JP6024886B2 - Reactor, converter, and power converter - Google Patents

Reactor, converter, and power converter Download PDF

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Publication number
JP6024886B2
JP6024886B2 JP2012222230A JP2012222230A JP6024886B2 JP 6024886 B2 JP6024886 B2 JP 6024886B2 JP 2012222230 A JP2012222230 A JP 2012222230A JP 2012222230 A JP2012222230 A JP 2012222230A JP 6024886 B2 JP6024886 B2 JP 6024886B2
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coil
shielding plate
core portion
reactor
portion
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JP2013149943A (en
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和宏 稲葉
和宏 稲葉
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住友電気工業株式会社
住友電装株式会社
株式会社オートネットワーク技術研究所
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  The present invention relates to a reactor used as a component of a power conversion device such as an in-vehicle DC-DC converter mounted on a vehicle such as a hybrid vehicle, a converter including the reactor, and a power conversion device including the converter. It is. In particular, the present invention relates to a reactor that can reduce magnetic flux leakage and is excellent in productivity.

  A reactor is one of the parts of a circuit that performs a voltage step-up operation or a voltage step-down operation. This reactor is used for 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 comprises the structure which accommodated the assembly of the coil and the magnetic core in the case. The magnetic core has a cylindrical inner core portion disposed inside the coil, and a connecting core portion (outer core portion) that is disposed on the outer periphery of the coil and is composed of a mixture (composite material) of magnetic powder and resin. ) The case is a square box-shaped body (bottomed cylindrical shape) made of a metal such as aluminum.

JP 2011-124310 A

  In a reactor in which the outer periphery of the coil includes an outer core portion made of the composite material, magnetic flux may leak to the outside of the outer core portion when the coil is energized with an alternating current. As described above, the leakage magnetic flux can be reduced by covering the outer periphery of the combined body of the coil and the magnetic core with the bottomed cylindrical case made of aluminum. However, it is a typical manufacturing method that a bottomed cylindrical case is formed in a casting process and then shaped into a desired shape by post-processing such as cutting, and the manufacturing is likely to be complicated. For this reason, the productivity of the reactor is reduced.

  The present invention has been made in view of the above circumstances, and one of its purposes is to provide a reactor that can effectively reduce leakage of magnetic flux when a coil is excited and that is excellent in productivity. .

  Another object of the present invention is to provide a converter including the reactor and a power converter including the converter.

  The reactor of the present invention includes a cylindrical coil and a magnetic core that is disposed inside and outside the coil to form a closed magnetic circuit, and at least a part of the magnetic core that is disposed on the outer peripheral side of the coil is provided. It is comprised from the composite material containing magnetic body powder and resin. And the shielding board fixed to at least one part of the parallel area | region parallel to the axial direction of the coil in the outer peripheral surface of a composite material is provided.

  The reactor of this invention can suppress the leakage of the magnetic flux at the time of exciting by energizing alternating current to a coil by providing a shielding board in at least one part of the said parallel area | region. By making the fixing part of the shielding plate the parallel region where the magnetic flux easily leaks, it is effective in reducing the leakage magnetic flux.

  Since the shielding member for reducing the leakage magnetic flux is a plate material, it is possible to produce an effective reactor for reducing the leakage magnetic flux by fixing the shielding plate to the composite material. Moreover, it is not necessary to prepare a bottomed cylindrical case by using a plate member as the shielding member. In addition, the production of the plate material is easier than the case of producing a bottomed cylindrical case. This is because a typical manufacturing method of the case includes a post-process for adjusting to a desired shape by cutting or the like after the casting process. Therefore, the production of the plate material does not involve the trouble as in the case production. Therefore, the reactor of the present invention is excellent in productivity.

  As one form of the reactor of this invention, it is mentioned that the roughening process is given to at least one part of the contact area | region with the said composite material in the said shielding board.

  According to said structure, a contact area with a composite material can be increased by performing a roughening process, and a composite material and a shielding board can be fixed with sufficient adhesiveness.

  As one form of the reactor of this invention, providing the bottom part shielding board fixed to a bottom part and the side part shielding board fixed to a side part in the said parallel area | region is mentioned. The bottom portion is a portion that is disposed to face the installation target when the reactor is installed on the installation target. A side part is a location connected to the bottom part.

  According to said structure, the said leakage magnetic flux can be reduced more effectively by providing a bottom part shielding board and a side part shielding board. By fixing the bottom shielding plate to the bottom that is in contact with the installation target, when the reactor is installed on the installation target, heat can be radiated to the installation target via the bottom shielding plate, so that the heat dissipation of the reactor can be improved.

  As one aspect of the reactor of the present invention, when the bottom shielding plate and the side shielding plate are provided, a top shielding plate fixed to the top portion opposed to the bottom portion with the coil interposed therebetween may be further provided. Can be mentioned.

  According to said structure, a leakage flux can be reduced more effectively by providing a top part shielding board. In addition, since the top shielding plate is provided, the composite material is easily protected from the external environment because the entire circumference of the parallel region is covered with the shielding plate.

  As one form of the reactor of this invention, when providing the said top part shielding board, a composite material is provided with the cylinder member which penetrates the attachment member for fixing a top part shielding board to the said composite material.

  According to said structure, a top shielding board can be attached to a composite material easily and reliably by providing the cylinder member which penetrates the said attachment member in composite material itself.

  As one aspect of the reactor of the present invention, when the bottom shielding plate and the side shielding plate are provided, the end shielding plate fixed to the facing region disposed opposite to the end surface of the coil on the outer peripheral surface of the composite material Can be included.

  According to said structure, in addition to providing a bottom part shielding board and a side part shielding board in the said parallel area | region, the said leakage flux can be effectively shielded by providing an edge part shielding board in the said opposing area | region. . Moreover, it is easy to protect the composite material from the external environment.

  As one form of the reactor of the present invention, when the end shielding plate is provided, it further includes an exposed region where a part of the composite material is exposed from between the side shielding plate and the end shielding plate. It is done.

  According to the above configuration, by providing the exposed region, when the shielding plates are fixed to the composite material, it is not necessary to align the side shielding plates and the end shielding plates so as to contact each other. Reactor productivity can be improved. In addition, since it is not necessary to obtain a highly accurate dimensional accuracy such that the two plates come into contact with each other, options for the size and shape of the plate material fixed to the composite material are expanded. And the material of a shielding board can be reduced by the amount of an exposed area | region.

  As one form of the reactor of this invention, when providing the said bottom part shielding board and a side part shielding board, providing a resin mold part is mentioned further. The resin mold part covers at least a part of the outer periphery of the coil, holds the shape of the coil, and integrally holds the coil and the bottom shielding plate.

  According to said structure, it is easy to handle a coil by hold | maintaining a coil integrally by the resin mold part. In addition, since the bottom shielding plate is also integrated by the resin mold portion, the number of parts is small and the assembly workability of the reactor is excellent.

  As one form of the reactor of the present invention, when the resin mold part is provided, the inner core part arranged inside the coil among the magnetic cores is held integrally with the coil by the constituent resin of the resin mold part. Can be mentioned.

  According to said structure, when manufacturing a reactor by hold | maintaining an inner core part and a coil integrally by a resin mold part, since an inner core part and a coil do not fall, it is excellent in assembly workability | operativity. In addition, since the inner core portion and the coil are positioned by the resin mold portion, the assembly work can be simplified. Therefore, the productivity of the reactor is excellent.

  As one form of the reactor of the present invention, the coil includes a pair of cylindrical coil elements arranged side by side.

  According to the above configuration, when a coil (coil element) is formed by winding a winding spirally, the number of turns (turns) is the same as that of a coil composed of one coil element arranged vertically. When it does, the length from the one end side of a coil (both coil elements) to the other end side can be shortened. Therefore, the reactor can be downsized.

  As one form of the reactor of this invention, it is mentioned that the magnetic core is comprised with the composite material containing magnetic body powder and resin.

  According to said structure, the magnetic core of various magnetic characteristics can be easily manufactured with the kind and content of magnetic body powder, and also the freedom degree of the shape of a magnetic core is also large.

  As one form of the reactor of this invention, it is mentioned that the inner core part arrange | positioned inside a coil is comprised with the compacting body.

  According to said structure, a compacting body is easy to shape | mold into a desired shape, and can shape | mold the shape along the inner peripheral shape of a coil easily. Moreover, it can contribute to size reduction of a reactor. For example, when the inner core portion is formed of a compacted body having a higher saturation magnetic flux density than the portion disposed on the outer periphery of the coil, the magnetic core has a uniform saturation magnetic flux density including the inner and outer sides of the coil. This is because the cross-sectional area of the green compact can be reduced when the same magnetic flux is obtained.

  The reactor of this invention can be utilized suitably for the component of a converter. The converter of the present invention includes the reactor of the present invention described above. Examples of the converter include a switching element, a drive circuit that controls the operation of the switching element, and a reactor that smoothes the switching operation, and an input voltage is converted by the operation of the switching element.

  Moreover, the converter of this invention can be utilized suitably for the component of a power converter device. The power converter of the present invention includes the above-described converter of the present invention. The power converter includes a converter that converts an input voltage, and an inverter that is connected to the converter and converts DC and AC to each other, and a load is driven by the power converted by the inverter. It is done.

  According to said structure, it is hard to influence other electric equipment by providing the reactor of this invention which can reduce a magnetic flux leakage and is excellent in productivity, and can use it suitably for a vehicle-mounted component etc.

  The reactor of the present invention can effectively reduce leakage of magnetic flux when a coil is excited, and is excellent in productivity.

  The converter and the power conversion device of the present invention are less likely to be affected by leakage magnetic flux to other electric devices, and can be suitably used for in-vehicle components.

