JP6106645B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor used in a vehicle such as an electric vehicle or a hybrid vehicle.

  The reactor is configured by mounting a coil around the core. For the purpose of insulation from the coil, the core is entirely or partially embedded in the resin by molding, or inserted into a cylindrical resin molded product. A reactor in which a reactor main body having such a core and a coil mounted around the core is housed in a metal case such as aluminum for reasons of dust prevention, protection, heat dissipation, and the like has also been known.

  In this type of reactor, various configurations have been proposed for fixing the reactor body to the case. For example, the base of a metal support fitting is embedded by molding in a resin molded product with a core embedded or inserted, and the tip of the support bracket exposed from the resin molded product is screwed to the case with a bolt or the like. Things are known.

  In this case, for example, in the conventional techniques shown in Patent Document 1 and Patent Document 2, four support metal fittings are projected at diagonal positions of the reactor body and fixed to the case. When the support bracket is provided at the diagonal of the reactor in this way, the general reactor main body is a rounded quadrangular shape with the four corners chamfered at its corners. There was an advantage of effective use of space.

JP 2013-197567 A JP 2013-229406 A

  In this type of reactor, there is a difference in linear expansion between the reactor body and the case generated by the heat generated by the core when energized.Therefore, it is necessary to provide an elastic part that absorbs vibration and thermal expansion in a part of the support bracket. is there. However, in the above-mentioned prior art, since the dead space between the case and the reactor is effectively used and the support brackets are provided at the diagonals of the reactor body, this is constrained and a large support bracket is used. I couldn't. As a result, the size of the elastic portion for absorbing the linear expansion difference is limited, and the linear expansion difference cannot be effectively absorbed.

  In addition, when the reactor body is housed in the case, it is desirable to absorb the vertical dimension error (flatness difference) between the two, but in the prior art, the size of the support bracket is limited, so the reactor body It was perfect to absorb the difference in linear expansion that appears in the longitudinal direction of the film, and it was impossible to provide an elastic part that could absorb the difference in flatness.

  Further, since the small support fitting has a small contact portion between the mouth portion and the resin end portion in which the support fitting is embedded, there is a possibility that stress is concentrated on the end portion of the resin and the resin is cracked. .

  The present invention has been proposed to solve the above-described problems of the prior art. The objective of this invention is providing the reactor which can absorb the linear expansion difference and flatness difference of a reactor main body and a case.

(1) The reactor of this invention has the following structures, It is characterized by the above-mentioned.
(a) A reactor body having a core and a coil mounted around the core.
(b) A housing member for housing the reactor body.
(c) A resin molded product integrated with at least a part of the reactor body.
(d) A support fitting provided on the reactor main body, a base portion of which is fixed to the resin molded product, and a tip portion of which protrudes outward from the resin molded product.
(e) An elastic portion that is provided on the support fitting and is deformed in the linear expansion difference direction and the flatness difference direction of the reactor body.
(f) A fixing member that fixes the support fitting and the housing member.

(2) As the above-mentioned support metal fittings, those having a plate-like base fixed to the resin molded product and an arm protruding outward from the resin molded product from the base are used. It is preferable to provide the elastic portion on the surface.

(3) The elastic portion continuously forms a first curved portion protruding outward of the resin molded product and a second curved portion recessed toward the inner side of the resin molded product. It is good that it is a substantially S-shape.

(4) It is preferable that a plurality of arms are provided for the base, the tips of the plurality of arms are connected by a connecting portion, and an insertion hole for a fixing member between the support fitting and the housing member is provided in the connecting portion. .

(5) The base part of the support metal fitting and the connection part are plate-like members parallel to the horizontal cross section of the reactor body, and the connection part is connected to the base part of the support metal fitting fixed in the resin molded product. It is good to position it below with respect to the vertical direction of the main body.

  According to the present invention, it is possible to absorb the linear expansion difference and flatness difference between the reactor main body and the case with a single support fitting, and the shape of the mouth portion of the support fitting does not concentrate stress on the resin molded product. It becomes possible to prevent cracking of the resin molded product.

