surface 81 that faces the installation side surface of the assembly 10 and a boss 82 that protrudes from the attachment surface 81 and fixes the assembly 10 in the case 8. By doing so, it is possible to secure the fastening length of the bolt 36 to be fastened to the boss 82 without increasing the thickness of the entire mounting surface 81 of the case 8, and it is easy to firmly fix the assembly 10 to the boss 82. By reducing the thickness of the mounting surface 81, the case 8 can be reduced in weight. The shape of the boss 82 is a cylindrical shape, but can be appropriately changed such as a prismatic shape.

  The number of the bosses 82 can be the same as the number of the attachment portions 33, and the arrangement location of the bosses 82 can be a location corresponding to the attachment portion 33. An insertion hole through which the bolt 36 for fixing the attachment portion 33 is inserted is formed on the contact surface of the boss 82 with the attachment portion 33. The insertion hole is internally threaded, and the mounting portion 33 (combined body 10) can be fixed to the case 8 by screwing a bolt 36 into the insertion hole.

  Examples of the material of the case 8 include metals such as aluminum and alloys thereof, magnesium and alloys thereof, copper and alloys thereof, silver and alloys thereof, iron, and austenitic stainless steel. In particular, aluminum, magnesium, and alloys thereof are lightweight and can be expected to have a shielding function. In addition, aluminum and its alloys are excellent in heat dissipation and corrosion resistance, and magnesium and its alloys are excellent in vibration damping properties. In addition, examples of the material of the case 8 include insulating resins such as polybutylene terephthalate (PBT) resin, urethane resin, PPS resin, and acrylonitrile-butadiene-styrene (ABS) resin. The insulating resin may contain at least one ceramic filler selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide.

[Liquid refrigerant]
As the liquid refrigerant C, a liquid refrigerant whose form does not change (not vaporized) depending on the maximum temperature achieved when the reactor 1A is used can be suitably used. Specifically, fluorine-based inert liquids such as ATF (Automatic Transmission Fluid) and Fluorinert (registered trademark), which are lubricating oils for automatic transmissions, chlorofluorocarbon refrigerants such as HCFC-123 and HFC-134a, methanol, alcohol, and the like Examples thereof include alcohol-based refrigerants and ketone-based refrigerants such as acetone. In the case where the reactor 1A is used for automobiles, if the ATF is diverted, the liquid refrigerant C does not have to be prepared separately, and if the ATF circulation supply mechanism is used, the heat dissipation structure in the reactor 1A using the liquid refrigerant C can be simplified. Can be formed.

[Sensor]
Reactor 1A can include a sensor 7s that measures a physical quantity (eg, temperature, current value, voltage value, acceleration, etc.) during operation of reactor 1A (FIG. 2). Based on the measurement result by the sensor 7s, the operation of the reactor 1A can be stabilized. The sensor 7s is a temperature sensor including a thermal element such as a thermistor, and includes a protection unit (for example, a tube of resin or the like) that protects the thermal element, and a wiring 7c that transmits information from the thermal element to the outside. For example, the sensor 7s may be disposed in a region surrounded by the corners of the coil elements 2a and 2b among the lower and upper sides between the coil elements 2a and 2b.

  For example, a holder 70 as shown in FIG. 2 can be used for assembling the sensor 7 s to the combination 10. The holder 70 includes a main body 71 supported between the coil elements 2 a and 2 b so as to be interposed between the partition portions 34, and hooks 72 f that engage with the partition portion 34 at both ends of the main body portion 71. When the holder 70 is inserted between the coil elements 2 a and 2 b, the hook 72 f is engaged with the lower end of the partition part 34, and the main body part 71 is supported by both the partition parts 34. Thereby, since the position of the holder 70 does not substantially shift, this position can be maintained well. The holder 70 covers a part of the sensor 7s. If it does so, sensor 7s will be hard to contact liquid refrigerant C, for example, and it will be easy to measure the physical quantity of reactor 1A appropriately. The constituent material of the holder 70 can be an insulating resin similar to the constituent material of the resin mold part described above. If it does so, even if the holder 70 contacts coil element 2a, 2b, it is excellent in both insulation. Without using the holder 70, the sensor 7s may be fixed at a predetermined position only with an adhesive such as an epoxy adhesive or an acrylic adhesive.

