JP6016035B2 - 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 an 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 of this invention is provided with the coil formed by winding a coil | winding, and the magnetic core which has an inner core part which is arrange | positioned inside a coil and comprises a part of closed magnetic circuit. The reactor includes an adhesive layer that is interposed between the inner peripheral surface of the coil and the inner core portion and fixes the coil and the inner core portion. The adhesive layer is provided on a part of the coil in the circumferential direction.

  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 (II)-(II) sectional drawing of the reactor shown in FIG. It is (III)-(III) sectional drawing of the reactor shown in FIG. It is a disassembled perspective view which shows the outline of the union body with which the reactor of Embodiment 1 is equipped. It is a schematic explanatory drawing which shows the use condition of the reactor of Embodiment 1. It is a schematic perspective view which shows the reactor which concerns on Embodiment 2. 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 1st reactor which concerns on embodiment is provided with the coil formed by winding a coil | winding, and the magnetic core which has an inner core part which is arrange | positioned inside a coil and comprises a part of closed magnetic circuit. The reactor includes an adhesive layer that is interposed between the inner peripheral surface of the coil and the inner core portion and fixes the coil and the inner core portion. The adhesive layer is provided on a part of the coil in the circumferential direction.

  According to the first reactor, the coil and the inner core portion are not fixed by the resin that covers the entire circumference of the coil integrally with the magnetic core as in the conventional case, but the inner peripheral surface of the coil and the inner core portion. And an 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 inner core portion with the adhesive layer, the axial direction of the coil due to the influence of the vibration of the coil and the magnetic core during the operation of the reactor or the external environment (for example, the liquid refrigerant). In addition, movement in 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 formation of the adhesive layer is, for example, a part in the circumferential direction of the coil and at least a part in the axial direction of the coil. Easy to insert.

  (2) The 2nd reactor which concerns on embodiment is provided with the coil formed by winding a coil | winding, and the magnetic core which has an inner core part which is arrange | positioned inside a coil and comprises a part of closed magnetic circuit. The reactor includes a heat dissipating plate disposed on the installation surface of the coil, and an adhesive layer that is interposed between the inner peripheral surface of the coil and the inner core portion and fixes the coil and the inner core portion. The adhesive layer is provided on a part of the coil in the circumferential direction.

  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, it is mentioned that the contact bonding layer is provided in the edge part side of a coil | winding among coils.

  According to said structure, it is easy to suppress application of the excessive stress to the edge part of a coil | winding. When the end portion side of the winding in the turn forming portion of the coil moves in the axial direction and the circumferential direction, the end portion of the winding tends to follow the movement. Usually, a terminal fitting to which an external device such as a power source for supplying power to the coil is connected is connected to the end of the winding. The terminal fitting is fixed to a terminal block or the like. For this reason, when the coil moves, excessive stress is applied to the connection portion between the end of the winding and the terminal fitting due to the movement. According to said structure, since the contact bonding layer is provided in the coil end part side among coils, the movement of the said end part side of a turn formation part can be suppressed, and the coil of the coil part at the end of a coil | winding can be suppressed. Follow-up with movement can be suppressed.

  (4) As one form of said 1st and 2nd reactor, it is mentioned that the inner peripheral surface of the coil and the surface of an inner core part which an adhesive layer contacts are comprised by the plane.

  According to said structure, since the inner peripheral surface of a coil and the surface of an inner core part which an adhesive layer contacts are comprised by the plane, it is easy to form the adhesive layer where the thickness of an adhesive layer is equal over the whole region. Therefore, it is easy to fix the coil and the inner core portion uniformly over the entire adhesive layer, and it is easy to fix the coil and the inner core portion more firmly.

  (5) As one form of said 1st and 2nd reactor, it is mentioned that the contact bonding layer is interposed in at least one part between the turns of a coil.

  According to said structure, the space | interval between turns of a coil can be fixed and the collision and rubbing of turns can be suppressed further.

  (6) As one form of said 1st and 2nd reactor, it is mentioned that the contact bonding 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.

  (7) As one form of said 1st and 2nd reactor, an inner core part covers at least one part of the outer periphery of a middle main-body part used as a magnetic path, and 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.