(A) is a schematic perspective view of the reactor according to the first embodiment, and (B) is a schematic cross-sectional view of the reactor cut along line (B)-(B). 1 is a schematic exploded perspective view of a reactor according to Embodiment 1. FIG. FIG. 3 is a schematic perspective view of a component member held by a resin mold part in a coil component included in the reactor according to the first embodiment. (A) is a schematic perspective view showing the reactor according to Embodiment 2, and (B) is a schematic cross-sectional view of the reactor cut along line (B)-(B). (A) is a schematic perspective view which shows the reactor which concerns on Embodiment 4, (B) is a schematic perspective view which shows the coil components with which this reactor is provided. 1 is a schematic configuration diagram schematically showing a power supply system of a hybrid vehicle. It is a schematic circuit diagram which shows an example of the power converter device of this invention provided with the converter of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The same reference numerals in the figure indicate the same names.

Embodiment 1
A reactor 1A according to the first embodiment will be described with reference to FIGS. The reactor 1A includes one coil 2 formed by winding a winding 2w in a spiral shape, and a magnetic core 3 disposed inside and outside the coil 2 to form a closed magnetic circuit. The magnetic core 3 includes a columnar inner core portion 31 disposed in the coil 2 and an outer core portion 32 disposed on the outer peripheral side of the coil 2, and the outer core portion 32 includes magnetic powder and resin. Consists of composite material containing. Reactor 1A is characterized in that the outer core of magnetic flux generated when coil 2 is excited is fixed to at least a part of a parallel region arranged in parallel to the axial direction of coil 2 on the outer peripheral surface of outer core portion 32. This is in that a shielding plate for blocking leakage to the outside of the portion 32 is provided. Details will be described below. In FIG. 2, the outer core portion is omitted.

[Reactor]
Reactor 1A is typically used by being installed on an installation target such as a cooling base. In the parallel region of the outer core portion 32 in the reactor 1A, when the reactor 1A is installed on the installation target, the place where the reactor 1A is arranged to face the installation target is arranged to stand on the bottom, and the bottom is arranged above, A portion connected to the bottom portion is a side portion, the bottom portion is opposed to the coil 2 with the coil 2 interposed therebetween, and a portion connected to the side portion is a top portion. On the other hand, an opposing region disposed opposite to the end face of the coil 2 in the outer core portion 32 is an end portion. The opposing region (end portion) is a portion that is arranged so as to stand on the bottom and is connected to the bottom, the side, and the top. Here, the outer shape of the outer core portion 32 is a rectangular parallelepiped shape. The bottom shielding plate 40 fixed to the bottom portion (bottom surface) of the outer core portion 32 includes a coil component 20A held integrally with the coil 2 by the resin mold portion 21. Hereinafter, the shielding plate which is one of the features of the reactor 1A will be described first.

[Shield]
The shielding plate blocks leakage of magnetic flux generated when the coil 2 is excited to the outside of the outer core portion 32.

  Examples of the constituent material of the shielding plate include nonmagnetic materials that can reduce leakage magnetic flux. In addition, a material having higher thermal conductivity than the magnetic powder constituting the magnetic core 3 is preferable. Then, heat dissipation can be improved. Specific examples include nonmagnetic metal materials such as aluminum, aluminum alloys, magnesium, and magnesium alloys. The listed nonmagnetic metals are lightweight, and are therefore suitable as a constituent material for in-vehicle components that are desired to be reduced in weight. Thus, it is a board | plate material comprised from a metal, It can manufacture easily to a desired shape by casting, cutting, plastic working, etc.

  The shape and size of the shielding plate can be selected as appropriate. It is preferable that the shape and size correspond to the outer shape and size of each surface of the outer core portion 32 that fixes the shielding plate. If it does so, in addition to being able to reduce a leakage flux over the whole surface of the fixed outer core part 32, it can protect from an external environment.

  Appropriate means can be used as the means for fixing the shielding plate. For example, it may be fixed by an adhesive, may be integrally fixed by a constituent resin of the outer core portion 32, or may be separately fixed by a fastening member such as a bolt.

  Among the shielding plates, the shielding plate fixed to the surface from which each end of the winding 2w in the outer core portion 32 is drawn out includes a through hole or a notch for drawing out each end of the winding 2w to the outside. It is preferable. Then, the shielding plate can be arranged at a predetermined position or fixed to the outer core portion 32 by inserting the end of the winding 2w into the through hole of the shielding plate or fitting it into the notch. When the cutout is provided, when the shielding plate is fixed to the outer core portion 32, it is not necessary to insert each end of the winding 2w like a through hole, so that the assembly workability of the reactor 1A is excellent.

  The shielding plate is preferably composed of a plurality of independent flat plates. In particular, it is preferable to use a rectangular flat plate. Specifically, the bottom shielding plate 40 and the side shielding plate 41s that are independent of each other are fixed to the bottom (bottom surface) and both side portions (side surfaces) of the outer core portion 32, respectively.

(Bottom shielding plate)
The bottom shielding plate 40 constitutes a part of the shielding plate that shields the leakage of magnetic flux and also functions as a heat dissipation path while supporting the coil 2. When the reactor 1A is installed on an installation target such as a cooling base, the outer bottom surface 40o (Fig. 1 (B)) of the bottom shielding plate 40 is placed in contact with the installation target, and the opposite side of the installation target: the inner bottom surface 40i and the coil 2 And a magnetic core 3 are disposed, and a side shielding plate 41s, which will be described later, is attached to the peripheral edge thereof. The bottom shielding plate 40 is arranged so as to cover a part of the surface of the coil 2, and this arrangement state is maintained by the resin mold part 21. A plate-like member can be suitably used for the bottom shielding plate 40.

  As shown in FIG. 3, the bottom shielding plate 40 is a rectangular plate-like member whose front and back surfaces: an inner bottom surface 40 i and an outer bottom surface 40 o (FIG. 1 (B)) are configured as a plane. A heat radiating base 401 is integrally formed at a place where 2 is disposed. Here, a heat radiation base 401 is provided in parallel with a gap between two protrusions having a triangular cross section. Each of the heat radiating base portions 401 is disposed along the outer peripheral surface of the coil 2 over the entire length of the coil 2 and includes a support surface 402 having a shape along the outer peripheral surface. The support surface 402 has an area that can cover a part of the curved surface portion on the installation side (the lower side in FIG. 3) of the outer peripheral surface of the coil 2. The heat sink 401 is connected to the support surface 402 in addition to the support surface 402, a pair of end surfaces 401e parallel to the end surface of the coil 2, and the support surface 402 and both end surfaces 401e, and side surfaces 401s parallel to the axis of the coil 2. Both end surfaces 401e and side surfaces 401s are both flat surfaces. The two heat sinks 401 are arranged in parallel so that the support surfaces 402 face each other, and the parallel interval corresponds to the length of the outer peripheral plane of the racetrack-like coil 2.

  In the bottom shielding plate 40, a tube receiver 403 is integrally formed at a position corresponding to a position where a later-described tube member 50 (FIG. 2) is disposed. The tube receiver 403 is housed in the tube member 50 and is fitted to the tube member 50 to support the tube member 50. A bolt hole is provided at the center of the tube receiver 403. The inner peripheral surface of the bolt hole is internally threaded, and the bolt 500 is inserted into the bolt hole and fastened. The outer peripheral surface of the tube receiver 403 may be subjected to male screw processing. The height and size (outer diameter) of the tube receiver 403 can be selected as appropriate. For example, when the tube member 50 is fitted to the tube receiver 403 without the outer core portion 32, the tube member 50 is predetermined. It is preferable that the height and the size be such that they can be supported stably at the position. Then, when the outer core portion 32 is formed, the cylindrical member 50 can be kept in a predetermined position, and the cylindrical member 50 can be easily formed integrally with the outer core portion 32. The mounting position, the number, and the like of the tube receiver 403 can be appropriately selected according to the number of bolts 500 and tube members 50 to be used. Here, four tube receivers 403 are provided at the four corners of the bottom shielding plate 40.

  The bottom shielding plate 40 includes an attachment portion for fixing the reactor 1A to the installation target. Here, the bottom shielding plate 40 is provided with a mounting portion 400 provided with a bolt hole (either a screw hole or a through hole without a female screw) through which a fixing bolt (not shown) is inserted. The mounting portion 400 is a protruding piece that protrudes from each corner of a rectangle, and has a bolt hole at the center thereof. By providing the mounting portion 400, the reactor 1A can be easily fixed to the installation target. The mounting position, number, shape, etc. of the mounting portion 400 can be selected as appropriate. A configuration without the attachment portion 400 may also be adopted.

  Since the outer periphery of the coil 2 is covered with a resin mold portion 21 described later, the constituent resin of the resin mold portion 21 is interposed between the coil 2 and the bottom shielding plate 40. Therefore, the insulation property between the two mainly composed of a metal material can be enhanced. Here, the support surface 402 of the heat sink 401 is along the outer peripheral surface of the coil 2, and the two heat sinks 401 are provided along the outer peripheral surface of the coil 2, so that the coil 2 and the bottom portion The resin exists between the shielding plates 40 with a uniform thickness.

  The wider the area covered by the resin mold portion 21 in the bottom shielding plate 40, the higher the adhesion between the bottom shielding plate 40 and the resin mold portion 21, and as a result, the coil 2 together with the bottom shielding plate 40 is also attached to the resin mold portion 21. Firmly held. Here, of the bottom shielding plate 40, the heat radiating base 401 (support surface 402, end face 401e, side 401s) is covered with the resin mold part 21, and the area other than the heat radiating base 401 on the inner bottom 40i, the side, and the outer The bottom surface 40o (FIG. 1 (B)) is not covered with the resin mold portion 21, and is exposed. Since the outer bottom surface 40o is exposed from the resin mold part 21, the heat of the coil 2 can be easily transferred from the heat radiation base part 401 to the installation target, and the heat dissipation is excellent. In addition, the end surface 401e and the side surface 401s may be partly or entirely exposed from the resin mold portion 21, and the entire inner bottom surface 40i may be covered with the resin mold portion 21.