[Manufacture of reactors]
The reactor 1 </ b> A can be typically manufactured by a process of preparing the coil 2 and the magnetic core 3 ⇒ applying an adhesive ⇒ assembling the assembly 10 ⇒ curing the adhesive and forming the adhesive layer 4.

  The coil 2 mentioned above and the magnetic core 3 provided with the above-mentioned core molded object 3b and the other outer core part 32 are prepared. Subsequently, an end adhesive constituting the end adhesive layer 4e is applied to at least one of the outer core facing region 2f and the coil facing region 32f of the outer core portion 32 on the end surfaces of the coil elements 2a and 2b. Here, an end adhesive was applied to the coil facing region 32 f of both outer core portions 32. A core adhesive is also applied to the end surfaces of the inner core portions 31 on the other outer core portion 32 side. Next, the inner core portion 31 of the core molded body 3b is inserted into the coil elements 2a and 2b, and the end surface 32e of the other outer core portion 32 and the end surface of the inner core portion 31 are brought into contact with each other to combine the constituent members. In this state, when the end adhesive and the core adhesive are cured, the core molded body 3b and the other outer core portion 32 are fixed, and the coil elements 2a and 2b and both the outer core portions 32 are fixed. . As described above, the reactor 1A in which the coil elements 2a and 2b and the outer core portion 32 are fixed by the end adhesive layer 4e is obtained.

  When the reactor 1 </ b> A includes the case 8, the combined body 10 is stored and fixed in the case 8. The assembly 10 is arranged on the attachment surface 81 so that the insertion hole of the collar 35 of the attachment portion 33 is aligned with the insertion hole of the boss 82 of the case 8. Then, the bolt 35 is inserted into the collar 35 and screwed into the insertion hole. Then, the combined body 10 is fixed to the boss 82. In this state, the liquid refrigerant C is supplied into the case 8 from the supply port 80i of the case 8, and the liquid refrigerant C is circulated and supplied into the case 8 by discharging the liquid refrigerant C out of the case 8 through the discharge port 80o. Then, the reactor 1A is cooled.

<< Embodiment 2 >>
In the second embodiment, with reference to FIG. 5, a mode including an inner adhesive layer 4 i that fixes the coil 2 and the inner core portion 31 in addition to the end adhesive layer 4 e described in the first embodiment will be described. Since the reactor 1B of the second embodiment is the same as the first embodiment except that the inner adhesive layer 4i is provided, the following description will be focused on differences from the first embodiment. FIG. 5 shows a longitudinal sectional view of the coil element 2a of the reactor 1B cut in the vertical direction along the axial direction thereof.

[Inner adhesive layer]
The inner adhesive layer 4i is provided along a part in the coil circumferential direction and along a part in the coil axial direction in the cylindrical region between the turn forming part of the coil elements 2a and 2b and the inner core part 31. Is mentioned. The coil 2 and the outer core portion 32 can be fixed by the end adhesive layer 4e, and the movement of the coil 2 can be further suppressed even if the region where the inner adhesive layer 4i is formed is part of the cylindrical region.

  The formation location of the inner adhesive layer 4i in the coil circumferential direction may be on the upper side or the lower side of the cylindrical region. The formation length of the inner adhesive layer 4i in the coil circumferential direction is set such that the vibration of the coil 2 can be appropriately suppressed and the inner core portion 31 is not easily inserted into the coil elements 2a and 2b during assembly. For example, the circumferential region in the coil circumferential direction of the inner adhesive layer 4i is preferably about 15% or more and 50% or less of the entire circumferential length of the inner circumferential surface of the coil 2 (the outer circumferential surface of the inner core portion 31). In addition, when the inner adhesive layer 4i is formed in the circumferential direction of the coil, the inner circumferential surface of the coil elements 2a and 2b and the inner core portion 31 have a plane formed by a flat surface. The total length (length along the coil circumferential direction in the plane) is preferable.