  (8) As one form of said 1st and 2nd reactor, a magnetic core is provided with the outer core part connected with an inner core part and forming a closed magnetic circuit with an inner core part. In this case, an outer core part is provided with a side main-body part, a terminal metal fitting, and a side resin mold part. A side main-body part becomes a magnetic path. The terminal fitting is connected to the end of the coil winding. The side resin mold part covers at least a part of the outer periphery of the side main body part, insulates the side main body part and the coil, and between the side main body part and the terminal metal fitting, and between the side main body part and the terminal metal fitting. Hold it together.

  According to said structure, the insulation between a side main-body part and a coil and between a side main-body part and a terminal metal fitting is securable by providing a side resin mold part. 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. And since a side main-body part and a terminal metal fitting can be handled as an integrated object, a number of parts can be reduced and the assembly workability | operativity of a reactor can be improved.

<< 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. 1-5, 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 the coil 2 and the inner core portion 31 are arranged at a specific location between the coil 2 and the inner core portion 31 arranged inside the coil 2 of the magnetic core 3. The adhesive layer 4 to be fixed is provided. 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 4, 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, and both the coil elements 2 a and 2 b. Connecting portion 2r. As the winding 2w, a coated rectangular wire in which an outer periphery of a conductor made of a rectangular wire is coated with an insulating coating is used, and the coil elements 2a and 2b are configured by edgewise coils in which the coated rectangular wire is wound edgewise. The coil elements 2a and 2b are arranged in parallel (side by side) so that the axial directions are parallel to each other. The shape of the coil elements 2a and 2b is a hollow cylindrical body (square tube) having the same number of turns, and the end face shape of the coil elements 2a and 2b is a shape obtained by rounding the corners of the rectangular frame. That is, the inner peripheral surfaces of the coil elements 2a and 2b are composed of four planes and four curved surfaces that connect adjacent planes. The connecting portion 2r is formed by bending a part of the winding in a U shape on one end side (FIG. 1, right side of FIG. 1) of the coil 2.

  Both end portions 2e of the winding 2w of the coil elements 2a and 2b are flatwise bent on the side opposite to the connecting portion 2r side and extended from the turn forming portion. The lead portion extending from the turn forming portion to the end portion 2e of the winding 2w is located on the upper side (upper side in FIG. 2) in the coil circumferential direction, and the lead direction of both end portions 2e is the axial direction of the coil elements 2a and 2b. Is one end side. A conductive member (here, a terminal fitting 5 to be described later) is connected to both end portions 2e.

(Magnetic core)
As shown in FIG. 4, 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) from the coil 2 where the coil 2 is not disposed. Outer core portions 32 and 320 are provided. The magnetic core 3 has outer core portions 32 and 320 disposed so as to sandwich the inner core portion 31 that is spaced apart, and the end surface of the inner core portion 31 and the inner end surface 32e of the outer core portion 320 are brought into contact with each other to form an annular shape. Formed. When the coil 2 is excited by the inner core portions 31 and 31 and the outer core portions 32 and 320, a closed magnetic circuit is formed. A specific connection / separation form between the inner core portions 31 and 31 and the outer core portions 32 and 320 will be described later.

<Inner core part>
The shape of the inner core portion 31 is preferably a shape that matches the shape of the coil 2 (the internal space of the coil 2). Here, as shown in FIG. 4, the shape of the inner core portion 31 is a rectangular parallelepiped shape, and the corner portions (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 inner core portion 31 is a rectangular shape with rounded corners, and the side surfaces (surfaces along the circumferential direction of the coil elements 2a and 2b) of the inner core portion 31 are adjacent to four planes. It is comprised with four curved surfaces which connect planes (FIGS. 3, 4).

[Adhesive layer]
The adhesive layer 4 fixes the coil 2 and the inner core portion 31. The adhesive layer 4 is a part of the circumferential direction of the coil elements 2a, 2b and at least in the axial direction of the coil elements 2a, 2b between the inner peripheral surfaces of the coil elements 2a, 2b and the surface of the inner core portion 31. It is provided along a part. The shape of the adhesive layer 4 can take various shapes such as a piece shape, a tape shape, and a sheet shape according to the range of the adhesion region between the coil elements 2 a and 2 b and the inner core portion 31.