The perspective view of 1st Embodiment. The disassembled perspective view of the reactor main body of 1st Embodiment, a filler, and a case. It is a disassembled perspective view of 1st Embodiment. The perspective view of the cyclic | annular core in 1st Embodiment. The disassembled perspective view which shows the combination of each core and its resin molded product in 1st Embodiment. The disassembled perspective view of the U-shaped core in 1st Embodiment and its resin molded product. The disassembled perspective view of the T-shaped core in 1st Embodiment and its resin molded product. The perspective view which shows the 1st fixing | fixed part in 1st Embodiment. The upper and lower perspective views of the support fitting in the first embodiment. The perspective view of the 2nd fixing | fixed part in 1st Embodiment. The perspective view which shows the lower part of the reactor main body 1 in 1st Embodiment. The top view which shows the position of the 1st and 2nd fixing | fixed part in 1st Embodiment. The perspective view which shows the connection coil of 1st Embodiment.

[1. First Embodiment]
[1.1 Configuration]
Hereinafter, a first embodiment of the present invention will be described with reference to the drawings.
As shown in FIGS. 1 and 2, the reactor of the present embodiment includes a case 2 made of metal such as aluminum having an open top surface, a reactor main body 1 accommodated therein, a case 2, and a reactor main body 1. And a filler 3 injected and solidified therebetween.

(1) Reactor body As shown in FIG. 3, the reactor body 1 includes a θ-shaped annular core formed by combining two U-shaped cores 4 a and 4 b and two T-shaped cores 5 a and 5 b, and a leg portion of the annular core. Two connected coils 6a and 6b are provided. The reactor body 1 has a rounded rectangular shape (a rectangular shape with rounded corners) having two long sides and two short sides, and the case 2 has a rectangular parallelepiped shape whose upper surface is opened accordingly.

(2) Core As shown in FIG. 4, the annular core butts the both ends of the U-shaped cores 4 a and 4 b and the left and right ends of the T-shaped cores 5 a and 5 b, and arranges and adheres the spacer 8 therebetween, The T-shaped cores 5a and 5b facing each other are combined so that a predetermined gap 10 is formed between the central protrusions 7a and 7b. Thus, the annular core includes a pair of opposing yoke portions, a central middle leg provided in parallel with the yoke portion, and a pair of coils 6a, 6b provided on both sides of the middle leg, respectively. (Hereinafter referred to as an outer leg) is formed. As the U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b of this embodiment, dust cores are used, but other laminated cores in which ferrite cores and silicon steel are laminated can be used alone or in combination. Further, without using the spacer 8, both end portions of the U-shaped cores 4a and 4b and the left and right end portions of the T-shaped cores 5a and 5b may be directly butted. The gap 10 may be an air gap or a gap provided with a spacer.

(3) Coil As shown in FIGS. 1 and 2, the two connecting coils 6a and 6b are respectively attached to the parts constituting the outer legs of the U-shaped cores 4a and 4b on both sides of the middle leg. Yes. As shown in FIG. 13, each of the connecting coils 6a and 6b is formed by forming two coils 6a-1 and 6a-2 or 6b-1 and 6b-2 using a single conductor. In the mounted state, one conductor is wound around the outer periphery of one outer leg to form the first coils 6a-1 and 6b-1, and the same conductor is wound around the outer leg on the opposite side. Two coils 6a-2 and 6b-2 are formed. Therefore, as shown in FIGS. 1 and 2, one winding start end 11 and one winding end 12 of each coil 6a, 6b are provided on both sides of the middle leg. A bus bar is welded to each of the winding start end 11 and the winding end end 12 of the coils 6a and 6b, and an external wiring of the reactor is connected to the end of the bus bar. As shown in FIG. 13, the connecting portion 63 of the two coils 6a-1, 6a-2 or 6b-1, 6b-2 has a rectangular wire on the same plane in a plane perpendicular to the coil winding direction. It is connected with.

  As the coils 6a and 6b, ones in which various conductors are wound can be used. In this embodiment, edgewise coils obtained by edgewise winding a rectangular conductor are used. The winding start and end ends 11 and 12 of the coils 6a and 6b may be provided on the middle leg side as in the coil 6a, or may be provided on the yoke side as in the coil 6b. Thus, both the two coils 6a and 6b may be provided on either the middle leg side or the yoke part side.

  The two coils 6a and 6b are wound in such a direction that the DC magnetic fluxes generated from the coils 6a and 6b cancel each other. In order to wind the DC magnetic flux generated from the two coils 6a and 6b in a direction that cancels each other, in this embodiment, the direction of the current flowing through the coil is the same and the winding direction of the coil is reversed. The winding direction may be the same, and the direction of the energized current may be reversed. Each of the coils 6a and 6b is formed by connecting the coils 6a and 6b wound in advance into a cylindrical shape when the U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b embedded in the resin molded product are bonded in a θ shape. It is wound around the core by fitting it into the core.