  The central portion of the coil 2 in the axial direction is preferably formed in the coil axial direction of the inner adhesive layer 4i. If it does so, since the end surface and axial direction center of coil element 2a, 2b can be fixed with the magnetic core 3, the movement of the coil 2 is easy to be suppressed. The formation length of the inner adhesive layer 4i in the coil axial direction may be the length of the entire length in the coil axial direction, but the coil 2 and the outer core portion 32 can be fixed by the end adhesive layer 4e as described above. It may not be the length over the axial direction full length of coil element 2a, 2b. For example, the axial region of the inner adhesive layer 4i may be 50% or more and 100% or less, particularly 50% or more and 80% or less of the length in the coil axial direction.

  The thickness of the inner adhesive layer 4i is such that the coil elements 2a, 2b and the inner core part 31 can be set to a desired distance while the coil elements 2a, 2b and the inner core part 31 are fixed. The desired distance includes, for example, a degree that the coil elements 2a and 2b and the inner core portion 31 can ensure sufficient insulation by the inner adhesive layer 4i. In particular, when the coil elements 2a, 2b and the inner core part 31 are fixed via the inner adhesive layer 4i, the distance between the inner peripheral surface of the coil elements 2a, 2b and the surface of the inner core part 31 is the entire circumferential direction. It is preferable to make it uniform over the circumference. Specifically, the inner adhesive layer 4i has a thickness of 0.05 mm or more and 0.5 mm or less.

  Here, the shape of the inner adhesive layer 4i is a piece. The inner adhesive layer 4i is formed in the coil circumferential direction only on the lower surface side of the coil elements 2a and 2b, and the axially formed position is substantially the center in the axial direction of the coil elements 2a and 2b. The circumferential region of the inner adhesive layer 4i covers the entire length of one plane of the inner circumferential surfaces of the coil elements 2a and 2b, and the axial region is about 30% of the axial length of the coil elements 2a and 2b. (FIG. 5).

  The inner adhesive layer 4i is preferably interposed at least in part between the turns of the coil elements 2a and 2b. If it does so, the surface which adjoins each turn of coil element 2a, 2b can be fixed, the space | interval between turns can be fixed, and the collision and rubbing of turns can be suppressed further. Such an inner adhesive layer 4i can be formed by pressing the coil 2 from the outside toward the inner core portion 31 and allowing the inner adhesive to enter between the turns of the coil elements 2a and 2b.

  The inner adhesive layer 4 i is formed by hanging the inner adhesive from the outside of each coil element 2 a, 2 b to the outer peripheral surface thereof and between the coil elements 2 a, 2 b and the inner core portion 31 between the turns of the coil elements 2 a, 2 b. It can also be done by curing the adhesive after flowing. When the inner adhesive layer 4i is provided on the lower side of the inner core 31 as in this example, after the coil 2 and the magnetic core 3 are fixed by the end adhesive 4e, the upper and lower sides of the combined body 10 are once turned upside down. Adhesive should be hung. In this case, a liquid adhesive having a low viscosity (for example, about 1 Pa · s) can be used as the inner adhesive. If it does so, it will be easy to flow an inner side adhesive agent inside each coil element 2a, 2b (between the inner core parts 31). Further, it is easy to maintain a state in which the inner adhesive flowing between the coil elements 2a and 2b and the inner core portion 31 through the turns is interposed therebetween. As the constituent material of the inner adhesive layer 4i, the same material as that of the end adhesive layer 4e can be used.