  The formation location of the adhesive layer 4 is the end portion 2e side of the winding 2w in both the axial direction and the circumferential direction of the coil 2, that is, the cylindrical region between the turn forming portion of the coil 2 and the inner core portion 31. The side close to the end 2e of the winding 2w is preferable. For example, when the lead portion from the turn forming portion to the end portion 2e of the winding 2w is on one end side in the coil axis direction of the winding 2w, the adhesive layer 4 is formed on at least one end side of the cylindrical region. When this lead-out portion is on the upper side of the inner core portion 31, the adhesive layer 4 may be formed at least above the inner core portion 31 in the cylindrical region. This is because it is possible to suppress the vibration of the turn forming portion from adversely affecting the joined state between the end 2e of the winding 2w and the terminal fitting 5.

  The end 2 e of the coil 2 is fixed to the terminal fitting 5, but when the adhesive layer 4 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, the influence of the vibration of the turn forming portion reaches the lead-out portion of the winding 2w by setting the adhesive layer 4 to be formed at least on the side close to the end 2e of the winding 2w in the cylindrical region. , And the occurrence of the above-mentioned bonding failure can be reduced as much as possible.

  The formation length of the adhesive layer in the coil circumferential direction is preferably about 15% to 50% of the total circumferential length of the inner circumferential surface of the coil 2 (the outer circumferential surface of the inner core portion 31). If it is 15% or more of the entire circumference, the vibration of the coil 2 can be appropriately suppressed. It is hard to become.

  The formation length of the adhesive layer 4 in the coil axis direction is preferably 25% or more, more preferably 50% or more, and 75% or more of the entire length of the coil 2, and particularly preferably the full length. If it is 25% or more of the total length of the coil 2, it is easy to suppress a bonding failure between the end 2 e of the winding 2 w and the terminal fitting 5. If the adhesive layer 4 is formed over the entire length of the coil 2, vibration and movement of the coil 2 can be more reliably suppressed, and rubbing between all turns can be easily suppressed.

  The thickness of the adhesive layer 4 is such that the coil elements 2a, 2b and the inner core part 31 can be fixed at 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 to which the coil elements 2 a and 2 b and the inner core portion 31 can ensure sufficient insulation by the adhesive layer 4. In particular, when the coil elements 2a, 2b and the inner core portion 31 are fixed via the adhesive layer 4, the distance between the inner peripheral surface of the coil elements 2a, 2b and the surface of the inner core portion 31 is the entire circumference. It is preferable to make it uniform over the range. Specifically, the thickness of the adhesive layer 4 is 0.05 mm or more and 0.5 mm or less.

  In the present embodiment, the shape of the adhesive layer 4 is a rectangular sheet. The adhesive layer 4 is formed only on the upper surface side in the circumferential direction of the coil 2 (inner core portion 31), and is an area extending over the entire length in the axial direction (FIGS. 2 and 3). In particular, the formation location of the adhesive layer 4 in the coil circumferential direction is one flat surface of the inner peripheral surfaces of the coil elements 2a and 2b. The lead-out portion of the winding 2w is located on one end side in the coil axis direction (left side in FIG. 2) and on the upper side in the coil circumferential direction (upper side in FIG. 2). Therefore, if it is a formation location of the contact bonding layer 4 of this embodiment, the inner core part 31 can be fixed not only on the one end side of the internal peripheral surface and the upper side but the inner core part 31 over the full length of an axial direction. In particular, when the adhesive layer 4 is provided only on the upper surface side of the inner core portion 31, when the coil 2 and the inner core portion 31 are assembled, the coil 2 is pushed toward the inner core portion 31 from the upper portion, whereby the inner core portion 31 is pressed. It is easy to press the inner peripheral surface of the coil 2 on the upper surface of the coil.

  The adhesive layer 4 is preferably interposed at least at a 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, and the space | interval of a turn can be fixed, and the collision and rubbing of turns can be suppressed further. Such an adhesive layer 4 can be formed by pressing the coil 2 from the upper part toward the inner core part 31 and allowing the adhesive to enter between the turns of the coil elements 2a and 2b.