  The direct current magnetic flux generated from the two coils 6a and 6b is wound in a direction that cancels each other, and the two coils 6a and 6b are arranged such that the magnetic flux density on the outer periphery of the reactor main body 1 is in the long side direction of the reactor main body 1. It is attached to the annular core so as to be lower in the two spaces located with 1 therebetween. That is, since the middle leg is formed on the annular core, the magnetic flux density is low around the yoke portion, which is the short side of the annular core, when the reactor is energized.

(4) Resin molded product The U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b are respectively embedded in dedicated resin molded products. Each core is integrally formed with the resin molded product by being injected and solidified into the mold while being set in the mold of the respective resin molded product. The resin molded product is a member that insulates each core and the coils 6a and 6b, and also a member to which a support member for fixing the reactor body 1 to the case 2 is fixed. As the main material of the resin molded product, for example, unsaturated polyester resin, urethane resin, epoxy resin, BMC (bulk molding compound), PPS (polyphenylene sulfide), PBT (polybutylene terephthalate) and the like can be used.

  As shown in FIG. 6, the resin molded products 13a and 13b for the U-shaped core include a coil mounting portion 15 that covers the left and right legs of the U-shaped cores 4a and 4b, and a yoke that covers the yoke portions of the U-shaped cores 4a and 4b. And a covering portion 16. An opening that exposes the end faces of the U-shaped cores 4a and 4b is provided in a portion corresponding to the joint surface between the U-shaped cores 4a and 4b and the T-shaped cores 5a and 5b in the coil mounting portion 15. Are provided with ribs 17 for inserting the end portions of the resin molded products 14a and 14b for the T-shaped core.

  A base portion of a plate-like support fitting 18 for fixing the reactor main body 1 to the case 2 is fixed to the central portion in the width direction of the reactor main body 1 above the yoke covering portion 16. The base portion of the plate-shaped support fitting 18 is set in a mold together with the U-shaped cores 4a and 4b and molded when the resin molded products 13a and 13b for the U-shaped core are molded.

  As shown in FIG. 7, the resin molded products 14a and 14b for the T-shaped core include the coil mounting portion 19 that covers the leg portions of the T-shaped cores 5a and 5b, and the central protrusions 7a and 7b of the T-shaped cores 5a and 5b. The middle leg covering portion 20 is provided. The end face of the coil mounting portion 19 on the U-shaped core 4a, 4b side is an opening through which the end face of the internal T-shaped core 5a, 5b is exposed. Around this opening, there is formed a recess 21 into which the rib 17 provided on the resin molded product 13a, 13b for the U-shaped core is fitted.

  Since the end surfaces of the central protrusions 7a and 7b of the T-shaped cores 5a and 5b are opposed to the end surfaces of the central protrusions 7a and 7b of the T-shaped cores 5a and 5b through the gap 10, this portion of the middle leg covering portion 20 is used. Covers the entire end faces of the T-shaped cores 5a, 5b. In the case where a gap is formed using a spacer instead of the gap or no gap is formed at all, an opening may be provided in the middle leg covering portion 20 to expose the end faces of the central projections 7a and 7b.

  A cylindrical collar 22 into which a bolt 23 as a fixing member is inserted when the reactor body 1 is fixed to the case 2 on the opposite side of the middle leg covering portion 20 of the resin molded products 14a and 14b for the T-shaped core. Buried. The cylindrical collar 22 is set in the mold together with the U-shaped cores 4a and 4b and molded when the resin molded products 13a and 13b for the U-shaped core are molded.

  As shown in FIGS. 6 and 7, the resin molded products 13a and 13b for the U-shaped core and the resin molded products 14a and 14b for the T-shaped core cover the periphery of each core except for the butted portion of each core. However, since it is necessary to use a jig for positioning the cores and the support fittings 18 in the mold, openings corresponding to the jig are formed with no resin. The surface of each core is exposed.

