JP6308036B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor having a core made of a magnetic powder mixed resin.

  Some reactors have a core made of a magnetic powder mixed resin and a coil embedded in the core. Patent Document 1 discloses a reactor having a coil having a so-called double pancake structure (α winding structure) in which winding portions around which conductor wires are wound are arranged.

  In the reactor having such a structure, the magnetic path is brought close to an ideal shape so that the magnetic flux is easily formed, and the magnetic performance of the reactor is easily improved. Further, the number of turns of the coil can be increased without increasing the size of the reactor.

JP 2011-138940 A

  However, when a coil having a double pancake structure as described in Patent Document 1 is employed, there is a possibility that a site where voltage stress between adjacent winding portions increases is generated (see a comparative example described later). Thereby, it becomes difficult to ensure the insulation between adjacent winding parts.

  In order to solve the above-mentioned problem, it is conceivable to interpose insulating paper or the like between adjacent winding parts, but this causes a problem in terms of heat dissipation. That is, when insulating paper or the like is provided, the heat dissipation path through the core from each winding part is limited, which may lead to a decrease in heat dissipation as the entire reactor.

  The present invention has been made in view of such a background, and an object of the present invention is to provide a reactor that can prevent a region where voltage stress between adjacent winding portions increases.

One aspect of the present invention is a core comprising a magnetic powder mixed resin;
A reactor having a coil embedded in the core,
The coil has a plurality of winding portions in which the conductor wires are stacked by winding the conductor wires,
The coil is formed by connecting the plurality of winding portions in series, and arranging the winding portions in a direction orthogonal to both the winding direction and the laminating direction of the conductor wire,
The winding parts connected in series to each other are in a reactor characterized in that they are connected to each other at opposite ends in the stacking direction.

  In the reactor, the winding portions connected in series to each other are connected to each other at opposite ends in the stacking direction. Therefore, end portions on the same side in the stacking direction of adjacent winding portions are not extremely separated on the conductive path of the conductor wire. Thereby, it can prevent that the site | part where the voltage stress between adjacent winding parts becomes large arises. In addition, it is not necessary to interpose insulating paper or the like between the plurality of winding portions, and the thickness can be reduced, so that it is easy to improve the heat dissipation of the reactor.

  As described above, according to the present invention, it is possible to provide a reactor that can prevent a portion where voltage stress between adjacent winding portions is increased.

The perspective view of the reactor in Example 1. FIG. The top view of the reactor in Example 1. FIG. Sectional drawing of the reactor in Example 1. FIG. The perspective view of the coil in Example 1. FIG. The perspective view of the coil in a comparative example. The coil sectional view in a comparative example. Sectional drawing of the reactor in Example 2. FIG. The top view of the reactor in Example 2. FIG.

  The reactor can be used as a component in a power conversion device mounted on, for example, an electric vehicle or a hybrid vehicle. More specifically, a reactor can be used as a component of the boosting unit that boosts the power supply voltage to a predetermined voltage in the power conversion device.

  In this specification, the direction of the winding axis of the conductor wire in the coil is referred to as the winding axis direction. Further, in the radial direction orthogonal to the winding axis of the coil, the inner side of the coil is referred to as the inner peripheral side, and the outer side is referred to as the outer peripheral side. In addition, one of the winding axis directions is appropriately referred to as “downward” and the opposite direction is appropriately referred to as “upward”, but the upper and lower expressions do not limit the vertical direction.

  In addition, for example, when each winding portion of the coil is formed by winding a conductor wire in a spiral shape, the radial direction is “stacking direction”, and when the coil is wound spirally, the winding axis direction is “stacking direction”. "

Example 1
Examples of the reactor will be described with reference to FIGS.
As shown in FIGS. 1 to 3, the reactor 1 of this example includes a core 2 made of a magnetic powder mixed resin and a coil 3 embedded in the core 2. As shown in FIGS. 3 and 4, the coil 3 has a plurality of winding portions 5 in which the conductor wire 4 is laminated by winding the conductor wire 4. The coil 3 includes a plurality of winding portions 5 connected in series, and the winding portions 5 are arranged in a direction orthogonal to both the winding direction of the conductor wire 4 and the lamination direction. As shown in FIG. 4, the winding parts 5 connected in series with each other are connected with each other at the ends opposite to each other in the stacking direction.