  The adhesive layer 4 is formed by hanging an adhesive from the outside of the coil elements 2 a and 2 b to the outer peripheral surface (upper surface) and between the turns of the coil elements 2 a and 2 b to between the coil elements 2 a and 2 b and the inner core portion 31. It can also be done by curing the adhesive after flowing. In this case, a liquid adhesive having a low viscosity (for example, about 1 Pa · s) can be used as the adhesive. If it does so, it will be easy to make an adhesive flow inside each coil element 2a, 2b (between the inner core parts 31). In addition, it is easy to maintain a state in which the adhesive flowing between the coil elements 2a, 2b and the inner core portion 31 through the turns is interposed therebetween.

  The constituent material of the adhesive layer 4 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. If it does so, the coil 2 and the inner core part 31 can be fixed reliably at the time of operation | movement of the reactor 1A.

  The constituent material of the adhesive layer 4 is, for example, a thermosetting insulating adhesive such as an epoxy resin, a silicone resin or an unsaturated polyester, a thermoplastic insulating adhesive such as a polyphenylene sulfide (PPS) resin or a liquid crystal polymer (LCP). An ultraviolet (light) curable insulating adhesive such as an agent, 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 adhesive can be cured by irradiating with ultraviolet rays, and it is not necessary to heat the adhesive layer 4 to a higher temperature than the thermosetting adhesive when the adhesive layer 4 is formed. Further, since the adhesive is not cured unless it is irradiated with ultraviolet rays, there are few restrictions on the time until curing, for example, when the adhesive layer 4 is formed. Furthermore, since the curing rate of the adhesive is relatively fast, it is easy to shorten the time for forming the adhesive layer 4 and thus the time for manufacturing the reactor 1A.

[Effects of the main features of the reactor]
According to the reactor 1A, between the inner peripheral surfaces of the coil elements 2a and 2b and the surface of the inner core portion 31, a part of the coil elements 2a and 2b in the circumferential direction has a full axial length of the coil elements 2a and 2b. By providing the adhesive layer 4 over the coil 2, the coil 2 and the magnetic 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, the liquid refrigerant C and the coil 2 can be made to contact directly and the heat dissipation of reactor 1A 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 from the external environment such as the liquid refrigerant C and the vibration of the coil 2 and the magnetic core 3 during the operation of the actuator 1A. 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 and 320. Here, the form of the magnetic core 3 includes a U-shaped core molded body 3b in which one outer core portion 32 (right side in FIG. 4) and both inner core portions 31 are integrated, and the other outer core portion 320 ( Left side of FIG. 4). The U-shaped core molded body 3b and the other outer core portion 320 can be joined via an adhesive. The upper surfaces of the outer core portions 32 and 320 and the inner core portion 31 are substantially flush. On the other hand, the sizes of the outer core portions 32 and 320 are adjusted so that the lower surfaces of the outer core portions 32 and 320 protrude from the lower surface of the inner core portion 31 and are 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 320 and the lower surface of the coil 2.

(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 ( FIG. 4). 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.

{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 side main body 32b 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 the shape of the side main body 32b, for example, a prismatic body can be used.

  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 one side main body portion 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 320 side of 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 320 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 facing surface of the middle main body portion 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 320 is made of a constituent material of the middle resin mold portion 31c. .

{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 part 32c may be at least a part of the inner end face 32e facing the coil elements 2a and 2b and a part facing the connecting part 2r on the upper surface. 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. . The side main body portion 32b protrudes (exposes) from the coil 2, and if the side main body portion 32b is formed of a powder molded body and is covered with the side resin mold portion 32c, the side main body portion 32b is made insulating and rustproof. In addition, it is effective in preventing the 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 between the side main body portion 32b and the pair of middle main body portions 31b.

  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 320 (left side of FIG. 4) 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 32 c is at least a portion facing the coil elements 2 a and 2 b in the side main body portion 32 b and a portion facing the terminal fitting 5. 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 region facing the end face of the inner core portion 31 in the other side main body portion 32b is exposed and the other portions are covered.

<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 31b and the side main body 32b include nonmetals such as iron, iron alloys, 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 may be configured to include a pair of L-shaped core molded bodies in which one outer core portion 32 (320) 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 and 320 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 and 320 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 portions 32 and 320 can be joined with an adhesive.

[Other configuration of magnetic core]
(Mounting part)
Both side resin mold portions 32c preferably include attachment portions 33 for fixing the combined body 10 to an installation target (FIGS. 1 and 4). 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 portions 32 and 320 are provided at substantially intermediate positions in the height direction.