  As shown in FIG. 11, positioning protrusions 30a and 30b are provided on the bottoms of the resin molded products 14a and 14b for the T-shaped core. The protrusions 30a and 30b are provided on portions of the resin molded products 14a and 14b that avoid the coil mounting portion 19, and protrude from the bottom of the reactor body 1 even when the coils 6a and 6b are mounted on the core. When the reactor main body 1 is accommodated in the case 2, the protrusions 30 a and 30 b are fitted into a recess (not shown) provided at the bottom of the case 2 to position the reactor main body 1 and the case 2.

(5) Support metal fittings As shown in Drawing 1, reactor main part 1 is being fixed to case 2 with fixing members, such as support metal fitting 18 integrated with each resin-molded product, and bolt 23. The first fixing portion A is provided on two opposite sides of the reactor main body 1, in this embodiment, on the short side (yoke portion) of the reactor main body 1, and due to the linear expansion difference between the reactor main body 1 and the case 2. When a certain force is applied, it is fixed movably so that the relative position of both can be changed. The second fixing portion B is provided between the two first fixing portions A, in the present embodiment, in the vicinity of the center portion of each of the opposing long sides (outer legs) of the reactor main body 1. The case 2 is fixed at a fixed position so that its relative position does not change.

  According to the position of the second fixing portion B, only one first fixing portion A absorbs the linear expansion difference according to one side. It is desirable to provide it. Specifically, the position of the second fixing portion is provided at a predetermined position that is determined according to the proportion of the linear expansion difference shared by the plurality of first fixing portions. For example, the position is determined by a balance of linear expansion differences that can be absorbed by the two first fixing portions A, for example, 7: 3 or 6: 4.

  FIG. 8 shows a state in which the reactor main body 1 is fixed to the case 2 by the movable support bracket 18 and the bolt 23 which is a fixing member in the first fixing portion A. As shown in FIG. 12, the movable side support fitting 18 is provided at the center of the short side of the reactor body 1, and has a base portion extending in the width direction of the reactor body 1 and two arms protruding from the base portion toward the case 2. 24a and 24b are provided. The base is fixed to the resin molded product, and the tip of the base projects outward from the resin molded product toward the case 2 side. That is, in the present embodiment, the base portion of the support fitting extends in a direction orthogonal to the protruding direction of the support fitting 18 from the reactor body 1 (outward of the reactor body).

  As shown in FIGS. 8 and 9, the two arms 24 a and 24 b are provided with a first curved portion 181 projecting outward from the reactor body 1 and inward in the longitudinal direction of the reactor body 1. A substantially S-shaped elastic portion is provided in which a concave second curved portion 182 is continuously formed. The distal ends of the two arms 24 a and 24 b are connected by a plate-like connecting portion 25, and the connecting portion 25 is provided with an insertion hole 27 for a fixing member between the movable side support fitting 18 and the case 2. The base portion and the connecting portion 25 of the movable side support fitting 18 are plate-like members parallel to the horizontal cross section of the reactor body 1, and the movable side support fitting fixed to the resin molded products 13a and 13b for the U-shaped core. The connecting portion 25 is positioned below the 18 base portion with respect to the vertical direction of the reactor body 1. Thereby, the S-shaped elastic portion of the support bracket 18 on the movable side is arranged in a vertical shape in accordance with the position of the screw hole 26 provided on the upper edge of the case 2. Depending on the positional relationship between the case 2 and the reactor main body 1, the connecting portion 25 can be positioned upward with respect to the vertical direction of the reactor main body 1.

  As shown in FIGS. 7 and 10, the second fixing portion B includes an insertion hole provided in the resin molded products 14 a and 14 b for the T-shaped core, and a cylindrical collar 22 embedded in the insertion hole. And a bolt 23 inserted into the cylindrical collar 22. The reactor body 1 is fixed without moving relative to the case 2 by fastening the bolt 23 to the screw hole 26 provided at the upper edge of the case 2.

  As shown in FIG. 12, the second fixing portion B is provided at the center of the long side of the reactor main body 1, and the first fixing portion A is provided at the center of the short side of the reactor main body 1. Therefore, the distance from the 2nd fixing | fixed part B which fixes the reactor main body 1 to the case 2 in a fixed position from the 2nd fixing | fixed part A which is provided in the both sides and movably fixes the reactor main body 1 to the case 2 Are equal. As a result, in the present embodiment, the linear expansion difference between the reactor main body 1 and the case 2 appears equally with respect to the first fixed portions A on both sides, with the second fixed portion B as the center.