  A region of the inner bottom surface 40i of the bottom shielding plate 40 that is not covered with the resin mold portion 21 is fixed integrally with the outer core portion 32 by the constituent resin of the outer core portion 32.

  In the bottom shielding plate 40, the inner bottom surface 40i serves as a mounting surface for the assembly of the coil 2 and the magnetic core 3, a mounting surface or a fixing surface for the side shielding plate 41s and the end shielding plate 41e, and the outer bottom surface 40o At least a part (the whole here) becomes a cooling surface that is cooled in contact with the installation target. It is allowed that a region (which may be a flat surface or a curved surface) that does not contact the installation target exists in a part of the outer bottom surface 40o. Although FIG. 1 shows a form in which the outer bottom surface 40o is arranged below, it may be arranged on the side (left and right in FIG. 1) or above.

(Side shield)
In addition to the bottom shielding plate 40 that is fixed to the bottom surface of the outer core portion 32, the side shielding plates 41s that are fixed to both side surfaces of the outer core portion 32 are provided as shielding plates that shield magnetic flux leakage. If it does so, a leakage magnetic flux can be reduced in the said side surface. Both side surfaces of the parallel region of the outer core portion 32 generally have a larger amount of constituent material (magnetic powder) of the outer core portion 32 than the top surface side and bottom surface side, and thus tend to be a magnetic path. Leakage magnetic flux tends to increase. Therefore, providing the side shielding plates 41s fixed to both side surfaces is effective in reducing the leakage magnetic flux. In addition, the influence of other magnetic devices due to the leakage magnetic flux can be reduced. For example, when the reactor 1A is used as a vehicle-mounted component, another electrical device may be disposed outside the side surface. The side shielding plate 41s is fixed integrally with the outer core portion 32 by the constituent resin of the outer core portion 32.

(Top shield)
In addition to the bottom shielding plate 40 and the side shielding plate 41s, a top shielding plate 42 fixed to the top (top surface) of the outer core portion 32 is preferably provided as a shielding plate for shielding magnetic flux leakage. . As described above, the leakage flux compared to the side surface side of the outer core portion 32 may not increase on the top surface side of the outer core portion 32 in some cases. In addition, another electrical device may not be disposed outside the top surface of the outer core portion 32. Therefore, even if the top shielding plate 42 is not provided, the influence on other electric devices is small, but the provision of the top shielding plate 42 is effective in reducing the leakage magnetic flux of the reactor 1A itself. The top shielding plate 42 has a bolt hole 42b through which the bolt 500 is inserted, and is fixed to the outer core portion 32 by inserting the bolt 500 into the bolt hole 42b.

(End shield)
Furthermore, it is preferable to provide end shielding plates 41e fixed to both ends (end surfaces) of the outer core portion 32 as shielding plates that shield magnetic flux leakage. The end surface side of the outer core portion 32 has a smaller area facing the coil 2 than the side surface side and the top surface side of the outer core portion 32, and has fewer magnetic paths than the side surface side and the top surface side. Since there are few magnetic paths, there is not much leakage magnetic flux, but by providing the end shielding plate 41e, it is more effective in reducing leakage magnetic flux. The end shielding plate 41e includes a U-shaped notch 41n so that the end of the winding 2w can be pulled out from the end face of the outer core portion 32. The end shielding plate 41e is fixed integrally with the outer core portion 32 by the constituent resin of the outer core portion 32.

  A plurality of shielding plates fixed to each surface are independent of all the outer peripheral surfaces of the outer core portion 32. Thus, by fixing the shielding plate to the entire outer peripheral surface of the outer core portion 32 (composite material), the leakage magnetic flux can be reduced and the outer core portion 32 can be protected.

  Adjacent shielding plates among the shielding plates may or may not be fixed to each other. When the shielding plates are fixed to each other, "bottom shielding plate 40 and side shielding plate 41s", "bottom shielding plate 40 and end shielding plate 41e", "side shielding plate 41s and end shielding plate 41e", "side Any one of the combinations of the partial shielding plate 41s and the top shielding plate 42 "and the" end shielding plate 41e and the top shielding plate 42 "may be fixed to each other. This fixing is performed before the outer core portion 32 is molded using a molding die. For example, if the bottom shielding plate 40 and the side shielding plate 41s (end shielding plate 41e) are fixed to each other, the side shielding plate 41s (end shielding plate 41e) is integrated with the constituent resin of the outer core portion 32. In the case of fixing to the bottom shielding plate 40, the side shielding plate 41s (end shielding plate 41e) can be positioned when the molding material is filled with the constituent material of the outer core portion 32. In addition, the side shielding plate 41s (end shielding plate 41e) can be supported on the inner bottom surface 40i of the bottom shielding plate 40. When fixing the shielding plates, various fixing materials such as an adhesive can be used. Of course, three or more types of shielding plates may be fixed.

  On the other hand, when the shielding plates are not fixed, adjacent shielding plates may or may not be in contact with each other. When each shielding board contacts, the positioning part which positions the other shielding board may exist in the contact location of the other shielding board in one shielding board. As the positioning portion, a recess formed in the contact portion can be suitably used.

  Here, any adjacent independent shielding plates are not fixed to each other. The side shielding plate 41s and the end shielding plate 41e are in contact (placed) with the bottom shielding plate 40, and the side shielding plate 41s and the end shielding plate 41e are not in contact with each other. The plate 41e and the top shielding plate 42 are in contact. When the adjacent shielding plates are not in contact with each other, an exposed region in which a part of the composite material is exposed from between the adjacent shielding plates is provided. Here, an exposed region 32o (FIG. 1 (A)) in which a part of the outer core portion 32 is exposed is provided between the side shielding plate 41s and the end shielding plate 41e. Since the magnetic flux hardly leaks from the corner portion of the outer core portion 32, an exposed region 32o may be provided near the corner portion (including the corner portion itself). In that case, it is not necessary to align the shielding plates at each corner, and the productivity of the reactor 1A can be improved. In addition, when manufacturing the reactor 1A, the dimensional accuracy of the prepared shielding plates is not required to be so high that the positions of the shielding plates are matched. That is, options for the shape and size of the shielding plate are expanded.

  Since each shielding plate is an independent member, each constituent material can be made different. For example, the bottom shielding plate 40 and the side shielding plate 41s can be made of different nonmagnetic metal materials. Specifically, the constituent material of the bottom shielding plate 40 can be a metal material having a higher thermal conductivity than the side shielding plate 41s. Here, all the shielding plates are made of an aluminum alloy.

[Coil parts]
The coil component 20A will be described with reference to FIGS. The coil component 20A included in the reactor 1A of the first embodiment includes the coil 2, the above-described bottom shielding plate 40, the inner core portion 31 that constitutes the magnetic core 3, and the resin mold portion 21 that integrally holds them. Have.

(coil)
The coil 2 is a cylindrical body formed by spirally winding one continuous winding 2w, and is constituted by one coil element. The winding 2w is preferably a coated wire having an insulating coating made of an insulating material (typically an enamel material such as polyamideimide) on the outer periphery of a conductor made of a conductive material such as copper, aluminum, or an alloy thereof. The conductor may have various shapes such as a rectangular wire having a rectangular cross-sectional shape, a round wire having a circular shape, and a deformed wire having a polygonal shape. Here, the coil (coil element) 2 is an edgewise coil formed by edgewise winding a rectangular wire with a conductor made of a copper rectangular wire and an insulating coating made of enamel. The edgewise coil is easy to make a small coil by increasing the space factor, and contributes to the miniaturization of the reactor 1A.

  The shape of the end face of the coil 2 can be selected as appropriate. Here, the end surface shape is a racetrack shape configured by combining a straight line and an arc, and at least a part of the outer peripheral surface of the coil 2 is configured as a flat surface. The coil 2 is placed on the bottom shielding plate 40 so that the axis of the coil 2 is parallel to the outer bottom surface 40o (FIG. 1 (B)) configured in a plane on the bottom shielding plate 40. In such a horizontal storage configuration, by arranging the plane in the outer peripheral surface of the coil 2 in parallel with the outer bottom surface 40o of the bottom shielding plate 40, an area having a short distance from the outer peripheral surface of the coil 2 to the outer bottom surface 40o is obtained. The heat dissipation can be increased. Therefore, in the horizontal storage configuration, a coil in which at least a part of the outer peripheral surface is a flat surface as in the above-described racetrack shape is preferable. As other shapes, for example, a coil having a polygonal shape (for example, a rectangle) and rounded corners can be suitably used. On the other hand, when the end face shape of the coil 2 is made of a substantially curved shape such as a circle or an ellipse, it is easy to wind even when a rectangular wire is used for the winding, and the productivity of the coil is excellent. In the present invention, even the cylindrical coil is fixed to the bottom shielding plate 40 by the resin mold portion 21, so that the position of the coil 2 with respect to the bottom shielding plate 40 is stably maintained when the reactor 1A is assembled.

  Each end of the winding 2w forming the coil 2 is appropriately extended from the turn portion as shown in FIG. 3 and connected to a terminal member (not shown) made of a conductive material such as copper or aluminum, Electric power is supplied to the coil 2 via the terminal member. The drawing direction of each end of the winding 2w can be appropriately selected. Here, both ends of the winding 2w are arranged on one end side of the coil 2. Specifically, one end of the winding 2w is folded back from the other end side of the coil 2 to one end side to be parallel to the axial direction of the coil 2, and the other end of the winding 2w is opposite to the other end side of the coil 2. It is bent toward the side (one end side) and is also parallel to the axial direction. Thus, since both ends of the winding 2w are arranged on one end side of the coil 2, it is easy to attach a terminal member or the like. Each end of the winding 2w may be arranged in a different direction in the coil axis direction.