  A collar 35 that receives a tightening force by the bolt 36 through which a bolt 36 (FIG. 5) used when the assembly 10 is fixed to an installation target is passed 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 parts 32c preferably include a partition part 34 that ensures insulation between the coil elements 2a and 2b (FIG. 4). 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.

(Terminal bracket)
The other outer core portion 320 includes a terminal fitting 5 that supplies power to the coil 2 from an external device (not shown) such as a power source. The terminal fitting 5 is a substantially L-shaped fitting obtained by bending a flat metal piece. The terminal fitting 5 includes a thin plate-like coil side connection piece 51 connected to the end 2e of each coil element 2a, 2b, a thick plate-like lead side connection piece 52 for connecting a lead connected to the external device, And a thick plate-like intermediate piece that connects both pieces 51 and 52. This intermediate piece is preferably embedded in the side resin mold portion 32c. Then, the embedded piece can be held together with the side main body portion 32b by the side resin mold portion 32c, and the terminal fitting 5 and the side main body portion 32b can be handled integrally, so that the number of parts can be reduced and the reactor 1A Assembly workability can be improved. The connection between the coil side connection piece 51 and the end 2e can be performed by various means such as welding (thermal caulking), welding such as TIG (Tungsten Inert Gas) welding, soldering, brazing, caulking.

  It is preferable that the connection surface with the end part 2e in the coil side connection piece 51 is wider than the connection surface with the coil side connection piece 51 in the end part 2e. If it does so, it will be easy to connect the edge part 2e and the coil connection piece 51. FIG. When the adhesive layer 4 is formed, the outer peripheral surfaces of the coil elements 2a and 2b may be pressed toward the inner core portion 31 as described above. If the terminal fitting 5 is held integrally with the side main body portion 32 b by the side resin mold portion 32 c, the end portion 2 e may be displaced with respect to the coil side connection piece 51. However, if the connection surface of the coil-side connection piece 51 is wider than the connection surface of the end 2e, a contact area between the two is ensured even if the position of the end 2e is slightly shifted due to the pressing of the coil elements 2a and 2b. Easy to do.

  On the other hand, the lead-side connection piece 52 is provided with a through hole 52h. A connecting member (not shown) such as a bolt for connecting the lead wire to the terminal fitting 5 is fitted into the through hole 52h. When the reactor 1 </ b> A includes a case 8 which will be described later, the lead side connection piece 52 is pulled out of the case 8.

  The terminal metal fitting 5 is integrally held with the side main body portion 32b by the side resin mold portion 32c. However, the terminal metal fitting 5 is not integrally held by the side resin mold portion 32c, but is connected to the side resin mold portion 32c separately by a terminal block or the like. You can also. In that case, it is mentioned that the terminal block and the side resin mold part 32c are provided with the engaging part which mutually engages.

  In addition, although the form provided with the plate-shaped terminal metal fitting 5 as a electrically-conductive member which supplies the electric power to the coil 2 is shown in this example, it can also be set as a conductor wire. 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.

(Other)
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 projecting portion of the ridge portion can be appropriately selected as long as it is on the outer peripheral surface of the inner core portion 31, but the surface (upper surface) in contact with the adhesive layer 4 in the middle resin mold portion 31c and other surfaces (lower surface and side surfaces). Is mentioned. When provided on the upper surface side, it is preferable to provide the two protrusions apart. If it does so, when forming the contact bonding layer 4, between protrusion parts can be utilized for the formation location of an adhesive agent. Further, when the adhesive is cured to form the adhesive layer 4, even if the adhesive is pressed by pressing the coil elements 2 a and 2 b toward the inner core portion 31 as described above, the protruding portion is not attached to the wall. It becomes difficult for the adhesive to flow on the other surface (side surface). Therefore, it is easy to make the formed adhesive layer 4 have a uniform thickness over the entire area. When provided on a surface other than the upper surface, it is possible to provide two protrusions on the lower surface and one on each side surface. If it does so, it is easy to hold | maintain the space | interval with the coil elements 2a and 2b over the coil circumferential direction whole periphery of the inner core part 31.

  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 protruding portion is preferably the length over the entire length in the coil axial direction.