[Magnetic core]
(Projection)
Both middle resin mold parts 31c can also be provided with a ridge part (not shown) that maintains the distance between the coil elements 2a, 2b and the inner core part 31. The protruding portion is formed along at least a part of the axial direction of the coil elements 2a and 2b. The protruding portion may be formed integrally with the middle resin mold portion 31c using the constituent material of the middle resin mold portion 31c.

  The formation part of the ridge part can be selected as appropriate as long as it is on the outer peripheral surface of the inner core part 31, but other than the surface (lower surface) in contact with the inner adhesive layer 4 i and the surface in contact with the inner adhesive layer 4 i in the middle resin mold part 31 c (For example, a surface (upper surface) facing the inner adhesive layer 4i across the middle main body 31). When provided on the lower surface side, it is preferable that the two protrusions are provided separately. If it does so, when forming the inner side adhesive layer 4i, between the protrusion parts can be utilized for the formation location of an adhesive agent. In addition, when the inner adhesive is cured to form the inner adhesive layer 4i, even if the adhesive is pressed by pressing the coil elements 2a and 2b toward the inner core 31 as described above, the ridge portion Becomes a wall and it is difficult for the adhesive to flow on the other surface (side surface). Therefore, it is easy to make the formed inner adhesive layer 4i have a uniform thickness over the entire area. In the latter case, the protrusions are not provided on the lower surface in contact with the inner adhesive layer 4i or on the upper surface facing each other, but one is provided on each side surface. If it does so, it is easy to hold | maintain the space | interval of the inner core part 31 and coil element 2a, 2b.

  The longer the length of the ridge portion along the coil axis direction, the easier it is to keep the inner core portion 31 and the coil elements 2a, 2b uniformly spaced along the axial direction of the coil 2. Therefore, the length of the protrusion is preferably the length over the entire axial length of the coil 2.

[Manufacture of reactors]
In the manufacture of the reactor 1A described above, the reactor 1B applies the inner adhesive also to the lower surface of the inner core portion 31 when applying the end adhesive and the core adhesive. When the constituent members are combined as described above and the adhesive is cured, the lower surfaces of the coil elements 2a and 2b are pushed toward the inner core portion 31 side, and the inner peripheral surfaces of the coil elements 2a and 2b are moved to the inner core. Fully contact the inner adhesive on the lower surface of the part 31. In that state, the end adhesive, the core adhesive, and the inner adhesive are cured. Thus, the reactor 1B is obtained in which the coil elements 2a, 2b and the outer core portions 32 are fixed by the end adhesive layer 4e, and the coil elements 2a, 2b and the inner core portion 31 are fixed by the inner adhesive layer 4i. .

  According to the reactor 1B, in addition to fixing the end surfaces of the coil elements 2a and 2b and the outer core portion 32 by the end adhesive layer 4e, the inner peripheral surface and the inner core portion 31 of the coil elements 2a and 2b by the inner adhesive layer 4i. Can also be fixed. Therefore, the movement of the coil 2 can be further suppressed. Of course, it is not necessary to provide the resin which covers the whole surface of the coil 2 like the past. Therefore, it is possible to reduce noise and damage to the insulation coating of the coil 2 while improving the heat dissipation of the reactor.

<< Embodiment 3 >>
In the third embodiment, with reference to FIG. 6, in addition to the end adhesive layer 4e described in the first embodiment, a mode including a fixed covering layer 4o that fixes the interval between the turns of the coil elements 2a and 2b will be described. . Since the reactor 1C of the third embodiment is the same as the first and second embodiments except that the reactor 1C includes the fixed coating layer 4o, the following description will be focused on differences from the first embodiment. FIG. 6 shows an overall perspective view of the reactor 1C.

[Fixed coating layer]
The fixed coating layer 4o may be provided on a part of the outer circumferential surface of the coil elements 2a and 2b along at least a part of the axial direction of the coil elements 2a and 2b. If it does so, the space | interval of turns can be fixed, increasing the exposed area of the outer peripheral surface of coil element 2a, 2b, and the collision and friction of turns can be suppressed further.