(6) Housing member As shown in FIGS. 1 and 2, the case 2 that is the housing member of the reactor body 1 is formed in a box shape having an opening on the upper surface, and has a size that matches the size of the reactor body 1. Has a storage space. A screw hole 26 for fastening a bolt 23 for fixing the reactor main body 1 to the case 2 is provided in the upper part of the case 2. The case 2 is formed of a metal having high thermal conductivity, and has a function as a heat radiating member for heat generated from the reactor body 1 while accommodating the reactor body 1. Aluminum or magnesium can be used as the metal having high thermal conductivity. Further, it is not always necessary to use a metal, and it is also possible to use a resin excellent in thermal conductivity or a resin in which a metal heat sink is embedded in part of the resin.

(7) Filler Filler 3 is filled and solidified in the gap between reactor body 1 and case 2. As the filler 3, it is desirable to use a resin having some elasticity even when solidified. For example, an epoxy-based, polyacrylate-based, or silicone-based resin potting agent mixed with a heat-dissipating material such as aluminum oxide or aluminum nitride can be used by adjusting its curing degree.

[1.2 Manufacturing method]
The reactor according to this embodiment having the above-described configuration is manufactured as follows.
First, the U-shaped cores 4a and 4b or the T-shaped cores 5a and 5b and their support fittings 18 and collars 22 are set in a mold of a resin molded product, and then the resin is injected into the mold and solidified. Thus, resin molded products 13a and 13b for the U-shaped core and resin molded products 14a and 14b for the T-shaped core are produced.

  Next, as shown in FIG. 5, two U-shaped cores 4a and 4b and T-shaped cores 5a and 5b each having a core, a support metal fitting 18 and a collar 22 are integrated inside a resin molded product, and the outer legs are coiled. The reactor main body 1 is produced by joining the whole in a θ shape while being inserted inside 6a and 6b. In that case, spacers 8 are disposed between the end surfaces of the cores exposed from the resin molded product, and these are fixed with an adhesive, and provided at the ends of the resin molded products 14a and 14b for the T-shaped cores. The ribs 17 provided at the end portions of the resin molded products 13a and 13b for the U-shaped core are fitted into the outer periphery of the recessed portion 21. Thereby, each resin molded product and the core can be accurately positioned.

  The reactor main body 1 thus manufactured is inserted into the collar 22 provided on the resin molded products 14a and 14b for the T-shaped core, and is fastened to the screw hole 26 of the case 2, whereby the reactor main body The central part of 1 is fixed so as not to move with respect to the case 2. Further, the bolt 23 is inserted into the insertion hole 27 provided in the movable support metal 18 having the elastic portion provided in the resin molded products 13 a and 13 b for the U-shaped core, and the bolt 23 is inserted into the screw hole 26 of the case 2. By fastening, both ends of the reactor body 1 are movably fixed to the case 2. In this case, the term “movable” means that the reactor main body 1 and the case 2 are fixed without moving when a normal reactor is used, but a line is formed between the reactor main body 1 and the case 2 due to heat generated during energization. When an expansion difference occurs, it means that the reactor main body 1 moves relative to the case 2 and is fixed with a strength that can absorb the linear expansion difference.

  Further, when the reactor main body 1 and the case 2 are fixed, even if there is a difference in flatness between the central portion and both ends of the reactor main body 1 due to manufacturing tolerances between them, the first fixing portion A is supported. A difference in flatness can be absorbed by the S-shaped elastic portion provided in the metal fitting 18 being deformed in the longitudinal direction and the vertical direction of the reactor body 1.

  After fixing the reactor body 1 and the case 2 in this way, the filler 3 is injected into the gap between the two and solidified. As a result, the reactor main body 1 can be more firmly fixed to the case 2, dust can be prevented from entering the gap between the two, and the insulation of the reactor main body 1 can be ensured. Furthermore, when a filler having a high thermal conductivity filler is used as the filler 3, the heat generated by the reactor body 1 can be efficiently radiated from the case 2.

[1.3 Effect]
The effects of the reactor of the present embodiment having the above-described configuration are as follows.