  In this example, as shown in FIG. 1 to FIG. 3, the coil 3 has a joint portion 7 in which a plurality of winding portions 5 are joined at a lead-out portion 6 drawn from each winding portion 5. 7 is located outside the core 2. Further, as shown in FIGS. 3 and 4, the coil 3 has two winding portions 5. The conductor wire 4 of the coil 3 is a flat conducting wire having a rectangular cross section perpendicular to the length direction. Each winding part 5 is formed by winding the conductor wire 4 in a spiral shape with the longitudinal direction of the rectangular cross section being the winding axis direction and the short direction being the radial direction. And the multiple (two) winding part 5 is located in a line with the winding axis direction. Hereinafter, for convenience, the lower winding part 5 is referred to as a first winding part 51, and the upper winding part 5 is referred to as a second winding part 522.

  As shown in FIGS. 1 to 3, the core 2 and the coil 3 are accommodated in the case 11. The case 11 has a cylindrical side wall portion 111 and a bottom wall portion 112 that closes the lower end side of the side wall portion 111. The case 11 can be formed using, for example, aluminum which is excellent in heat dissipation and is a nonmagnetic material.

  The core 2 is made of a magnetic powder mixed resin obtained by mixing and dispersing an iron powder as a magnetic powder in an epoxy resin as a resin.

  The surface of the conductor wire 4 of the coil 3 is covered with an insulating film (not shown). And as shown in FIG. 3, the conductor wire 4 which consists of the rectangular conducting wire of the cross-sectional rectangle mentioned above is wound in a spiral shape in the state where the width direction is an axial direction and the thickness direction is a radial direction. A winding portion 5 in which 4 is laminated in the radial direction is formed. That is, the conductor wire 4 is wound spirally in a so-called flat width, and the lamination direction of the conductor wire 4 in this example is the radial direction.

  As shown in FIGS. 3 and 4, the first winding part 51 and the second winding part 52 have the same winding axis and are arranged in the winding axis direction. The inner diameter and outer diameter of the first winding part 51 and the second winding part 52 are substantially the same. The first winding part 51 and the second winding part have substantially the same number of turns of the conductor wire 4. As shown in FIG. 3, a gap is provided between the first winding part 51 and the second winding part 52, and a part of the core 2 is disposed in this gap.

  From the both ends of the conductor wire 4 in each winding part 5, the lead-out part 6 is pulled out upward. As shown in FIGS. 3 and 4, a lead portion 611 is drawn from the inner peripheral end of the conductor wire 4 of the first winding portion 51, and a lead portion 612 is drawn from the outer peripheral end. A lead portion 621 is drawn from the inner peripheral end of the conductor wire 4 of the second winding portion 52, and a lead portion 622 is drawn from the outer peripheral end. As shown in FIG. 3, the lead portion 6 protrudes from the surface of the core 2. Moreover, as shown in FIG. 2, these drawer | drawing-out parts 6 are located in a straight line seeing from upper direction.

  The lead-out part 612 and the lead-out part 621 have terminals (not shown) for electrically connecting the outside and the reactor 1. The surface of the terminal is exposed from the insulating film and is located outside the core 2.

  As shown in FIGS. 1 to 3, the lead-out portion 611 is bent toward the lead-out portion 622 on the outside of the core 2, and is further bent upward from a portion in contact with the lead-out portion 622. This portion is overlapped with and joined to the lead-out portion 622 to constitute the joint portion 7. Thereby, the 1st winding part 51 and the 2nd winding part 52 are mutually the edge parts on the opposite side of a lamination direction, specifically, the inner peripheral end of the 1st winding part 51, and 2nd winding. At the outer peripheral end of the part 52, the first winding part 51 and the second winding part 52 are connected in series. The joint portion 7 is formed by welding or the like.

  When tracing from the lead-out portion 612 that is one end of the conductor wire 4 to the lead-out portion 621 that is the other end of the conductor wire 4, first, from the outer peripheral side of the first winding portion 51, while following the spiral path, the inner peripheral side Move to. Next, it moves to the outer peripheral end of the second winding part 52 via the lead parts 611 and 622. Next, it moves from the outer peripheral side of the second winding part 52 to the inner peripheral side while following a spiral path, and reaches the lead-out part 621. Thereby, when a current is passed through the coil 3, the current flows in the same direction in the radial direction at each winding part 5. That is, when a current is passed through the coil 3 in the direction from the lead-out part 612 to the lead-out part 621, the currents flowing through the first winding part 51 and the second winding part 52 are both from the outer peripheral side to the inner peripheral side. Flowing.