  It is preferable that the other outer core part 320 is provided with a protrusion interval holding part 37 (FIG. 1) that is interposed between the lead side connection pieces 52 and maintains the interval between the two pieces 52. Then, the insulation between the lead side connection pieces 52 can be enhanced. The space | interval holding | maintenance part 37 is formed integrally with the side resin mold part 32c with the constituent material of the side resin mold part 32c.

  The reactor 1 </ b> A can also include a pressing piece (not shown) that firmly fixes the coil elements 2 a and 2 b and the inner core portion 31 with the adhesive layer 4. The pressing piece is inserted into the cylindrical region and presses the inner core portion 31 toward the coil 2 on the side facing the pressing piece in the cylindrical region. The pressing piece may be formed integrally with the side resin mold part 32c by the constituent material of the side resin mold part 32c, or may be constituted by a member different from the side resin mold part 32c. In the former case, the pressing piece may be provided on the inner end surface 32e of the outer core portion 320 so as to be interposed in a portion of the cylindrical region facing the adhesive layer 4 with the middle main body portion 31b interposed therebetween. . Examples of the shape of the pressing piece include a rectangular shape. The pressing piece may have a tapered shape in which the thickness on the tip side of the pressing piece is gradually reduced so that the pressing piece can be easily inserted between the coil 2 and the inner core portion 31. If the pressing piece is provided, when the pressing piece is inserted between the inner core portion 31 and the coil elements 2a and 2b, the upper surface of the inner core portion 31 and the inner peripheral surface of the coil 2 can be brought close to each other. Therefore, when forming the adhesive layer 4, the adhesive layer 4 can be formed by curing the adhesive in a state where the coil 2 and the inner core portion 31 are sufficiently in contact with the adhesive, and the coil elements 2a and 2b and the inner core are formed. It is easy to fix the part 31 firmly. When the pressing piece is provided with a protruding portion, it may be provided so as not to interfere with the protruding portion.

[Reactor usage status]
The use 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. 5). 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. Since the entire circumference of the coil 2 is not covered with resin as in the prior art and the coil 2 can be cooled by being brought into direct contact with the liquid refrigerant C, the heat dissipation of the reactor 1A can be improved. 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 case 8 can control the flow of the liquid refrigerant C that cools the combined body 10 by supplying and discharging the liquid refrigerant C, and can effectively cool the combined body 10. Further, since the coil 2 and the magnetic core 3 are fixed by the adhesive layer 4, even if the liquid refrigerant C is applied to the coil 2, the movement and deformation of the coil 2 in the axial direction and the circumferential direction can be suppressed. 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, and noise can be reduced. In the case where the coil 2 is composed of a covered wire, damage to the covered wire can be suppressed.

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]
The reactor 1A can include a sensor 7s that measures physical quantities (for example, temperature, current value, voltage value, acceleration, etc.) during operation of the reactor 1A (FIGS. 3 and 4). 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. As for the arrangement | positioning location of the sensor 7s, the area | region enclosed by the corner | angular part of coil element 2a, 2b is mentioned among the lower side and upper side between coil element 2a, 2b, for example.

  For example, a holder 70 as shown in FIG. 4 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, the position of the holder 70 is not substantially displaced and the position can be maintained satisfactorily. 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 described above and the magnetic core 3 including the core molded body 3b and the other outer core portion 320 are prepared. Subsequently, an adhesive constituting the adhesive layer 4 is applied to at least one of the inner peripheral surfaces of the coil elements 2a and 2b and the upper surface of the inner core portion 31 of the core molded body 3b. Here, an adhesive was applied to the upper surface of the inner core portion 31. Next, the inner core portion 31 is inserted into each of the coil elements 2a and 2b, and the inner end surface 32e of the other outer core portion 320 and the end surface of the inner core portion 31 are fixed with an adhesive, and the coil 2 and the magnetic core 3 are fixed. And combine. Then, the upper surfaces of the coil elements 2a and 2b are pushed toward the inner core portion 31 so that the inner peripheral surfaces of the coil elements 2a and 2b are sufficiently brought into contact with the adhesive on the upper surface of the inner core portion 31. In this state, the adhesive on the upper surface of the inner core portion 31 is cured, and the coil elements 2a and 2b and the inner core portion 31 are fixed. As described above, the reactor 1A in which the coil elements 2a, 2b and the inner core portion 31 are fixed by the adhesive layer 4 interposed between the coil elements 2a, 2b and the inner core portion 31 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 out of the case 8 through the discharge port 80o. Reactor 1A is cooled.