  In the coil 2, a higher voltage may be applied to the lead-out portion of the winding 2 w extended from the turn portion than in the turn portion. Accordingly, when an insulator is disposed at least in a contact portion with the magnetic core 3 (outer core portion 32) in the drawing portion of the winding 2w, the insulation between the coil 2 and the outer core portion 32 can be enhanced. Here, as shown in FIGS. 1 and 2, the lead-out portion of the winding 2w is covered with the resin mold portion 21. In addition, insulating paper, insulating tape (e.g., polyimide tape), insulating film (e.g., polyimide film), etc. are appropriately wrapped around the drawer, dip coating with insulating material, insulating tube (heat shrinkable tube and room temperature shrinkage) Any of the tubes) may be arranged. In the form that does not cover the lead-out part of the winding 2w with the resin mold part, the outer shape of the resin mold part can be simplified, so it is easy to mold the coil parts. In the form covered with the resin mold part, it is necessary to arrange an insulator separately. The number of processes can be reduced.

(Inner core part)
The inner core portion 31 inserted and arranged inside the coil 2 is a columnar body having an outer shape along the inner peripheral shape of the coil 2 as shown in FIG. 3, and is composed of a compacted body using soft magnetic powder. Has been. Details will be described later.

(Resin mold part)
The resin mold part 21 covers at least a part of the surface of the coil 2 and holds the coil 2 in a certain shape. Therefore, the coil 2 is not expanded and contracted by the resin mold portion 21, and is easy to handle during assembly. Further, the resin mold part 21 also has a function of holding the coil 2 in a compressed state than the natural length. Therefore, the length of the coil 2 is shorter than the natural length and is small. Further, the resin mold part 21 is made of an insulating resin and covers the surface of the coil 2 so that the coil 2 and its peripheral members (the magnetic core 3 and the bottom plate shielding plate 40 (heat radiation base part 401)) are covered. It also has a function of improving the insulation. The resin mold portion 21 also functions as a member that holds the coil 2 and the bottom shielding plate 40 together. In the reactor 1A of the first embodiment, the resin mold portion 21 further holds the coil 2, the bottom shielding plate 40, and the inner core portion 31 integrally. By using such a coil component 20A, the reactor 1A has a small number of assembly parts and is excellent in assembly workability.

  Here, the resin mold part 21 is provided with the coil 2, the inner core part 31 inserted and arranged in the coil 2, and the bottom part including the heat radiation base part 401 arranged so as to cover a part of the outer peripheral surface of the coil 2. In the assembly with the shielding plate 40, both ends of the winding 2w to which the above-described terminal member is connected and the portion of the inner bottom surface 40i of the bottom shielding plate 40 excluding the heat radiation base 401 are covered. That is, the coil 2 has an inner peripheral surface and an outer peripheral surface, a pair of end surfaces, a part of the drawing portion of the winding 2w, the inner core portion 31 is the entire outer peripheral surface, and the bottom shielding plate 40 is the The entire support surface 402, side surface 401s, and end surface 401e are covered with the resin mold portion 21.

  The covering region of the resin mold part 21 can be selected as appropriate. For example, a part of the turn part of the coil 2 is not covered with the resin mold part 21 and can be exposed. However, as in this example, when the coil 2 is covered substantially entirely, the resin mold portion 21 is formed between the coil 2 and the magnetic core 3 and between the coil 2 and the bottom shielding plate 40 (heat radiation base portion 401). Insulation with respect to the coil 2 can be enhanced by the presence of the constituent resin.

  Here, both end surfaces 31e of the inner core portion 31 and the vicinity thereof are exposed without being covered with the resin mold portion 21, and are in contact with a composite material constituting the outer core portion 32 described later, but at least one end surface 31e may be covered with the resin mold part 21. At this time, the resin present on the end surface 31e of the inner core portion 31 can be used as a gap.

  The thickness of the resin mold part 21 can be selected as appropriate, and examples thereof include about 0.1 mm to 10 mm. The thicker the resin mold portion 21 is, the higher the insulation is, and the thinner the resin mold portion 21 is, the heat dissipation is improved and the coil component can be downsized. In the case of reducing the thickness, the thickness is preferably about 0.1 mm to 3 mm, and may be appropriately selected within a range that satisfies a desired insulation strength. Either a form having the same thickness over the entire coated part or a form having a part partially different in thickness can be used. Here, the thickness of the portion covering the surface of the coil 2 in the resin mold portion 21 and the thickness covering the portion covering the heat radiating base portion 401 are uniform. That is, the outer shape of the coil component 20A has a similar shape to an assembly obtained by combining the coil 2, the inner core portion 31, and the bottom shielding plate 40 including the heat radiating base portion 401. In addition, for example, in the resin mold portion 21, the thickness of the portion covering only the heat radiating base portion 401 may be relatively thin, and the thickness of the portion covering the coil 2 may be relatively thick. In that case, the insulation between the coil 2 and the magnetic core 3 and the insulation between the coil 2 and the heat sink 401 can be effectively enhanced. Note that the coil 2 and the inner core portion 31 are coaxially arranged by the constituent resin of the resin mold portion 21 interposed between the coil 2 and the inner core portion 31.

  The insulating resin that constitutes the resin mold part 21 has insulation characteristics that can sufficiently insulate between the coil 2 and the magnetic core 3, and between the coil 2 and the bottom shielding plate 40 (heat radiation base part 401), and use of the reactor 1A Resins that have heat resistance that does not soften at the highest temperature achieved at the time, and that can be used for transfer molding or injection molding can be suitably used. For example, thermosetting resins such as epoxy resins, silicone resins and unsaturated polyester resins, and thermoplastic resins such as polyphenylene sulfide (PPS) resins and liquid crystal polymers (LCP) can be suitably used. Insulating properties can be improved by using a resin mold part 21 in which a filler made of at least one ceramic selected from silicon nitride, alumina, aluminum nitride, boron nitride, and silicon carbide is mixed with the resin. And heat dissipation is improved. In particular, it is preferable to use a resin having a thermal conductivity of 1 W / m · K or more, more preferably 2 W / m · K or more, for the resin mold part 21 because of excellent heat dissipation. Here, the resin mold part 21 uses an epoxy resin (thermal conductivity: 2 W / m · K) containing a filler.

  For manufacturing the coil component 20A, for example, a manufacturing method described in JP-A-2009-218293 can be used. The coil component 20A can be manufactured by various molding methods such as injection molding, transfer molding, and cast molding. More specifically, the coil 2, the inner core portion 31, and the bottom shielding plate 40 are accommodated in a molding die, and an appropriate support member is disposed so as to be covered with a resin having a desired thickness, and the resin mold portion. By molding 21, the coil component 20A can be manufactured.

  The coil 2 can be bonded to the bottom shielding plate 40 with an insulating adhesive (which may be a sheet), and the resin mold portion 21 can be formed on this bonded product. In this case, it is not necessary to position the coil 2 and the bottom shielding plate 40 with respect to the molding die and to maintain the positions of both, and the moldability is excellent. In this manufacturing method, a coil component in which an insulating adhesive is interposed between at least part of the coil 2 and the bottom shielding plate 40 is obtained. Therefore, in the present invention, a configuration in which the constituent resin of the resin mold portion 21 is not interposed between the coil 2 and the bottom shielding plate 40 and only the insulating adhesive is interposed is allowed. The insulating adhesive is made of an epoxy resin, an acrylic resin, or the like, and further contains a filler made of a ceramic such as silicon nitride or alumina (preferably having a thermal conductivity of more than 2 W / m · K, more than 3 W / m · K or more, particularly 10 W / m · K or more, particularly 20 W / m · K or more). The thinner the adhesive, the higher the heat dissipation. For example, it can be 1 mm or less, and further 0.5 mm or less. When the thermal conductivity is large, the thickness of the adhesive may be 1 mm or more. When screen printing or sheet adhesive is used, a thin adhesive layer can be easily formed.

  In manufacturing the coil component 20A, if a gap holding member (not shown) for holding the gap between the coil 2 and the inner core portion 31 is disposed, the configuration of the molding die can be easily simplified. The spacing member is, for example, a cylindrical member disposed on the outer periphery of the inner core portion 31 (may be short, or may be a cylinder formed by combining a plurality of divided pieces), and the cylindrical member and the cylindrical member. An L-shaped annular member having one or more flat plate-like flange portions projecting outward from the peripheral edge of the plate, a plate member disposed between the coil 2 and the inner core portion 31, and the like. May be used in combination. Since the interval holding member is integrated into the coil 2 or the like by the constituent resin of the resin mold portion 21, the coil 2 is formed by the insulating resin such as the above-described PPS resin, LCP, or polytetrafluoroethylene (PTFE) resin. The insulation between the inner core portion 31 and the inner core portion 31 can be enhanced. When using the above-described cylindrical member or annular member, a part of the resin mold part 21 is made thin enough to be filled between the coil 2 and the inner core part 31, or a notch is provided. Adjust the shape and thickness.

[Magnetic core]
The magnetic core 3 will be described mainly with reference to FIGS. As described above, the columnar inner core portion 31, at least one end surface 31e (here, both end surfaces) of the inner core portion 31, and the outer peripheral surface of the coil component 20A (mainly the coil 2) are disposed on the outer peripheral side of the coil 2. And an outer core portion 32 that covers the outer peripheral surface), and forms a closed magnetic circuit when the coil 2 is excited.

(Inner core part)
The inner core portion 31 is slightly longer than the axial length of the coil 2. That is, both end surfaces 31e and the outer peripheral surface in the vicinity thereof protrude slightly from the end surface of the coil 2 in a state of being inserted and arranged in the coil 2. This state is maintained by the resin mold portion 21. The length of the inner core portion 31 protruding from each end face of the coil 2 (hereinafter referred to as the protruding length) can be selected as appropriate. Although the protruding lengths are equal, they may be different, and the length of the inner core portion and the position of the inner core portion relative to the coil 2 so that the protruding portion exists only from one end surface of the coil 2 Can be adjusted. When the length of the inner core portion is equal to or greater than the length of the coil 2, the magnetic flux generated by the coil 2 can be sufficiently passed through the inner core portion 31.

