JP6343141B2 - Reactor - Google Patents

Description

  The present invention relates to a reactor having an improved arrangement of sensor connectors.

  As a reactor used in an in-vehicle booster circuit, a coil is wound around a resin bobbin placed around the core, then housed in a metal case, and filled with a filler into the case. Is often used.

  One of these types of reactors has a structure in which a plurality of split cores are combined to form an annular core, and coils are wound around the left and right legs. Each divided core is embedded in the resin, and the resin portion is a core cover or a coil bobbin. In general, a molding method is employed to arrange the resin around the core.

  In this type of reactor, a bus bar is connected to an end of a coil, and wiring for connecting to a device outside the reactor is screwed into a screw hole provided at the tip of the bus bar. That is, it is difficult to directly connect a wire such as a covered electric wire to the end of a coil formed by winding a wire such as a flat wire, so a bus bar is connected to the end of the coil by means such as welding. A screw insertion hole is provided at the end of the bus bar to connect the wiring and the bus bar, or a connector provided on the wiring side is crimped or fitted to the end of the bus bar.

  Conventionally, a bus bar connected to the coil end as described above is a metal fitting (called a stay) for fixing a core and a reactor to a case inside a resin molded product integrally formed with a bobbin for mounting a coil. ). When configuring a reactor, a coil wound in a cylindrical shape is attached to the outer periphery of the bobbin of this resin molded product, and the end of the coil is in contact with the bus bar molded in the resin molded product We were welding both.

JP 2010-203998 A JP 2012-243913 A

  However, even if the cylindrical bobbin is molded integrally with the resin molded product, the mold shape is complicated, and in addition to that, molding the core, fixing bracket, and even the bus bar into the resin molded product There is a drawback in that the structure of the molded product is complicated and its manufacture is difficult. In addition, when connecting the reactor to an external device, it is necessary to perform wiring in various directions according to the position, shape, size, etc. of the external device to be connected, but when molding the bus bar to a resin molded product, The position of the bus bar would be limited to the part molded in the resin molded product, and it was impossible to pull out the bus bar in the free direction before and after the reactor.

  In particular, since the bus bar supplies power to the coil, it is necessary to ensure sufficient insulation with respect to the core and fixing bracket, but the bus bar, core and fixing bracket coexist in the same resin molded product. In addition, because of the insulation between these members, it is necessary to increase the thickness of the resin molded product, which has the disadvantage of increasing the size of the resin molded product and increasing the amount of resin used.

  In addition, in this type of reactor, if a high current continues to flow, the coil will overheat and its electrical characteristics will deteriorate, and the temperature will exceed the heat resistance temperature of the material, and the reliability will deteriorate. By measuring the internal temperature, the energization control is performed so that the coil does not generate heat above a certain temperature. When arranging a temperature sensor in a reactor, in order to perform accurate temperature detection, it is necessary to arrange a sensor close to a coil or a core that becomes a heating element. On the other hand, in order to transmit a detection signal from the sensor to an external device, it is necessary to provide a sensor connector on the reactor.

  Conventionally, this connector is fixed to the reactor by a holder provided in a part of the resin molded product. However, conventionally, since a core, a fixing bracket, a bus bar, and the like are molded inside the resin molded product, a holder must be provided to avoid them, and there is a restriction on the arrangement of connectors.

  This point will be described with reference to the conventional reactor shown in FIGS. In this reactor, the bobbin 102 is provided on the outer periphery of the left and right legs of the annular core 101, and the coil 103 is wound around the outer periphery. The yoke portion of the core 101 around which the coil 103 is not wound is covered with a cover 104 molded integrally with the bobbin 102. Between the left and right bobbins 102, a support plate 105 for holding the sensor is provided integrally with the bobbin 102. In the vicinity of the bobbin 102 of the cover 104, a locking portion 106 for hooking the sensor lead wire is provided.

  In this reactor, in order to arrange the bobbin 102 around the core 101, a mold molding method is generally used in which the core 101 is arranged in a mold and a resin is injected into the mold around the core 101 to be solidified. In this case, if there is a gap between the mold surface and the core 101, the resin enters the gap and becomes a burr after molding. In particular, in the prior art, since the core 101 is brought into contact with the bottom surface of the aluminum case 108 that houses the reactor and heat is directly radiated from the core 101, if there is a burr, a gap is generated between the case 108 and the core 101, Heat transfer is reduced. Therefore, in the prior art, the gap between the mold surface and the core 101 is eliminated by pressing with a spring from above the core 101 to prevent the generation of burrs.