  And the length of the conductive path which passed along the conductor wire 4 between the parts of the conductor wire 4 adjacent in the winding axis direction becomes substantially the same in every part in the winding direction of the conductor wire 4. Therefore, the voltage between the portions of the conductor wire 4 adjacent to each other in the winding axis direction is substantially the same at every portion in the winding direction of the conductor wire 4.

  A sleeve made of an insulator is provided in a portion facing the second winding portion 52 in the drawing portion 611 and a portion facing the second winding portion 52 in the drawing portion 612. Thereby, the insulation between the drawer | drawing-out part 611 and the 2nd winding part 52 and the insulation between the drawer | drawing-out part 612 and the 2nd winding part 52 are ensured.

Next, the function and effect of this example will be described.
In the reactor 1, the winding parts 5 connected in series with each other are connected with each other at opposite ends in the stacking direction. Therefore, the end portions on the same side in the stacking direction of the adjacent winding portions 5 are not extremely separated on the conductive path of the conductor wire 4. Thereby, it can prevent that the site | part where the voltage stress between the adjacent winding parts 5 becomes large arises. In addition, it is not necessary to interpose insulating paper or the like between the plurality of winding portions 5 or the thickness thereof can be reduced, so that it is easy to improve the heat dissipation of the reactor 1.

  In addition, the coil 3 has a joint portion 7 in which a plurality of winding portions 5 are joined at a lead portion 6 drawn from each winding portion 5, and the joint portion 7 is located outside the core 2. . Thereby, the insulation test between the 1st winding part 51 and the 2nd winding part 52 can be performed easily. That is, the insulation resistance between the first winding part 51 and the second winding part 52 can be easily measured in a state before the joining part 7 is joined.

  Moreover, since the winding part 5 which comprises the coil 3 is two, the reactor 1 can be made into a simple structure.

  In addition, each winding part 5 has a conductor wire 4 made of a rectangular conductor having a rectangular cross section perpendicular to the length direction, the longitudinal direction of the cross section rectangle being the winding axis direction, and the short direction being the radial direction. It is formed by winding in a spiral shape, and the plurality of winding portions 5 are arranged in the winding axis direction. Therefore, when the coil 3 is manufactured, the flat conducting wire is bent and wound in a direction with relatively low rigidity, so that workability can be improved.

  As described above, according to this example, it is possible to provide a reactor that can prevent a portion where voltage stress between adjacent winding portions is increased.

(Comparative example)
In this example, as shown in FIGS. 5 and 6, the winding portions 5 connected in series with each other are connected to each other at the end portions on the same side in the stacking direction. That is, in this example, the 1st winding part 51 and the 2nd winding part 52 are connected in mutual inner peripheral ends.

  The first winding part 51 and the second winding part 52 are connected by the transition part 9 of the conductor wire 4. The transition portion 9 extends from the inner peripheral end of the first winding portion 51 so as to move upward while being wound and to be connected to the inner peripheral end of the second winding portion 52. That is, the coil 93 of this example does not have the joint part 7 (refer FIGS. 1-4).

  When tracing from the lead-out portion 612 that is one end of the conductor wire 4 to the lead-out portion 621 that is the other end of the conductor wire 4, first, while following the spiral path from the outer peripheral side of the first winding portion 51, Move to the side. Next, it moves to the inner peripheral end of the second winding part 52 via the transition part 9. Next, it moves from the inner circumference side of the second winding part 52 to the outer circumference side while following a spiral path. Thereby, when a current is passed through the coil 3, the current flows in the first winding portion 51 and the second winding portion 52 in opposite directions in the radial direction. That is, when tracing from the lead portion 612 that is one end of the conductor wire 4 to the lead portion 621 that is the other end of the conductor wire 4, the first winding portion 51 moves from the outer peripheral side to the inner peripheral side, The two winding parts 52 move from the inner peripheral side to the outer peripheral side.

  Others are the same as in the first embodiment. Of the reference numerals used in this example or the drawings relating to this example, the same reference numerals as those used in the first embodiment denote the same components as in the first embodiment unless otherwise specified.

  In the case of this example, since the winding part 5 is connected by the inner peripheral ends of each winding part 5, as shown in FIG. 6, the lamination | stacking in the 1st winding part 51 and the 2nd winding part 52 is carried out. The end portions 951 and 952 on the same side (outer peripheral side) in the direction are extremely separated from each other on the conductive path of the conductor wire 4. And the edge part 951 and the edge part 952 will be arrange | positioned adjacent to an axial direction. Thereby, a large voltage stress is applied between the first winding part 51 and the second winding part 52 in the outermost peripheral part of the coil 3. Therefore, it becomes difficult to achieve insulation between the plurality of winding portions 5.