(1) Since the support metal fitting 18 is provided at the center of the short side of the reactor body 1 and its base portion is fixed to the resin molded product, and its tip portion is protruded outward from the resin molded product, the support metal fitting 18 is There is no restriction as if it were placed in the dead space between the case 2 and the reactor body 1. As a result, the degree of freedom of the shape and dimensions of the support fitting 18 is improved, and the linear expansion difference and flatness difference between the reactor main body 1 and the case 2 can be absorbed by the support fitting 18 at one place. In addition, the shape of the boundary portion of the support fitting 18 with the surface of the resin molded product (the mouth portion of the support fitting 18) can be a wide plate that does not concentrate stress on the resin molded product. It is also possible to prevent cracking of molded products.

(2) As the support metal fitting 18, a member having a plate-like base portion extending in the width direction of the reactor main body 1 and a plurality of arms 24 a and 24 b protruding from the base portion is used, and an elastic portion is provided on each arm 24 a and 24 b. Provided. If it does in this way, while the mouth part which contacts a resin molded product can be enlarged and stress concentration can be prevented, an elastic part can change easily and can absorb a linear expansion difference and flatness difference effectively.

(3) The elastic portion continuously formed a first curved portion 181 that protrudes outward from the reactor main body 1 and a second curved portion 182 that is recessed toward the inside of the reactor main body 1. It is substantially S-shaped. Therefore, it becomes possible to absorb the displacement in the longitudinal direction and the vertical direction of the reactor main body 1 with one member, and the displacement in each direction can be absorbed with a small number of parts.

(4) The tips of the arms 24 a and 24 b are connected by a connecting portion 25, and the connecting portion 25 is provided with an insertion hole 27 for a fixing member for the support fitting 18 and the case 2. As a result, it is possible to arrange the insertion hole 27 of the fixing member at the center of the short side of the reactor main body 1 while ensuring a large amount of deformation by the elastic portions of the arms 24a and 24b, and the reactor main body with one fixing member 1 and the case 2 can be fixed, and workability is improved.

(5) The base part of the support metal fitting 18 and the connection part 25 are plate-like members parallel to the horizontal cross section of the reactor body 1, and the connection part 25 is connected to the base part of the support metal fitting 18 fixed to the resin molded product. The main body 1 is positioned below with respect to the vertical direction. As a result, it becomes possible to arrange the vertical S-shaped arms 24a and 24b between the base portion of the support fitting 18 and the connecting portion 25, and without increasing the longitudinal dimensions of the reactor body 1 and the case 2, The amount of deformation can be secured.

(6) It is not necessary to apply the present invention to all the support fittings 18 for fixing the reactor body 1 and the case 2, and for some of the support fittings 18, the reactor body 1 and the case 2 are positioned relative to each other. It may be fixed at a fixed position so as not to change, and the present invention may be applied only to the remaining support fitting 18. If the support brackets 18 at both ends in the longitudinal direction of the reactor body 1 can absorb the linear expansion difference and / or flatness difference as in the present embodiment, even a large linear expansion difference and / or flatness difference can be effectively obtained. Can absorb.

[2. Other Embodiments]
The present invention is not limited to the above embodiment. The above embodiments are presented as examples, and can be implemented in various other forms. Various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope, gist and equivalent range of the invention. An example is shown below.

(1) In the illustrated embodiment, the case 2 is used as the housing member of the reactor body 1, but the embodiment is not necessarily limited to the case of being fixed to the case. The present invention can also be applied to the case where the reactor main body is fixed to a plate-like or block-like accommodation member. In this case, as the support fitting 18 used for the first and second fixing portions B, a member having a cross-sectional crank shape or an L-shaped cross-section can be used. Although the case 2 which is a housing member in this embodiment uses aluminum, the material is not limited. When used for a housing member made of a material that has a high linear expansion coefficient and generates a large linear expansion difference with the reactor main body 1 during heat generation, a particularly high effect is exhibited. However, even a magnesium oxide or stainless steel housing member having a lower linear expansion coefficient than aluminum is effective.

(2) In the illustrated embodiment, the reactor body is a rounded rectangle having a short side and a long side, but the present invention can also be applied to reactor bodies having other shapes such as a square, a circle, and an ellipse.