  As described above, in order to press the core 101 from above, it is necessary to bring the spring and the core 101 into contact with each other. In the prior art, an opening 107 having no resin is formed in the upper part of the cover 104 that covers the core 101 to position the core 101 in the mold. However, if the opening 107 exists in the upper part of the core 101, it is impossible to provide a member such as a fixing bracket, a bus bar, or a connector holder in that portion. Each member was placed on that portion.

  However, if a part of the resin molded product is extended to the side in this way, the lateral dimension of the reactor increases accordingly, which hinders the miniaturization of the reactor. In addition, there is a drawback in that the arrangement positions of the bus bar and the connector holder are also limited. In particular, known reactors include a type in which a coil end leading portion 103a is pulled out from the yoke side of the core. In this type of reactor, the end portions of the coil 103 are respectively provided from two opposing yoke portions. When the cable is pulled out, the drawer part 103a gets in the way, and the bus bar and the connector cannot be arranged on the upper surface of the cover 104.

The present invention has been proposed to solve the above-described problems of the prior art. The present invention reduces the number of parts embedded in a resin molded product in which the core is molded, simplifies the configuration of the resin molded product and its mold, simplifies the manufacturing work, and reduces the size of the entire reactor. It is to make it possible.
Another object of the present invention is to provide flexibility in the arrangement of the terminal block and to ensure excellent insulation performance. Also, a holder for a connector of an electronic component such as a temperature sensor can be placed in a free part of the reactor. It is to be able to arrange.

The reactor of this invention has the following structures, It is characterized by the above-mentioned.
(1) An annular core and a coil wound around the outer periphery of the leg portion of the annular core are provided.
(2) The electronic component provided in the said reactor and the connector connected with this electronic component are provided.
(3) A resin molded product obtained by molding the annular core is provided around the annular core.
(4) A terminal block obtained by molding a bus bar connected to the lead portion of the coil end is provided separately from the resin molded product.
(5) The holder of the connector which pulls out the wiring of the electronic component provided in the reactor is integrally formed on the terminal block.
(6) The terminal block is provided on the upper surface of the resin molded product.

  A plurality of terminal blocks are formed by molding a bus bar connected to the lead portion of the coil end, and at least one of the plurality of terminal blocks has a connector holder that pulls out the wiring of the electronic component provided in the reactor. It may be formed integrally.

Arbitrary desired that no opening in the upper surface of the resin molding. An exposed portion that does not cover the bottom surface of the core is provided on the lower surface of the resin molded product, and the core can be supported by a mold at the exposed portion when the core is molded.

  As the holder, an appropriate configuration such as a slide type, a fitting type, or a hook type can be adopted according to the shape of the connector to be fixed thereby. The holder of the connector may be provided on all of the plurality of terminal blocks or only one.

  According to the present invention, since the bus bar is molded on a terminal block separate from the resin molded product with a built-in core, it is possible to freely set the terminal block arrangement, and to the coil in any direction of the reactor. Connection wiring can be arranged. Moreover, the number of parts molded inside the resin molded product with a built-in core is reduced, and the structure of the resin molded product and its mold can be simplified.

The disassembled perspective view of the reactor of 1st Embodiment. The perspective view which looked at the reactor of FIG. 1 from the right front. The perspective view which looked at the reactor of FIG. The partial exploded perspective view which looked at the reactor of FIG. 1 from the right front. FIG. 5 is a partially exploded perspective view of the reactor of FIG. Sectional drawing seen from the right front of the reactor of FIG. The perspective view which shows an example of the conventional reactor. Sectional drawing which shows an example of the conventional reactor.

1. First Embodiment Hereinafter, a first embodiment of the present invention will be described in detail with reference to FIGS.

(1) Configuration The reactor according to the present embodiment has an annular core 1, and this annular core 1 is obtained by connecting two U-shaped cores 1a and 1b constituting the yoke portion via a spacer 1d. It is.

  The annular core 1 is covered with a first resin molded product 2 and a second resin molded product 3 provided on the outer periphery thereof. The first molded product 2 has cylindrical left and right bobbins 22a and 22b, and a core covering portion 21 provided so as to connect them, and the first U-shaped core 1a is molded inside them. It is buried by the molding method. The second molded product 3 includes left and right pressing members 32a and 32b and a core covering portion 31, and a second U-shaped core 1b is embedded therein by a molding method.