  The formation location of the fixed coating layer 4o in the coil circumferential direction may be the upper side or the lower side of the combined body 10. The formation length of the fixed covering layer 4o along the circumferential direction of the coil is set such that the exposed area of the coil elements 2a and 2b is narrowed and the heat dissipation is not deteriorated so much. For example, 5% or more and 40% or less of the entire peripheral length of the outer peripheral surface of the coil 2 is preferable. In addition, the formation length of the fixed coating layer 4o along the coil circumferential direction is such that, when the outer circumferential surface of the coil elements 2a and 2b has a plane formed by a plane, the width of one plane (along the coil circumferential direction on the plane). 30% or more of the length). If it does so, it can have the outstanding heat dissipation, fixing turns.

  As for the formation location in the coil axial direction of the fixed covering layer 4o, at least the center in the axial direction of the coil 2 can be cited. Further, the length of the fixed coating layer 4o along the coil axis direction is preferably, for example, 50% or more of the length in the coil axis direction, 75% or more, and particularly preferably the total axial length.

  The thickness of the fixed coating layer 4o is preferably as thin as possible. If it does so, it can have the outstanding heat dissipation. For example, the thickness of the fixed coating layer 4o is preferably 0.5 mm or less, and particularly preferably 0.2 mm or less. The lower limit of the thickness of the fixed coating layer 4o is about 0.05 mm.

  Here, as shown in FIG. 6, the formation location in the coil circumferential direction of the fixed covering layer 4o is the upper surface, and the formation location in the coil axial direction is the total axial length. That is, the formation length of the fixed coating layer 4o in the coil axis direction extends over the entire length in the coil axis direction. The formation length of the fixed covering layer 4o in the coil circumferential direction is about 30% of the width of the upper surface (about 5% of the entire circumference of the coil). The thickness of the fixed coating layer 4o is 0.2 mm.

  For the same reason as the inner adhesive layer 4i, the fixed covering layer 4o is preferably interposed at least at a part between the turns of the coil elements 2a and 2b. The fixed coating layer 4o can be formed by curing the constituent material before curing of the fixed coating layer 4o after application or spraying, or after immersion in the constituent material. At this time, if the constituent material is interposed between the turns, the fixed coating layer 4o interposed between the turns can be obtained.

  As a constituent material of the fixed coating layer 4o, an insulating resin (insulating varnish) used for insulating coating can be used. Specific examples include insulating resins such as polyamideimide resin, polyimide resin, polyesterimide resin, unsaturated polyester resin, alkyd resin, polyurethane resin, and epoxy resin.

[Manufacture of reactors]
The reactor 1 </ b> C coats the outer peripheral surface of the coil 2 with the fixed coating layer 4 o described above before combining the coil 2 and the magnetic core 3. Here, the constituent material of the fixed covering layer 4o is applied to a predetermined portion of the outer peripheral surface of the coil elements 2a and 2b with a brush, and then the constituent material is cured. Thereby, the coil elements 2a and 2b in which the interval between turns is fixed can be formed. The coil elements 2a and 2b are fixed to the outer core portion 32 by the end adhesive layer 4e in the same manner as the manufacture of the reactor 1A described above. Thus, the reactor 1C in which the turns of the coil elements 2a and 2b are fixed by the fixed coating layer 4o is obtained.

  According to the reactor 1C, in addition to fixing the end surfaces of the coil elements 2a and 2b and the outer core portion 32 by the end adhesive layer 4e, the interval between the turns of the coil elements 2a and 2b can be fixed by the fixed coating layer 4o. . Therefore, the movement of the coil 2 can be further suppressed. Of course, it is not necessary to provide the resin which covers the whole surface of the coil 2 like the past. Therefore, it is possible to reduce noise and damage to the insulation coating of the coil 2 while improving the heat dissipation of the reactor.