(3) In the above embodiment, the θ-shaped annular core having the T-shaped leg core is used. However, the shape of the core is not limited to this. For example, two U-shaped and J-shaped split cores are used. The present invention can also be applied to a combined rounded quadrangular annular core or a θ-shaped annular core having two E-shaped split cores. Instead of two T-shaped or two E-shaped cores, one may be E-shaped, the other may be I-shaped, and the two cores may be annular. In place of the T-shaped core, a Y-shaped core can be used. In this case, the central protrusions of the two Y-shaped cores are opposed to each other, and the gap is provided between the tips. Instead of configuring the T-shaped core from one member, a T-shaped core may be configured by combining two L-shaped cores. It is also possible to configure the outer leg by arranging the I-shaped core between the U-shaped core and the T-shaped core. The number of middle legs of the annular core is not limited to one, and the present invention can also be applied to an annular core having two or more middle legs. In that case, a plurality of middle legs can be configured by arranging a plurality of T-shaped cores on each outer leg. Moreover, you may form the cyclic | annular core which has a some middle leg by arrange | positioning two comb-tooth shaped division cores facing each other. A plurality of leg cores constituting the annular core and a yoke core connecting the both ends thereof, as long as both ends of the leg core are connected by the yoke core in any shape, the end surface of the leg is A configuration in which the yoke portion is connected or a configuration in which the end portion inner surface of the leg portion is connected by the yoke portion can be employed.

(4) The shapes of the coils 6a and 6b wound around the core can also be changed as appropriate. The coils 6a and 6b are wound around the left and right legs of the θ-shaped core, respectively, and the yoke portion of the θ-shaped core. The coils 6a and 6b may be wound around. When a circular or square loop-shaped core is used, the coils 6a and 6b may be wound around the left and right legs, or the coil is wound around only one of the two legs, and the other is a coil. It is not necessary to wear. Moreover, as a method of attaching the coil to the core, a coil may be formed by winding a wire around a resin molded product, or a coil wound in advance may be fitted into the resin molded product.

(5) As a resin molded product, in addition to the one in which the core is insert-molded, only a hollow cylindrical or box-shaped resin molded product is prepared in advance, and the core is fitted or bonded to the inside. Those fixed with an agent can also be used. Further, after joining the split cores, the annular core can be insert-molded or incorporated into the resin molded product. A core may be added to the inside of the resin molded product, and the coil may be fixed by being embedded or fitted, and the support metal fitting may be fixed to the resin molded product. You may fix a support metal fitting to the resin molding product only of a coil.

(6) As a support metal fitting, the thing comprised from one plate-shaped member with the whole wide other than what has several arm 24a, 24b can be used. The shape of the elastic portion is not limited to the vertical S-shape as shown in the figure, and when there is a margin in the longitudinal direction, the S-shaped elastic portion can be arranged horizontally. In addition, if it is possible to absorb the difference in linear expansion and the difference in flatness, the flat plate-like portion is not limited to the S shape, and the flat plate-like portion is curved in either the linear expansion difference or the flatness difference. It is also possible to use one that absorbs by bending and deforming the other by bending or bending the U-shape or V-shape. The elastic force can be appropriately adjusted by adjusting the widths of the arms 24a and 24b or changing the size of the opening between the arms 24a and 24b.

(7) The material of the support bracket 18 is not limited to aluminum or stainless steel, and other elastic materials can be used. It is not necessary that the support metal fitting 18 is entirely made of metal, and a part of the support metal fitting 18 can be made of resin. The support metal fitting 18 is not limited to the one in which the base is embedded and fixed in a resin molded product. The base portion of the support metal fitting 18 can be bolted to the surface of the resin molded product and fixed by means such as an adhesive. In addition to embedding the base portion of the support metal fitting 18 in the plane direction, the base portion of the support metal fitting 18 can be bent vertically and embedded inside the resin molded product. Further, even when the base portion of the support metal fitting 18 is embedded and fixed in the resin molded product, the base portion of the support metal fitting 18 does not have to be completely embedded, and the base portion of the support metal fitting 18 is connected to the arms 24a and 24b. The part may protrude from the resin molded product. Thereby, the stress is dispersed and the peak of the stress acting on the base portion of the support metal fitting 18 can be suppressed, and the crack of the resin molded product generated at the base portion can be prevented.

(8) When the amount of absorption of either the linear expansion difference or flatness difference is small, the shape of the support bracket 18 is such that a portion with a large absorption amount is deformed by bending or bending a portion that has a small absorption amount. You may absorb by the deformation | transformation of the connection part of these curved parts or a bending part, and the base part or front-end | tip part of the support metal fitting 18. That is, the combination of a plurality of curved portions such as an S shape is not necessarily required. Moreover, it is good also as a crank shape and Z shape instead of S shape.