<< Embodiment 2 >>
In the second embodiment, referring to FIG. 6, 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 1B of the second embodiment is the same as that of the first embodiment except that a heat sink 9 is provided instead of the case 8, the following description will be focused on the differences. FIG. 6 shows an overall perspective view of the reactor 1 </ b> B, and shows the radiator plate 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 interposed between the coil 2 and the installation target. 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, in addition to the heat of the coil 2, the reactor 1 </ b> B can transmit the heat of the magnetic core 3 to the installation target. 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). Although the movement of the coil 2 can be sufficiently suppressed by the adhesive layer 4 described above, the movement of the coil 2 (particularly, the bonding failure between the end 2e and the terminal fitting 5) can be further suppressed by this fixing.

<< Embodiment 3 >>
In the reactors of the first and second embodiments, the current application conditions are, for example, maximum current (direct current): about 100 A to 1000 A, average voltage: about 100 V to 1000 V, use frequency: about 5 kHz to 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. 7, 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. 7, 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. 8, 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. 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 of Embodiment 1, 2 is provided. In particular, when the converter 1110 includes the case 8 that can circulate and supply the liquid refrigerant, by storing the reactors 1A, 1B 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 and second embodiments, and a reactor whose size and shape are appropriately changed can be used. In addition, the reactor of the first and second embodiments can be used for a converter that performs conversion of input power and that only performs step-up or only performs step-down.

  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.

  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 reactor 10 combination 2 coil 2a, 2b coil element 2r connecting part 2w winding 2e end 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 32 320 Outer core portion 32e Inner end surface 32b Side main body portion 32c Side resin mold portion 33 Mounting portion 34 Partition portion 35 Color 36 Bolt 37 Spacing holding portion 4 Adhesive layer 5 Terminal fitting 51 Coil side connection piece 52 Lead side connection piece 52h Through hole 7s 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 sink 1100 power converter 1110 converter 1111 switching element 1112 drive circuit L reactor 112 Inverter 1150 power feeding device converter 1160 auxiliary power converter 1200 vehicle 1210 main battery 1220 motor 1230 sub-battery 1240 auxiliaries 1250 wheels

Claims (8)

A reactor comprising a coil formed by winding a winding, and a magnetic core having an inner core portion that is disposed inside the coil and forms a part of a closed magnetic path,
A heat dissipating plate disposed on an installation surface of the coil;
An adhesive layer interposed between the inner peripheral surface of the coil and the inner core portion to fix the coil and the inner core portion;
The said adhesive layer is a reactor provided in a part of circumferential direction of the said coil. A reactor comprising a coil formed by winding a winding, and a magnetic core having an inner core portion that is disposed inside the coil and forms a part of a closed magnetic path,
An adhesive layer interposed between the inner peripheral surface of the coil and the inner core portion to fix the coil and the inner core portion;
The said adhesive layer is a reactor provided in a part of circumferential direction of the said coil.   The reactor according to claim 1, wherein the adhesive layer is provided on an end side of the winding in the coil.   The reactor according to any one of claims 1 to 3, wherein the inner peripheral surface of the coil and the surface of the inner core portion that are in contact with the adhesive layer are configured as a flat surface.   The reactor according to any one of claims 1 to 4, wherein the adhesive layer is interposed in at least a part between the turns of the coil.   The reactor according to any one of claims 1 to 5, wherein the adhesive layer is made of an ultraviolet curable adhesive. The inner core portion is
Middle body part that becomes magnetic path,
The reactor of any one of Claims 1-6 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 magnetic core includes an outer core portion that is connected to the inner core portion and forms a closed magnetic path together with the inner core portion,
The outer core portion is
A side body part that becomes a magnetic path
A terminal fitting connected to an end of the winding of the coil;
Covering at least a part of the outer periphery of the side main body and insulating between the side main body and the coil, and between the side main body and the terminal fitting, and the side main body and the terminal fitting, The reactor of any one of Claims 1-7 provided with the side resin mold part which hold | maintains integrally.

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