  In addition, you may provide the inner side adhesion layer 4i (refer FIG. 5) demonstrated in Embodiment 2. FIG. In that case, the formation part of the fixed coating layer 4o includes the side facing the inner adhesive layer with the inner core portion interposed therebetween. Since the turns can be fixed by the fixed coating layer 4o, and the coil and the inner core portion can be fixed by the inner adhesive layer, the movement of the coil can be easily suppressed.

<< Embodiment 4 >>
In the first embodiment, the form in which the thickness of the intervening region 32i of the side resin mold portion 32c is uniform over the entire region has been described. That is, the embodiment including the end adhesive layer 4e whose thickness increases along the inclined surface of the coil 2 has been described. In the fourth embodiment, a mode in which the thickness of the intervening region 32i increases along the inclined surface of the coil will be described mainly with reference to FIG. The following description will focus on the differences from the first to third embodiments. FIG. 7 shows only the other outer core portion 32 (left side in FIG. 1) for convenience of explanation, but one outer core portion 32 (see right side in FIG. 1) also has the same configuration.

  As in the first to third embodiments, the intervening region 32i of the side resin mold portion 32c is formed along the periphery of the inner core facing region (inner end surface 32e) of the side main body portion 32b, as shown by the hatched portion in FIG. This is an L-shaped region. In the interposition area | region 32i, the opposing surface with the coil element is comprised by the inclined surface corresponding to the form of the end surface of a coil element. That is, the surface constituting the intervening region 32i and the end surface of the coil element are parallel. The thickness of the intervening region 32i is increased along the inclination of the end surface of the coil element as the end surface of the coil element is separated from the intervening region 31i (coil facing region 32f).

  Specifically, the thickness of the intervening region 32i gradually increases along the clockwise direction in FIG. That is, the thickness of the intervening region 32i (left side in FIG. 7) facing the coil element 2a (see FIG. 1) gradually increases from the upper side to the lower side of the outer core portion 32. The thickness of the intervening region 32i gradually increases from the center side (right side in FIG. 7) of the outer core portion 32 to the outer side in the width direction (left side in FIG. 7). On the other hand, the thickness of the intervening region 32i (right side in FIG. 7) facing the coil element 2b (see FIG. 1) is the lower side of the outer core portion 32, from the outer side in the width direction (right side in FIG. 7) to the center of the outer core portion 32. It gradually becomes thicker toward the side (left side in FIG. 7). The thickness of the intervening region 32 i gradually increases from the lower side to the upper side of the outer core portion 32. The side resin mold portion 32c having the intervening region 32i can be formed by insert molding or the like.

  According to this configuration, since the thickness of the end adhesive layer can be made uniform over the entire region, it is easy to make the adhesive strength between the coil element and the outer core portion 32 uniform over the entire end adhesive layer. And the outer core portion 32 are easily fixed firmly.

<< Embodiment 5 >>
In the first embodiment, the form in which the shape of the end adhesive layer 4e is L-shaped has been described. As Embodiment 5, the shape of the end adhesive layer may be U-shaped. Specifically, the outer core portion includes a protruding portion that protrudes outward in the width direction of the side main body portion and faces the outer surface in the width direction of the coil end surface, or a side main body portion whose width is equal to or greater than the coil width. The form provided is mentioned. In the former case, the overhanging part may be formed integrally with the side resin mold part by the constituent material of the side resin mold part. According to this configuration, the U-shaped end adhesive layer can be interposed between the coil end surface and the outer core portion to fix the coil and the outer core portion, and the end portion can be compared with the L-shaped end adhesive layer. Since the adhesive region of the partial adhesive layer is wide, the movement of the coil can be further suppressed.

Embodiment 6
In the sixth embodiment, with reference to FIG. 8, a mode in which a heat radiating plate 9 is provided instead of the case 8 described in the first embodiment will be described. Since the reactor 1D of the sixth embodiment is the same as the first to fifth embodiments except that the reactor 1D includes a heat radiating plate 9 instead of the case 8, the following description will be focused on the differences. FIG. 8 shows an overall perspective view of the reactor 1 D , and shows the heat sink 9 separated from the coil 2.