  The magnetic core 3 can be made of a uniform material as a whole, but here the material is partially different, and the inner core part 31 is a compacted body, the outer core part 32. Is composed of a composite material.

  The green compact is typically manufactured by subjecting raw material powder to pressure treatment and then appropriately heat treatment, and can be molded relatively easily even if it has a complicated three-dimensional shape. The raw material powder includes a coating powder or a ferrite powder having an insulating coating made of a silicone resin or a phosphate on the surface of a metal particle made of a soft magnetic material such as an iron-based material (iron group metal or iron alloy) or a rare earth metal. Furthermore, a mixed powder in which an additive such as a resin such as a thermoplastic resin and an additive such as a higher fatty acid (typically one that disappears or changes into an insulating material by heat treatment) is mixed as appropriate. By the above-described manufacturing method, a compacted body in which an insulator is interposed between soft magnetic particles is obtained. Since the compacted body is excellent in insulation, eddy current loss can be reduced. The green compact has a higher saturation magnetic flux density than the composite material composing the outer core 32 by adjusting the raw materials and manufacturing conditions, such as increasing the amount of raw soft magnetic powder and increasing the molding pressure. easy. A well-known thing can be utilized for a compacting body.

  The columnar inner core portion 31 can be formed as an integral body formed by using a mold having a desired shape, or can be formed as a laminated body in which a plurality of core pieces made of a compacted body are laminated. A laminated body can be fixed with an adhesive, an adhesive tape, or the like to be an integrated object. Here, the inner core portion 31 is a solid body in which no gap material or air gap is interposed.

(Outer core part)
The shape of the outer core portion 32 is a shape along the space formed by the inner peripheral surface of the side shielding plate 41s, the end shielding plate 41e, and the top shielding plate 42 and the portion surrounded by the outer peripheral surface of the coil component 20A. It is. That is, in the coil component 20A, the outer surface of each shielding plate (side surface and outer peripheral surface of the shielding plate) and the region excluding both ends of the winding 2w are covered with the outer core portion 32. The magnetic core 3 forms a closed magnetic path by providing a part of the outer core part 32 so as to be connected to both end faces 31e of the inner core part 31.

  The composite material constituting the outer core portion 32 is typically formed by injection molding, transfer molding, MIM (Metal Injection Molding), cast molding, press molding using magnetic powder and powdered solid resin, or the like. Can be manufactured. In the injection molding, a composite material is obtained by filling a molding die with a mixture containing a magnetic powder and a resin under a predetermined pressure, and then curing the resin. Transfer molding and MIM are also performed by filling the mold with raw materials. In cast molding, a composite material is obtained by injecting the mixture into a mold without applying pressure and molding and curing.

  The magnetic substance powder in the composite material constituting the outer core portion 32 may have the same composition as the soft magnetic powder constituting the inner core portion 31 described above or a different composition. Even in the case of the same composition, since the composite material contains a resin that is a nonmagnetic material, the saturation magnetic flux density is lower than that of the green compact and the relative magnetic permeability is also lower. Therefore, by configuring the outer core portion 32 with a composite material, the relative permeability can be made lower than that of the inner core portion 31 formed of the powder compact.

  The magnetic powder in the composite material may contain a single type or a plurality of types of powders having different materials. In the composite material constituting the outer core portion 32, iron-based powder such as pure iron powder is preferable. Even in the case of a composite material, if it is a coating powder as in the case of a compacted body, the insulation between soft magnetic particles can be enhanced and eddy current loss can be reduced.

  The average particle diameter of the magnetic powder in the composite material is 1 μm or more and 1000 μm or less, and particularly 10 μm or more and 500 μm or less. When the magnetic powder includes a plurality of types of powders (coarse powder and fine powder) having different particle diameters, it is easy to obtain a reactor having a high saturation magnetic flux density and a low loss. The magnetic powder in the composite material is substantially the same (maintained) as the raw material powder. When a powder having an average particle size satisfying the above range is used as a raw material, the fluidity is excellent, and a composite material can be produced with high productivity using injection molding or the like.

  The content of the magnetic substance powder in the composite material constituting the outer core portion 32 is 40% by volume or more and 75% by volume or less in terms of volume ratio when the composite material is 100%. When the magnetic substance powder is 40% by volume or more, since the ratio of the magnetic component is sufficiently high, the magnetic characteristics such as the saturation magnetic flux density of the entire magnetic core 3 can be easily improved. When the magnetic powder is 75% by volume or less, the productivity of the composite material is excellent. The content of the magnetic powder is particularly preferably 50% by volume or more and 65% by volume or less.

  Typically, the resin used as the binder in the composite material includes a thermosetting resin such as an epoxy resin, a phenol resin, a silicone resin, and a urethane resin. In addition, thermoplastic resins such as PPS resin, polyimide resin, fluorine resin, and polyamide resin, room temperature curable resin, or low temperature curable resin can be used.

  In addition to the magnetic powder and the resin, a composite material containing a powder (filler) made of a nonmagnetic material such as ceramics such as alumina or silica can be obtained. The filler contributes to improvement in heat dissipation and suppression (uniform dispersion) of uneven distribution of the magnetic powder. Since the filler is fine and is interposed between the magnetic particles, it is possible to suppress a decrease in the ratio of the magnetic powder due to the inclusion of the filler. When the content of the filler is 100% by mass of the composite material, the above effect is obtained when the content is 0.2% by mass or more and 20% by mass or less, further 0.3% by mass or more and 15% by mass or less, particularly 0.5% by mass or more and 10% by mass or less. Can be fully obtained.

  Here, the outer core portion 32 is composed of a composite material of a coating powder and an epoxy resin having an insulating coating on the surface of particles made of an iron-based material (pure iron) having an average particle size of 75 μm or less (composite material). The content of pure iron powder in it: 40% by volume). Further, the outer core portion 32 does not include a gap material or an air gap like the inner core portion 31. Therefore, the magnetic core 3 does not have a gap over the whole. By not having a gap, (1) downsizing, (2) reduction in loss, and (3) reduction in inductance reduction when energizing a large current can be achieved. The magnetic core 3 can be in a form in which a gap material made of a nonmagnetic material such as an alumina plate or an air gap is interposed.

  The shape of the outer core portion 32 is not particularly limited as long as a closed magnetic circuit can be formed. As in this example, the configuration in which the entire circumference of the coil component 20A except the outer surface of the bottom shielding plate 40 is covered with the composite material is a mechanical protection of the coil component 20A by the composite material (outer core portion 32). It can be strengthened. Since the outer core portion 32 can contact not only the bottom shielding plate 40 including the heat radiating base portion 401 but also the side shielding plate 41s, the end shielding plate 41e, and the top shielding plate 42, the outer core portion 32 Heat can be dissipated to the outside through the entire shielding plate.

  When the reactor 1A includes the top shielding plate 42, the outer core portion 32 preferably includes an insertion hole through which an attachment member (bolt 500) for fixing the top shielding plate 42 to the outer core portion 32 is inserted. A cylindrical member (collar) 50 is an example of the insertion hole. Here, the cylindrical members 50 are embedded in the four corners of the outer core portion 32, respectively.

  The length of the cylindrical member 50 can be selected as appropriate. For example, the length from the top surface to the bottom surface of the outer core portion 32, that is, the length so that both end surfaces of the cylindrical member 50 are flush with the top surface and the bottom surface of the outer core portion 32 can be mentioned. Further, the length from the top surface of the outer core portion 32 to the middle of the bottom surface, that is, the length at which the end surface on the bottom surface side of the cylindrical member 50 is embedded in the outer core portion 32 may be used. In the former case, the top shielding plate 42 can be fixed to the outer core portion 32 (the top surface) by fastening the bolt 500 to the bottom shielding plate 40 (tube receiver 403). The bolt 500 may be fastened directly to an installation target such as a cooling base. In that case, the inner peripheral surface of the tube receiver 403 is an insertion hole without a female screw groove, a screw hole having a female screw groove is provided in the installation target, and the height of the reactor 1A (the vertical direction in FIG. 1 (B)) What is necessary is just to fasten using a longer volt | bolt. In both the former and the latter cases, the bolt 500 may be fastened in the cylindrical member 50. In that case, it is preferable to use a tube member 50 whose inner peripheral surface is subjected to internal thread machining.

  The thickness (difference between the outer shape and the inner diameter) of the cylindrical member 50 is preferably uniform from one end side to the other end side (the top surface side to the bottom surface side of the outer core portion 32) of the cylindrical member. If it does so, the intensity | strength of the cylinder member 50 can be made constant over a full length. The inner diameter and the outer diameter of the cylindrical member 50 may be uniform from one end side to the other end side of the cylindrical member 50, or may be partially different. Here, the inner diameter and outer diameter on the bottom surface side of the cylindrical member 50 are made larger than the others. The tubular member 50 includes an insertion portion through which the bolt 500 is inserted on the top surface side and a connecting portion connected to the tube receiver 403 on the bottom surface side. The inner diameter and outer diameter of the insertion portion are uniform. By making the inner diameter uniform, the bolt 500 can be easily inserted. By making the outer diameter uniform, the cylindrical member 50 can be easily manufactured. On the other hand, the inner diameter and outer diameter of the connecting portion are larger than the inner diameter and outer diameter of the insertion portion. Thus, the connecting portion is configured to be fitted to the outside of the tube receiver 403. In addition to this configuration, the connecting portion may have a smaller outer diameter than the insertion portion and may be fitted inside the tube receiver 403. In either case, both may be fixed with an adhesive. In the former case (the latter), a female screw groove (male screw groove) is provided on the inner circumference (outer circumference) of the connecting portion, and an outer circumference (inner circumference) of the tube receiver 403. ) May be provided with male screw grooves (female screw grooves) and fastened. In this case, the tubular member 50 can be supported by the tubular receiver 403, and in addition to the easy positioning of the tubular member 50 during the manufacture of the reactor 1A, the tubular member 50 can be easily supported at a predetermined position. Become.