(9) The number of insertion holes for the fixing member is not limited to one, and a plurality of holes may be provided. The fixing member is not limited to screwing such as a bolt, and various configurations such as welding, adhesion, rivet, press-fitting of a pin, and press-fitting a protrusion provided on the fixing member into the hole of the case can be employed.

(10) The number of the first fixing portions A is not limited to one on one side of the reactor body, and a plurality of first fixing portions A can be provided on one side. In that case, the second fixing portion B is provided at one position close to one side of the reactor main body, and a plurality of first fixing portions A are provided on the opposite side of the reactor main body, so that the opposite side of the reactor main body is provided. A linear expansion difference and a flatness difference can be absorbed only by the side.

(11) The second fixing portion B is not necessarily provided at the center portion of the two first fixing portions A, and is displaced from the center portion in accordance with the linear expansion difference absorbed by the elastic portion of the movable support member. Can be provided. For example, when the shape and thickness of the support bracket 18 used for the first fixing portion A are different, the position of the second fixing portion B is determined according to the difference in linear expansion absorbed by the elastic portion of each support bracket 18. It is good to change. Moreover, even if it is the same support metal fitting 18, you may shift the position of the 2nd fixing | fixed part B from a center part according to the shape of a reactor main body or a case. Even in such a case, the first fixing portion A on both sides shares the difference between the first fixing portion at one end of the reactor main body and the second fixing portion B at the other end, so that the linear expansion difference is shared. Since it absorbs, the 1st fixing | fixed part A can be reduced in size.

(12) In order to fix the reactor body 1 to the case 2 by the second fixing part B, in addition to the collar 22 embedded in the resin molded product, the base part of the plate-like support metal fitting 18 having no elastic part is made of resin. It is possible to use one that is fixed to a molded product and is provided with an insertion hole of a fixing member or an engaging portion with the fixing member at a portion protruding from the resin molded product. Further, instead of using the collar 22, only a simple insertion hole may be provided in the resin molded product, and a bolt may be inserted there.

DESCRIPTION OF SYMBOLS 1 ... Reactor main body 2 ... Case 3 ... Filler 4a, 4b ... U-shaped core 5a, 5b ... T-shaped core 6a, 6b ... Coil 7a, 7b ... Center protrusion 8 ... Spacer 10 ... Gap 11 ... End of winding start 12 ... Ends 13a, 13b at the end of winding ... Resin molded products 14a, 14b for U-shaped core ... Resin molded product 15 for T-shaped core ... Coil mounting portion 16 ... Yoke covering portion 17 ... Rib 18 ... Support metal fitting 181 ... 1st bending part 182 ... 2nd bending part 19 ... Coil mounting part 20 ... Middle leg covering part 21 ... Recess 22 ... Collar 23 ... Bolt 24a, 24b ... Arm 25 ... Connection part 26 ... Screw hole 27 ... Insertion hole 30a , 30b ... projection 63 ... coil connection part A ... first fixing part B ... second fixing part

Claims (5)

A reactor body having a core and a coil mounted around the core;
A housing member for housing the reactor body;
A resin molded product integrated with at least a part of the reactor body;
Provided in the reactor main body, the base portion is fixed to the resin molded product, the tip of which protrudes outward from the resin molded product,
An elastic part provided on the support fitting and deformed in a linear expansion difference direction and a flatness difference direction of the reactor body;
A reactor including a fixing member that fixes the support metal fitting and the housing member.   The said support metal fitting is provided with the said plate-shaped base part fixed to the said resin molded product, and the arm which protruded to the outward of the said resin molded product from the base part, The said elastic part is provided in the said arm. 1. The reactor according to 1. A plurality of the arms are provided with respect to the base, and tips of the plurality of arms are connected by a connecting portion, and an insertion hole for the fixing member of the support fitting and the housing member is provided in the connecting portion. 2. The reactor according to 2 . The base part of the support metal fitting and the connection part are plate-like members parallel to the horizontal cross section of the reactor main body, and the connection part is in the vertical direction of the reactor main body with respect to the base part of the support metal fitting fixed to the resin molded product. The reactor according to claim 3 , wherein the reactor is positioned below with respect to. The elastic part is substantially S formed by continuously forming a first curved part protruding outward of the resin molded product and a second curved part recessed inward of the resin molded product. The reactor according to any one of claims 1 to 4, which has a character shape.

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