  Openings 21a and 31a used for holding the U-shaped cores 1a and 1b in the mold during molding are provided on the outer surfaces of the covering portions 21 and 31, respectively. The surface of internal U-shaped cores 1a and 1b is exposed at 31a. There is no resin at the bottoms of the covering parts 21 and 31 to set the U-shaped cores 1a and 1b on the mold surface, and the exposed parts 1e where the bottoms of the U-shaped cores 1a and 1b appear. . However, in this embodiment, since the U-shaped cores 1a and 1b are not pressed against the mold surface from above, there is a possibility that a resin that becomes a burr exists in this portion.

  Screw insertion holes 24 a and 24 b for fixing the assembled reactor main body to the case 4 are provided at both upper ends of the first covering portion 21. The first resin molded product 2 and the case 4 are fixed by fastening the screws 41 a and 41 b inserted into the screw insertion holes 24 a and 24 b into the screw holes of the case 4. Holding members 32 a and 32 b provided separately from the resin molded product 3 are engaged with both upper ends of the second covering portion 31, and the reactor main body is fixed to the case 4 with the holding members 32 a and 32 b. Screw insertion holes 34a and 34b are provided. By fastening the screws 41 a and 41 b inserted into the screw insertion holes 34 a and 34 b to the case 4, the second resin molded product 3 and the case 4 are fixed.

  Support plates 25 and 35 for holding the sensor are provided inside the first and second covering portions 21 and 31 at positions so as to be sandwiched between the left and right bobbins 22a and 22b. Each of the support plates 25 and 35 is a triangular member, and the sensor 6 is inserted into the gap between the two when the annular core 1 is assembled. The lead wire 61 of the sensor 6 is drawn out to the second covering portion 31 side, and a connector 62 is connected to the tip thereof.

  The left and right coils 51a and 51b are wound around the outer circumferences of the bobbins 22a and 22b. These left and right coils 51a and 51b are each constituted by a single conductor, and both ends of each coil are drawn out in the direction of the first and second covering portions 21 and 31, and are connected to the first and second terminal blocks 71a and 71c. It is connected to one end of the molded bus bars 73a, 73b, 73c.

  That is, a first terminal block 71a separate from the first covering portion 21 is detachably disposed on the upper portion of the first covering portion 21. The terminal block 71a is formed by molding bus bars 73a and 73b therein, and part of the bus bars 73a and 73b rises upward, and ends of the coils 51a and 51b are connected to the rising portions. ing. The terminal block 71a is integrally formed with two recesses 72a and 72b, and the ends of the bus bars on the wiring side are exposed in the recesses 72a and 72b. Screw insertion holes 74a and 74b are provided at the other ends of the recesses 72a and 72b and the bus bars 73a and 73b, and the other ends of the bus bars 73a and 73b are connected to external devices by screws (not shown) inserted into the screw insertion holes 74a and 74b. Is connected to the wiring.

  A second terminal block 71c separate from the second covering portion 31 is detachably disposed on the upper portion of the second covering portion 31. Inside the terminal block 71c, a bus bar 73c connected to the ends of the left and right coils 51a and 51b is embedded by molding. One end of the bus bar 73c is branched into two, and its tip protrudes from the terminal block 71c and is connected to the ends of the coils 51a and 51b. The other end of the bus bar 73c is exposed to a recess 72c provided in the terminal block 71c, and wiring to an external device is screwed into a screw insertion hole 74c provided in that portion.

  Screw insertion holes 75a and 75b are provided at the lower ends of both ends of the first terminal block 71a and the second terminal block 71c, and the screws 43a and 43b inserted into the screw insertion holes 75a and 75b are fastened to the case 4. As a result, the first terminal block 71 a and the second terminal block 71 c are fixed to the case 4.

  The holder 8 of the connector 62 is formed integrally with the second terminal block 71c. The holder 8 may have any shape as long as the connector 62 can be fixed to the covering portion 31. In the present embodiment, the following is adopted according to the shape of the connector 62.

  As shown in FIGS. 2 and 3, a vertically rising wall 81 is provided on a portion of the upper surface of the covering portion 31 on the bobbin side, and a locking portion 81 a for hooking a sensor lead wire on the upper edge of the wall 81. Is provided.