[Heatsink]
The heat radiating plate 9 can be disposed at any location of the coil 2 that generates heat during use. Here, the heat sink 9 is disposed on the lower surface of the coil 2 and is interposed between the coil 2 and the installation target (FIG. 8). The heat radiating plate 9 only needs to have a size capable of contacting the lower surface of the coil 2, and the size and shape can be selected as appropriate. Here, the heat radiating plate 9 is formed of a rectangular plate-shaped member having a size capable of contacting the lower surface of the combined body 10 including not only the coil 2 but also the magnetic core 3. Therefore, the reactor 1 </ b> D can transmit the heat of the magnetic core 3 to the installation target in addition to the heat of the coil 2. In addition, by making the heat sink 9 sufficiently larger than the lower surface of the combined body 10, the heat sink 9 can be provided with a function as a pedestal for supporting the combined body 10 integrally, and the reactor can be easily carried and handled. Expected to be. When the heat radiating plate 9 is made larger than the lower surface of the combined body 10, for example, heat radiation is performed so as not to interfere with the bolt 36 for fixing to the installation target and the boss 82 formed on the installation target (see FIG. 5). It is preferable to provide through holes and notches (not shown) at the four corners of the plate 9. The thickness of the heat sink 9 can be selected as appropriate. For example, the thickness is about 2 mm or more and 5 mm or less. The constituent material of the heat sink 9 may be the same metal material as the case described above.

The assembly 10 (coil 2) and the heat sink 9 can be fixed by an adhesive or an adhesive sheet (not shown). While the movement of the coil 2 by the end adhesive layer 4 e of the above can be sufficiently suppressed, the movement of the coil 2 by the fixed (in particular, poor bonding between the end portion 2e and the terminal fitting 5) can be further suppressed.

<< Embodiment 7 >>
In the reactors of the first to sixth embodiments, the current application conditions are, for example, maximum current (direct current): about 100 A to about 1000 A, average voltage: about 100 V to about 1000 V, use frequency: about 5 kHz to about 100 kHz, typically electric It can be used for a component part of a converter mounted on a vehicle such as an automobile or a hybrid car, or a component part of a power conversion device including this converter.

  As shown in FIG. 9, a vehicle 1200 such as a hybrid vehicle or an electric vehicle is driven by a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and power supplied from the main battery 1210. 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, vehicle 1200 includes an engine in addition to motor 1220. In FIG. 9, although an inlet is shown as a charging location of the vehicle 1200, it can be set as a form provided with a plug.

  Power conversion device 1100 includes converter 1110 connected to main battery 1210 and inverter 1120 connected to 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 200V to 300V to about 400V to 700V and supplies 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 the motor 1220 with electric power. 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. 10, 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). As the switching element 1111, a power device such as a field effect transistor (FET) or an insulated gate bipolar transistor (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 prevents the change of the current to flow through the circuit. As this reactor L, the reactor in any one of Embodiments 1-6 is provided. In particular, in the case where the converter 1110 includes the case 8 in which the liquid refrigerant C can be circulated and supplied, by storing the reactor 1A and the like in the case 8, a structure with excellent heat dissipation can be easily constructed. By providing the reactor etc. which are excellent in heat dissipation, the power converter device 1100 and the converter 1110 can also expect improvement in heat dissipation.

In addition to converter 1110, vehicle 1200 is connected to power supply device converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting 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 power supply device converters 1150 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. Moreover, the reactor of Embodiments 1-6 can also be utilized for the converter which performs conversion of input electric power, and performs only the pressure | voltage rise, and the converter which performs only pressure | voltage fall.

  The present invention is not limited to these exemplifications, but is defined by the scope of the claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of the claims. For example, a reactor having only one coil element can be used. Moreover, it can be set as a conductor wire as a electrically-conductive member which supplies the electric power to a coil. The conductor wire may be a single wire made of a metal having excellent conductivity such as copper, copper alloy, aluminum or aluminum alloy, a stranded wire obtained by twisting a plurality of wires, or a compression wire obtained by compression-molding a stranded wire. Can be mentioned. The conductor wire may be a bare wire that does not have an insulating coating, or may be a coated wire that includes an insulating coating.