  On the other hand, since the winding part 5 of the reactor 1 of Example 1 is connected in the edge parts of the other side of a lamination direction mutually, as mentioned above, the same side of the lamination direction in the adjacent winding part 5 is mentioned. End portions of the conductor wires 4 are not extremely separated on the conductive path of the conductor wire 4. Thereby, the reactor 1 of Example 1 has prevented that the site | part where the voltage stress between the adjacent winding parts 5 becomes large arises.

(Example 2)
In this example, as shown in FIGS. 7 and 8, each winding portion 5 is configured by winding the conductor wire 4 in an edgewise manner in a spiral shape. That is, each winding part 5 winds the conductor wire 4 which consists of a rectangular conducting wire helically in the state where the longitudinal direction (width direction) of a cross-sectional rectangle becomes a radial direction, and a transversal direction (thickness direction) becomes a winding axis direction. It is formed by turning. That is, in this example, the winding axis direction is the lamination direction of the conductor wires 4.

  The two winding parts 5 are arranged in the radial direction with the same winding axis. In this example, the inner peripheral winding portion 5 is referred to as a first winding portion 51, and the outer peripheral winding portion 5 is referred to as a second winding portion 52.

  In this example, a drawer portion 611 is drawn from the lower end of the first winding portion 51, and a drawer portion 612 is drawn from the upper end. And the drawer | drawing-out part 621 is pulled out from the lower end of the 2nd winding part 52, and the drawer | drawing-out part 622 is pulled out from the upper end.

  When tracing from the lead portion 612, which is one end of the conductor wire 4, to the lead portion 621, which is the other end of the conductor wire 4, first, it moves downward from the upper side of the first winding portion 51 while following the spiral path. To do. Next, it moves to the upper end of the second winding part 52 through the drawing parts 611 and 622. Next, it moves downward from the upper side of the second winding part 52 while following the spiral path, and reaches the lead-out part 621. Thereby, like Example 1, also in this example, when a current is passed through the coil 3, a current flows in the same direction in the winding axis direction at each winding part 5. That is, when a current is passed through the coil 3 in the direction from the lead-out portion 612 to the lead-out portion 621, the current flowing through the first winding portion 51 and the second winding portion 52 flows from the upper side to the lower side.

  As in the first embodiment, also in this example, the length of the conductive path passing through the conductor wire 4 between the portions of the conductor wire 4 adjacent in the radial direction is any portion in the winding direction of the conductor wire 4. In FIG. Therefore, the voltage between the portions of the conductor wire 4 adjacent in the radial direction is substantially the same at every portion in the winding direction of the conductor wire 4.

Others are the same as in the first embodiment. Of the reference numerals used in this example or the drawings relating to this example, the same reference numerals as those used in the first embodiment denote the same components as in the first embodiment unless otherwise specified.
Also in this example, the same effect as that of the first embodiment can be obtained.

  In the first and second embodiments, two winding portions are used, but three or more winding portions may be used.

1 Reactor 2 Core 3 Coil 4 Conductor wire 5 Winding part

Claims (4)

A core (2) made of magnetic powder mixed resin;
A reactor (1) having a coil (3) embedded in the core (2),
The coil (3) has a plurality of winding portions (5) in which the conductor wire (4) is laminated by winding the conductor wire (4),
The coil (3) is formed by connecting the plurality of winding portions (5) in series, and the winding portion (5) is arranged in both the winding direction and the laminating direction of the conductor wire (4). Arranged in orthogonal directions,
The reactor (1) characterized in that the winding parts (5) connected in series to each other are connected to each other at opposite ends in the stacking direction.   The coil (3) has a joint portion obtained by joining the plurality of winding portions (5) at the lead-out portion (6) drawn from each of the winding portions (5). The reactor (1) according to claim 1, which is located outside (2).   Reactor (1) according to claim 1 or 2, characterized in that the coil (3) has two windings (5).   Each winding part (5) has the conductor wire (4) made of a rectangular conducting wire having a rectangular cross section orthogonal to the length direction, the longitudinal direction of the cross section rectangle being the winding axis direction, and the short direction being the short axis direction. It is formed by winding in the state where it becomes a radial direction, and the said some winding part (5) is located in a line with the winding axis direction, The one of Claims 1-3 characterized by the above-mentioned. The reactor (1) according to claim 1.

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