  Examples of the material of the cylindrical member 50 include a nonmagnetic metal material. Specific examples include aluminum, an aluminum alloy, magnesium, and a magnesium alloy. Then, since these metals are lightweight, they are suitable as constituent materials for in-vehicle components that are desired to be reduced in weight. Further, since these metals are also excellent in thermal conductivity, heat radiation can be expected through the cylindrical member 50 by bringing the cylindrical member 50 into contact with the bottom shielding plate 40. In addition, as the material of the cylindrical member 50, a resin having heat resistance to the temperature at the time of manufacture or use of the outer core portion 32, specifically, PPS resin, epoxy resin, BMC (Bulk molding compound) resin, etc. Can also be used. This point also applies to the tube receiver 403 and the bolt 500, and these members can be made of the resin.

(Magnetic properties)
As described above, the magnetic material 3 is partially different in magnetic characteristics due to the different constituent materials. Specifically, the inner core portion 31 has a higher saturation magnetic flux density than the outer core portion 32, and the outer core portion 32 has a lower relative permeability than the inner core portion 31. More specifically, the inner core portion 31 composed of the compacted body has a saturation magnetic flux density of 1.6 T or more, a saturation magnetic flux density of 1.2 times or more of the outer core portion 32, and a relative permeability of 100 to 500. In the outer core portion 32 composed of the composite material, the saturation magnetic flux density: 0.6 T or more and less than the saturation magnetic flux density of the inner core portion 31, the relative magnetic permeability: 5 or more and 50 or less, preferably 10 or more and 35 or less, The relative permeability of the entire magnetic core 3 composed of the inner core portion 31 and the outer core portion 32 is 10 or more and 100 or less. The form in which the saturation magnetic flux density of the inner core portion is high can contribute to the downsizing of the reactor because the cross-sectional area of the inner core portion can be reduced when the same saturation magnetic flux density as the magnetic core is obtained. it can. The saturation magnetic flux density of the inner core portion 31 is preferably 1.8 T or more, more preferably 2 T or more, and more preferably 1.5 times or more, more preferably 1.8 times or more of the saturation magnetic flux density of the outer core portion 32. If a laminated body of electromagnetic steel sheets typified by silicon steel sheets is used instead of the green compact, the saturation magnetic flux density of the inner core portion can be further increased. On the other hand, if the relative permeability of the outer core portion 32 is lower than that of the inner core portion 31, magnetic saturation can be suppressed, and thus, for example, the magnetic core 3 having a gapless structure can be obtained. If the magnetic core 3 has a gapless structure, the leakage flux can be reduced.

(Roughening treatment)
It is preferable that at least a part of the contact area with the outer core portion 32 on the surface of the shielding plate is roughened. If it does so, while being able to improve the adhesiveness of the outer core part 32 and a shielding board, heat dissipation can be improved. The area to be roughened is preferably 50 area% or more, more preferably 80 area% or more.

  The roughening treatment includes, for example, a treatment for providing fine irregularities such that the maximum height is 1 mm or less, preferably 0.5 mm or less. Specifically, (1) anodization represented by alumite treatment, (2) needle-like plating by a known method, (3) implantation of a molecular bonding compound by a known method, (4) fine grooves by laser Processing, (5) nano-order dimple formation using a known special solution, (6) etching treatment, (7) sand blasting and shot blasting, (8) glazing, (9) matte treatment with sodium hydroxide, ( A known method for improving the adhesion between the metal and the resin, such as 10) CB (Chemical Bonding) treatment or (11) grinding with a metal brush, can be used. Improvement of heat dissipation can also be expected by increasing the surface area due to such roughening. In addition, the surface area is increased by forming grooves (not shown) and holes (not shown) by cutting a general metal, or making the surface uneven by casting or plastic working. It may be.

  In the case of the bottom shielding plate 40, in addition to at least a part of the contact area with the outer core part 32, it is preferable that a surface roughening process is also performed on an area covered by the resin mold part 21 described later. If it does so, the adhesiveness of the bottom part shielding board 40 and the resin of the resin mold part 21 can also be improved. In particular, in order to improve the adhesion between the coil 2 and the bottom shielding plate 40, at least the region covering the outer peripheral surface of the coil 2 in the bottom shielding plate 40, that is, the support surface 402, and the plane between the two heat sinks 401 It is preferable that a part of the surface is roughened. It can be expected to improve adhesion and heat dissipation by increasing the contact area between the constituent resin of the bottom shielding plate 40 and the resin mold portion 21 and the contact resin between the bottom shielding plate 40 and the constituent resin of the outer core portion 32.

[Use]
Reactor 1A having the above-described configuration has applications such as maximum current (DC): about 100A to 1000A, average voltage: about 100V to 1000V, operating frequency: about 5kHz to 100kHz, typically electric It can be suitably used as a component part of an in-vehicle power converter such as an automobile or a hybrid automobile.

[Reactor manufacturing method]
For example, the reactor 1A can be manufactured as follows. First, the coil 2, the inner core portion 31, and the bottom shielding plate 40 shown in FIG. 3 are prepared, and the coil component 20A (FIG. 2) integrally formed by the resin mold portion 21 (FIG. 2) is manufactured.

  Next, as shown in FIG. 2, two side shielding plates 41s and 41s, two end shielding plates 41e and 41e, and four cylindrical members 50 are prepared, and the coil component 20A and the inside of the molding die are prepared. To place. At this time, the tubular member 50 is fitted into a tubular receiver 403 provided on the bottom shielding plate 40. By sandwiching the two side shielding plates 41s, 41s and the two end shielding plates 41e, 41e between the molding die and the bottom shielding plate 40, the shielding plates are prevented from tilting in the molding die. Alternatively, these shielding plates may be supported using a support jig that supports the shielding plates so that they do not tilt in the mold. In the former case, the surface of the shielding plate facing the top shielding plate 42 may be brought into contact with the inside of the mold, and the opposite side of the facing surface may be brought into contact with the bottom shielding plate 40. In the latter case, the support jig may be removed after filling (curing) a mixture described later to such an extent that the side shielding plates 41s, 41s and the end shielding plates 41e, 41e can be supported. Thereafter, the mixture may be further filled.

  On the other hand, a magnetic material powder and a resin as raw materials for the outer core portion 32, a binder and a nonmagnetic material powder are prepared as appropriate, and a mixture is prepared. After filling the mixture in the mold, the resin is cured. Thereby, the two side shielding plates 41s and 41s and the two end shielding plates 41e and 41e are integrally molded (fixed) with the outer core portion 32 by the resin.

  After the resin is cured, the top shielding plate 42 is placed on the top of the outer core portion 32. The top shield plate 42 is fixed to the outer core portion 32 by inserting the bolt 500 through the bolt hole 42b of the top shield plate 42 and the cylindrical member 50 and fastening the bolt 500 to the bottom shield plate 40. Through this step, reactor 1A (FIG. 1) is obtained.

  Here, the side shielding plates 41s, 41s and the end shielding plates 41e, 41e are fixed integrally with the outer core portion 32 by the resin, but are not fixed integrally with the outer core portion 32 by the constituent resin, but the outer core After producing the portion 32, the side shielding plates 41s, 41s and the end shielding plates 41e, 41e may be fixed by bonding them to the outer core portion 32 with an adhesive or the like. In that case, after the coil component 20A and the four cylindrical members 50 are arranged in the mold, the mixture is filled and the resin is cured.

[Function and effect]
The reactor 1A described above has the following effects.

  The reactor 1A includes a shielding plate fixed to each surface of the outer peripheral surface of the outer core portion 32, a bottom shielding plate 40, a side shielding plate 41s, an end shielding plate 41e, and a top shielding plate 42. Since the substantially entire outer periphery of the core portion 32 is covered with the shielding plates, the leakage magnetic flux can be reduced. In addition, the entire coil 2 and magnetic core 3 can be protected from the external environment (such as dust and corrosion) and mechanically protected.

  Since the bottom shielding plate 40, the side shielding plate 41s, the end shielding plate 41e, and the top shielding plate 42 are independent plates, the reactor 1A can reduce leakage magnetic flux by fixing each shielding plate to the outer core portion 32. Can be manufactured. Moreover, since each shielding board is a board | plate material, it is not necessary to prepare a bottomed cylindrical case separately. In addition, the production of the plate material is easier than the production of the bottomed cylindrical case. In particular, since the plate material is a flat plate, the production is easy. This is because a typical manufacturing method of the case includes a post-process for adjusting to a desired shape by cutting or the like after the casting process. Therefore, the production of the plate material does not involve the trouble of the production work as in the case of producing the case. Therefore, the reactor 1A is excellent in productivity.

  Reactor 1A has coil component 20A as a constituent element, so that coil 2 can be easily handled, the number of assembly parts is small, and the assembly workability is excellent. In particular, in the reactor 1A, the coil component 20A also holds a part of the magnetic core 3 (inner core portion 31) integrally, so that the assembly workability is further improved. From these points, the reactor 1A is excellent in productivity.

  Since the coil 2 and the bottom shielding plate 40 are integrally held by the resin mold part 21, the arrangement state of the coil 2 is stable with respect to the bottom shielding plate 40. In particular, the coil 2 is stable even in a horizontal storage configuration such as the reactor 1A. Therefore, the heat of the coil 2 can be efficiently transmitted to the installation target via the bottom shielding plate 40. Therefore, in the reactor 1A, a part of the magnetic core 3 (here, the outer core portion 32) is composed of a composite material containing magnetic powder and resin, and the coil 2 is covered with this composite material. Excellent heat dissipation.