  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 conversion device.

1A, 1B, 1C , 1D reactor 10 Combination 2 Coil 2a, 2b Coil element 2r Connecting part 2w Winding 2e End 2f Outer core facing area 3 Magnetic core 3b Core molded body 31 Inner core part 31b Middle body part 31m Core piece 31g Gap material 31c Middle resin mold part 31t Thin wall part 32 Outer core part 32e Inner end surface (inner core facing area)
32b side body portion 32f coil facing area 32c side resin mold portion 32i intervening regions 32t tubular portion 33 mounting portion 34 partition portion 35 collar 36 volts 4e end adhesive layer 4i inner adhesive layer 4o fixed coating layer 5 pin gold instrument
7 s sensor 7c wiring 70 holder 71 main body 72f hook 8 case C liquid refrigerant 80i supply port 80o discharge port 81 mounting surface 82 boss 9 heat dissipation plate 1100 power converter 1110 converter 1111 switching element 1112 drive circuit L reactor 1120 inverter 1150 inverter 1150 Converter 1160 Auxiliary power supply converter 1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery 1240 Auxiliary equipment 1250 Wheel

Claims (9)

A coil formed by winding a winding, an inner core portion disposed inside the coil, and a magnetic core having an outer core portion connected to the inner core portion to form a closed magnetic path together with the inner core portion. A reactor with which
The outer core portion includes a side main body portion serving as a magnetic path,
The side body portion has an opposing surface including an inner core facing region facing the inner core portion and a coil facing region facing an end surface of the coil,
A heat dissipating plate disposed on an installation surface of the coil;
A reactor comprising an end adhesive layer that is interposed between an end face of the coil and the coil facing region and fixes the coil and the outer core portion. A coil formed by winding a winding, an inner core portion disposed inside the coil, and a magnetic core having an outer core portion connected to the inner core portion to form a closed magnetic path together with the inner core portion. A reactor with which
The outer core portion includes a side main body portion serving as a magnetic path,
The side body portion has an opposing surface including an inner core facing region facing the inner core portion and a coil facing region facing an end surface of the coil,
A reactor comprising an end adhesive layer that is interposed between an end face of the coil and the coil facing region and fixes the coil and the outer core portion. An inner adhesive layer that is interposed between the coil and the inner core portion and fixes the coil and the inner core portion;
The reactor according to claim 1, wherein the inner adhesive layer is provided on a part of a circumferential direction of the coil.   The fixed coating layer which fixes the space | interval of the turns of the said coil formed in a part of the circumferential direction in the outer peripheral surface of the said coil along at least one part of the axial direction of the said coil is provided. The reactor of any one of these.   The reactor according to any one of claims 1 to 4, wherein the end adhesive layer is made of an ultraviolet curable adhesive. The outer core portion includes a side resin mold portion that covers at least part of the outer periphery of the side main body portion and insulates the side main body portion and the coil from each other.
The said side resin mold part is a reactor of any one of Claims 1-5 which have the interposition area | region interposed between the said side main-body part and the said edge part adhesion layer. The surface facing the coil in the intervening region is composed of an inclined surface corresponding to the form of the end surface of the coil,
The reactor according to claim 6, wherein the thickness of the intervening region is increased along the inclination of the end surface of the coil as the end surface of the coil is separated from the coil facing region. The inner core portion is
Middle body part that becomes magnetic path,
The reactor of any one of Claims 1-7 provided with the middle resin mold part which covers at least one part of the outer periphery of the said middle main-body part, and insulates between the said middle main-body part and the said coil.   The reactor according to any one of claims 1 to 8, further comprising a case in which a combination of the coil and the magnetic core is housed and a liquid refrigerant is supplied and discharged.

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