  In particular, since the reactor 1A of the first embodiment is in the horizontal arrangement form as described above, there are many regions on the outer peripheral surface of the coil 2 where the distance to the installation target is short. In addition, the reactor 1A has a bottom shielding plate 40 integrally including a heat radiating base 401, and the heat radiating base 401 includes a support surface 402 along the outer peripheral surface of the coil 2. Easy to convey to the shielding plate 40. Also from these points, the reactor 1A is excellent in heat dissipation.

  Since the heat radiating base 401 is made of a nonmagnetic material, even if it is disposed close to the coil 2, it hardly affects the magnetic path. Furthermore, insulation between the coil 2 whose main constituent material is metal and the heat radiating base 401 (bottom shielding plate 40) can be secured by the resin mold portion 21 made of an insulating resin.

In addition, since at least a part of the magnetic core 3 (here, the outer core portion 32) is the above-described composite material, the following effects can be obtained.
(1) The outer core portion 32 can be easily formed even if the coil 2, the inner core portion 31, and the bottom shielding plate 40 (heat radiation base portion 401) cover the coil component 20 </ b> A integrated.
(2) The magnetic characteristics of the outer core portion 32 can be easily changed.
(3) Since the material covering the outer periphery of the coil component 20A (coil 2) contains magnetic powder, the thermal conductivity is higher and the heat dissipation is better than in the case of resin alone.

<Modification 1>
In the first embodiment, a case has been described in which a plurality of shielding plates that shield leakage of magnetic flux are independently fixed to each surface of the outer core portion 32. In addition, a single plate material is produced by plastic working such as bending, and an integral shielding plate that covers two contacting surfaces may be fixed, or two surfaces that are produced in the same manner and are adjacent to one surface An integral shielding plate covering a total of three surfaces may be fixed. In the former case, fixing the L-shaped shielding plate that covers the two surfaces of the side surface and the end surface of the outer core portion 32, the two surfaces of the side surface and the top surface, and the two surfaces of the end surface and the top surface is mentioned. These may be combined. For example, (1) one side and one end face, and the other side and the other end face, (2) one side and the end face, and the other side and the top face. (3) An L-shaped shielding plate may be fixed to each of the two surfaces of the side surface and one end surface, and the other end surface and top surface. On the other hand, in the latter case, the side surface of the outer core portion 32 and the two end surfaces adjacent to the side surface, a total of three surfaces, the end surface and the two side surfaces adjacent to the end surface, or the top surface and the top surface are adjacent. Fixing a bowl-shaped shielding plate covering a total of three sides of two side surfaces or two end surfaces. In any case, the shielding plate may be fixed to the outer core portion 32 integrally with the constituent material of the outer core portion 32 as described above, or may be fixed to the outer core portion 32 with an adhesive or the like. Good.

<Modification 2>
In the first embodiment and the first modification, the coil component that includes the inner core portion 31 integrally has been described. In addition, a coil component that does not have the inner core portion 31, that is, a coil component that has a hollow hole in which the coil and the bottom shielding plate are held by the resin mold portion and the inner core portion 31 is inserted and arranged. it can. For the manufacture of this coil component, a core may be used in place of the inner core portion 31 described above. The resin can be used for positioning the inner core portion 31 by adjusting the thickness of the resin provided inside the coil 2 to form the hollow hole.

Embodiment 2
In the first embodiment and the first and second modifications, the horizontal storage mode has been described. However, as in the reactor 1B shown in FIG.4 (B), the coil is formed with respect to the outer bottom surface 40o configured as a plane in the bottom shielding plate 40. A vertical arrangement in which the coil 2 is arranged so that the two axes are orthogonal to each other can be adopted. In the vertical arrangement mode, the contact area with respect to the installation target can be easily reduced as compared with the horizontal storage mode, and the installation area can be reduced.

  The reactor 1B of the second embodiment shown in FIG. 4 is different from the reactor 1A of the first embodiment mainly in that the storage configuration of the coil 2 is a vertical storage configuration, and the basic configuration is the same. In other words, the coil 2, the inner core portion 31, and the bottom shielding plate 40 are provided with a coil component 20 B that is integrally held by the resin mold portion 21. In this coil component 20B, a region excluding the side surface of the bottom shielding plate 40, the outer bottom surface 40o, the mounting portion 400, and both end portions of the winding 2w is covered with the outer core portion 32. A shielding plate (40, 41s, 42) is fixed to the entire outer peripheral surface (bottom surface, side surface, top surface) of the outer core portion 32. Here, on the outer peripheral surface of the outer core portion 32, when installed on the installation target, the bottom surface is disposed so as to face the installation target, and the turn portion of the coil 2 is disposed so as to stand upright on the bottom surface. The portion connected to the bottom is a side surface, the bottom surface is opposed to the coil 2 across the coil 2, and the portion connected to the side surface is a top surface. In other words, in the present example, the opposing areas arranged opposite to the end face of the coil 2 in the outer core portion 32 are the bottom face and the top face. In the first embodiment described above, the parallel region arranged in parallel to the axial direction of the coil 2 on the outer peripheral surface of the outer core portion 32 is composed of a bottom surface, two side surfaces, and a top surface (see FIG. 1). On the other hand, in the vertical storage configuration of the present example, as shown in FIG. 4 (A), the parallel region of the outer core portion 32 is configured with four side surfaces.

  The end face shape of the coil 2 is circular in this example. Both end portions of the winding 2w in the coil 2 are drawn upward from the top surface of the outer core portion 32 (upward in FIG. 4A). Specifically, one end of the winding 2w is extended in the axial direction of the coil 2 on one end side (upper side of FIG. 4A) of the coil 2, and the region on the other end side of the winding 2w is extended to one end of the coil 2. It is bent toward the part side and similarly pulled out parallel to the axial direction.

  The shape of the inner core portion 31 is a columnar shape along the inner peripheral shape of the coil 2. A part of the inner core portion 31 protrudes from the end surface on the other end side (downward in FIG. 4) of the coil 2 in a state of being inserted and arranged in the coil 2, and the end surface of the protruding portion is the bottom shielding plate 40. It is installed in contact with the inner bottom surface 40i (FIG. 4 (B)). The outer core portion 32 is provided so as to connect the end surface 31e on one end side of the inner core portion 31 and the outer peripheral surface of the protruding portion on the other end side to form a closed magnetic path.

  In addition to bolt holes (not shown), the top shielding plate 42 includes a rectangular through hole 42h through which both ends of the winding 2w are inserted. The through-hole 42h prevents the winding 2w and the top shielding plate 42 from interfering when both ends of the winding 2w are pulled out from the top surface of the outer core portion 32. Therefore, substantially the entire top surface of the outer core portion 32 can be covered with the top shielding plate 42, and magnetic flux leakage can be effectively suppressed.

  In this example, the coil component 20B that integrally includes the inner core portion 31 has been described. However, like the coil component described in the second modification, the coil component can be a coil component that does not have the inner core portion. . In addition, the bottom shielding plate is formed with, for example, a rod-like, plate-like, or L-shaped heat sink, and the state where the heat sink is arranged on one end surface side of the coil is maintained by the resin mold portion. It can be a coil component. In this case, the shape and number of the heat radiating base and the shape of the resin mold are selected so that the magnetic flux can sufficiently pass between the inner core and the outer core.

Embodiment 3
In the first and second embodiments and the first and second modifications, the embodiment has been described in which the inner core portion 31 is made of a compacted body and only the outer core portion 32 is made of a composite material. In addition, the inner core portion can also have a form made of a composite material containing magnetic powder and resin, that is, a form in which all of the magnetic core is made of a composite material. In this case, the inner core portion and the outer core portion can be made of the same composite material. The content of the magnetic powder of the composite material constituting each core part is 40% by volume or more and 75% by volume or less, the saturation magnetic flux density is 0.6T or more, preferably 1.0T or more, and the relative permeability is 5 or more and 50 or less, preferably The relative magnetic permeability of the entire magnetic core can be 5 or more and 50 or less. Both the inner core portion and the outer core portion may be integrally formed using a mold. For example, similarly to the coil component described in Modification 2, a coil component having a hollow hole in which the coil and the bottom shielding plate are held by the resin mold portion and the inner core portion is inserted and arranged is prepared. The coil component is housed in a molding die, the raw material of the composite material is filled in the molding die, the raw material is poured into the hollow hole of the coil component and the space between the coil component and the molding die, and the resin is cured. Then, the magnetic core which consists of a composite material with which the inner core part and the outer core part were united is obtained. In addition, it is good also as a molded object of the composite material which separately shape | molded the inner core part and the outer core part separately in the predetermined shape using the shaping | molding die, respectively. For example, an inner core part made of a composite material (molded body) molded using a molding die is prepared, and this inner core part is arranged inside the coil to produce a coil component in which the coil and the inner core part are integrated. To do. The coil component is housed in a molding die, and the raw material of the composite material is filled into the molding die to mold the outer core portion made of the composite material. Thereby, if the inner core portion and the outer core portion are formed of the same composite material, both core portions can be formed of the same composite material even if both core portions are formed separately.

  The inner core portion and the outer core portion can be made of different composite materials. In this configuration, for example, when the material of the magnetic powder is the same in both core parts, the saturation magnetic flux density and the relative magnetic permeability can be adjusted by changing the content of the magnetic powder, and desired characteristics can be obtained. There is also an advantage that it is easy to obtain the composite material. As a specific form, the inner core portion and the outer core portion are composed of composite materials having different magnetic powder materials and contents, and the inner core portion is similar to the first and second embodiments and the first and second modifications. The saturation magnetic flux density is high and the outer core portion has a low relative magnetic permeability, or the reverse configuration, that is, the inner core portion has a low relative magnetic permeability and the outer core portion has a high saturation magnetic flux density. It is done. Increasing the blending amount of the magnetic powder in the composite material makes it easy to obtain a composite material having a high saturation magnetic flux density and a high relative magnetic permeability, and reducing the blending amount results in a composite having a low saturation magnetic flux density and a low relative magnetic permeability. Easy to obtain materials. A columnar or block-shaped composite material (molded body) can be separately produced from a raw material having a desired composition, and these columnar or block-shaped composite materials can be used for the inner core portion and the outer core portion. Each of the composite materials constituting the inner core portion and the outer core portion has a magnetic powder content of 40% to 75% by volume, a saturation magnetic flux density of 0.6T or more, preferably 1.0T or more, and a relative permeability. 5 to 50, preferably 10 to 35, and the relative magnetic permeability of the entire magnetic core can be 5 to 50.

Embodiment 4
In the first to third embodiments and the first and second modifications, the embodiment in which the coil 2 includes one coil element has been described. In addition, it can be set as the form which provides a pair of coil element formed by winding a coil | winding helically. The pair of coil elements may be arranged side by side (parallel) so that the axes of the elements are parallel to each other and connected by a connecting portion formed by folding back a part of the winding (see FIG. 5). Each coil element is formed by separate windings, and one end of windings constituting both coil elements are joined by welding such as TIG welding, crimping, soldering, etc., and the one end is connected separately. It can also be set as the form joined through the member. For example, in the horizontal storage mode, the installation side surfaces of the coil elements arranged side by side are placed on the bottom plate shielding plate, and in this state, a coil component that integrally holds the coil and the bottom shielding plate is formed by the resin mold portion. In the case of providing a pair of coil elements, if the horizontal storage configuration is adopted, the heat dissipation is excellent, and the connecting portion does not get in the way, and coil parts and the like are easy to manufacture.

  Compared with the reactor 1A of the first embodiment, the reactor 1C of the fourth embodiment shown in FIG. 5 mainly includes a pair of coil elements 2a and 2b in which the coils 2 are arranged side by side, inside the coil elements 2a and 2b. The basic structure is the same except that the inner core is arranged. That is, the coil 2, the inner core portion 31, and the bottom shielding plate 40 are provided with a coil component 20 </ b> C that is integrally held by the resin mold portion 21. The coil component 20C is covered with the outer core portion 32 except for the side surface of the bottom shielding plate 40, the outer bottom surface 40o, the mounting portion 400, and both ends of the winding 2w. A shielding plate (40, 41s, 41e, 42) is fixed to the entire outer peripheral surface (bottom surface, side surface, end surface, top surface) of the outer core portion 32. Hereinafter, the difference will be mainly described.

  In this example, as shown in FIG. 5 (B), the coil 2 is composed of a pair of coil elements 2a and 2b, and is arranged side by side (in parallel) so that the axes of the coil elements are parallel to each other. This coil 2 (coil elements 2a, 2b) is formed by one continuous winding 2w. Specifically, after one coil element 2a is formed from one end side toward the other end side, the winding 2w is bent in a U shape on the other end side and folded, and the other coil element 2b is turned to the other end side. It forms toward one end side. The winding directions of both coil elements 2a and 2b are the same. Both coil elements 2a and 2b are electrically connected in series. From both ends of the coil 2 (coil elements 2a and 2b), both ends of the winding 2w are drawn out in the radial direction of the coil 2 (upward in FIG. 5). The end face shape of the coil elements 2a and 2b is a rectangular shape with rounded corners, but can be appropriately selected as described above, such as a racetrack shape or a circular shape.

  The inner core portion 31 is disposed inside each of the coil elements 2a and 2b, and has a prismatic shape along the inner peripheral shape of the coil elements 2a and 2b. On the other hand, as described in the first embodiment, the outer core portion 32 is formed by arranging the coil component 20C in a molding die and molding a composite material on the outer periphery of the coil component 20C.

  In addition to bolt holes (not shown), the top shielding plate 42 includes a rectangular through hole 42h through which both ends of the winding 2w are inserted. The through-hole 42h prevents the winding 2w and the top shielding plate 42 from interfering when both ends of the winding 2w are pulled out from the top surface of the outer core portion 32. Therefore, substantially the entire top surface of the outer core portion 32 can be covered with the top shielding plate 42, and magnetic flux leakage can be effectively suppressed.

  In this example, the coil component 20C that integrally includes the inner core portion 31 has been described. However, like the coil component described in the second modification, the coil component that does not have the inner core portion can be used. . Further, as described in the third embodiment, the inner core portion 31 may be a composite material (molded body) separately manufactured using a mold as described in the third embodiment.

Embodiment 5
The reactors of Embodiments 1 to 4 and Modifications 1 and 2 can be used for, for example, a component part of a converter mounted on a vehicle or the like, or a component part of a power conversion device including the converter.

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

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

  As shown in FIG. 7, the converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor L, and converts input voltage by ON / OFF repetition (switching operation). (In this case, step-up / down pressure) is performed. For the switching element 1111, a power device such as an FET or an IGBT is used. The reactor L has the function of smoothing the change when the current is going to increase or decrease by the switching operation by utilizing the property of the coil that tends to prevent the change of the current to flow through the circuit. The reactor L includes the reactors of the first to fourth embodiments and the first and second modifications. By providing the reactor 1A that can reduce the leakage magnetic flux and has excellent heat dissipation, the power conversion device 1100 and the converter 1110 are hardly affected by the leakage magnetic flux and have excellent heat dissipation. In addition, since the reactor 1 is excellent in productivity, the power conversion device 1100 and the converter 1110 are also excellent in productivity.

  Vehicle 1200 is connected to converter 1110, power supply converter 1150 connected to main battery 1210, sub-battery 1230 as a power source for auxiliary devices 1240, and main battery 1210. Auxiliary power converter 1160 for converting high voltage to low voltage is provided. The converter 1110 typically performs DC-DC conversion, while the power supply device converter 1150 and the auxiliary power supply converter 1160 perform AC-DC conversion. Some converters 1150 for power feeding devices perform DC-DC conversion. The reactor of power supply device converter 1150 and auxiliary power supply converter 1160 has the same configuration as the reactors of Embodiments 1 to 4 and Modifications 1 and 2, and uses a reactor whose size and shape are appropriately changed. be able to. Further, the reactors of the first to fourth embodiments, the first and second modifications, and the like can be used for a converter that performs conversion of input power and that only performs step-up or only performs step-down.

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

  The reactor of the present invention can be used for components of power conversion devices such as DC-DC converters and air conditioner converters mounted on vehicles such as hybrid vehicles, plug-in hybrid vehicles, electric vehicles, and fuel cell vehicles.

1A, 1B, 1C reactor
2 Coil 2w Winding 20A, 20B, 20C Coil parts 21 Resin mold part
2a, 2b coil element
3 Magnetic core 31 Inner core 31e End face
32 Outer core 32o Exposed area
40 Bottom shield 40i Inner bottom 40o Outer bottom
41s Side shield 41e End shield 41n Notch
42 Top shield 42b Bolt hole 42h Through hole
400 Mounting part 401 Heat sink part 401e End face 401s Side face 402 Supporting face
403 tube receiver
50 Tube member (color) 500 bolt
1100 Power converter 1110 Converter 1111 Switching element
1112 Drive circuit L Reactor 1120 Inverter
1150 Power supply converter 1160 Auxiliary power converter
1200 Vehicle 1210 Main battery 1220 Motor 1230 Sub battery
1240 Auxiliary 1250 Wheel

Claims (11)

  1. A cylindrical coil and a magnetic core disposed inside and outside of the coil to form a closed magnetic path, and at least a part of the magnetic core disposed at the outer peripheral side of the coil is magnetic powder. A reactor composed of a composite material including a resin,
    A shielding plate fixed to at least a part of a parallel region parallel to the axial direction of the coil on the outer peripheral surface of the composite material ;
    An end shielding plate fixed to an opposing region disposed opposite to an end face of the coil on the outer peripheral surface of the composite material;
    In the parallel region, the shielding plate is
    When the reactor is installed on the installation target, a bottom shielding plate that is fixed to the bottom part that is disposed to face the installation target;
    Comprising a side shielding plate fixed to the side connected to the bottom,
    The side shielding plate and reactor Ru comprising an exposed area partially exposed of the composite material from between the end shield.
  2.   The reactor according to claim 1, wherein a surface roughening process is performed on at least a part of a contact area of the shielding plate with the composite material.
  3. Furthermore, the reactor of Claim 1 or 2 provided with the top part shielding board fixed to the top part arrange | positioned facing the said bottom part on both sides of the said coil.
  4. Furthermore, the said composite material is a reactor of Claim 3 which provides the cylinder member which penetrates the attachment member for fixing the said top part shielding board to the said composite material.
  5. Furthermore, over at least a portion of the outer periphery of the coil, it holds the shape of the coil, and said with the coil bottom shield claims 1 comprising a resin mold portion for holding together of claims 4 The reactor of any one of Claims.
  6. The reactor according to claim 5 , wherein an inner core portion disposed inside the coil among the magnetic cores is held integrally with the coil by a constituent resin of the resin mold portion.
  7. The reactor according to any one of claims 1 to 6 , wherein the coil includes a pair of cylindrical coil elements arranged side by side.
  8. The reactor according to any one of claims 1 to 7 , wherein the magnetic core is made of a composite material including a magnetic powder and a resin.
  9. The reactor according to any one of claims 1 to 7 , wherein an inner core portion disposed inside the coil is formed of a compacted body.
  10. A converter comprising the reactor according to any one of claims 1 to 9 .
  11. A power converter comprising the converter according to claim 10 .
JP2012222230A 2011-12-19 2012-10-04 Reactor, converter, and power converter Active JP6024886B2 (en)

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WO2017029713A1 (en) * 2015-08-18 2017-02-23 株式会社 東芝 Inductor and wireless power transmission device
JPWO2018216465A1 (en) * 2017-05-24 2019-12-19 株式会社オートネットワーク技術研究所 Circuit components

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