  A block 82 is formed on the bobbin side of the upper surface of the second terminal block 71c in parallel with the wall 81 of the covering portion 31, and two upper and lower guides 83a and 83b extending perpendicular to the axial direction of the bobbin are provided on the block 82. It is provided in parallel with a constant interval. The upper and lower guides 83 a and 83 b are members having an L-shaped cross section, and the vertical portions thereof are slidably inserted into the two grooves 63 a and 63 b provided in the connector 62. Between the upper and lower guides 83a and 83b, there is provided a hook 84 having a base end fixed to the block 82 and a free end. The tip of the hook 84 engages with a convex portion 64 provided between the two grooves 63 a and 63 b of the connector 62.

  The reactor main body is configured by assembling the annular core 1 having the above-described configuration, the resin molded products 2 and 3, the left and right coils 51a and 51b, and the first and second terminal blocks 71a and 71c. The reactor body is fixed to the case 4 by screwing the molded products 2 and 3 to the case 4 with screws 41 a and 41 b and the terminal blocks 71 a and 71 c to the case 4 with screws 43 a and 43 b. In this case, as shown in the cross-sectional view of FIG. 6, the resin molded products 2 and 3 and the left and right coils 51 a and 51 b are fixed so that a predetermined gap is maintained between the outer periphery of the case 4 and the inner surface of the case 4. By filling the gap 9 with the filler 9 and solidifying it, the case 4 and the assembled reactor main body are integrated.

(2) Operational Effects According to the first embodiment having the configuration as described above, the following operational effects are exhibited.

(1) As shown in the sectional view of FIG. 6, the bottom portions (exposed portions 1 e) of the U-shaped cores 1 a and 1 b exposed at the bottom portions of the covering portions 21 and 31 are covered with the filled material 9 filled. The As a result, even if there is a resin that has become the bottom burr of the U-shaped cores 1a and 1b at the time of molding, the portion is covered with the filler 9, and no trouble occurs. On the other hand, since it is not necessary to provide an opening in the upper part of the covering portion 31, a terminal block 71c having the holder 8 can be provided at that portion to fix the connector 62. As a result, the connector 62 can be almost accommodated in the plane projection range of the resin molded product 2 and the reactor can be reduced in size.

(2) Since the bus bars 73a to 73c are molded on the terminal blocks 71a and 71c separate from the resin molded products 2 and 3, the cores 1a and 1b need only be molded in the resin molded products 2 and 3. The number of parts to be held in the mold during molding of the resin molded products 2 and 3 is reduced, the mold configuration can be simplified, and an opening for inserting a jig for holding the member is formed in the resin molded product. It can also be provided in a few free positions. As a result, the position of the bus bar and the holder is not restricted by the opening of the resin molded product, and the degree of freedom in the reactor configuration is increased.

(3) Since the resin molded products 2 and 3 and the terminal blocks 71a and 71c are separated from each other, the terminal blocks 71a and 71c can be provided at free positions of the resin molded products 2 and 3 and the case 4. The direction in which the bus bars 73a to 73c are drawn from the coils can be freely set without changing the products 2 and 3. Moreover, when the holder 8 is provided in the terminal block 71c as in this embodiment, the wiring of the electronic device provided in the reactor is changed by changing the position of the holder 8 according to the position of the terminal block 71c. Can be taken out in any direction.

(4) Since the bus bars 73a to 73c are embedded in the resin terminal blocks 71a and 71c by molding, the presence of the resin on the upper surfaces of the covering portions 21 and 31 as shown in FIGS. Even if there is an opening that does not, the bus bars 73a to 73c are insulated by the resin of the terminal blocks 71a and 71c, so that there is no possibility of causing a short circuit or the like between the core and the bus bar. In particular, in this embodiment, since there are no openings in the resin of the terminal blocks 71a and 71c and the covering portions 21 and 31 around the bus bar, it is possible to ensure better insulation.

(5) Thus, according to this embodiment, the connection to the reactor is facilitated, and the connector is laid out in the dead space. Further, even in a reactor having many joints, there is an advantage that a connector can be laid out while securing a joint work area such as welding. In addition, since the bus bar and connector holding functions and functions are integrated into the terminal block 71c, it can be expected to reduce the number of parts and the cost.

2. Other Embodiments The present invention is not limited to the above-described embodiments, and includes other embodiments described below.
(1) Although the terminal blocks 71a and 71c and the resin molded products 2 and 3 are screwed to the case 4 in the embodiment, the terminal blocks 71a and 71c may be fixed to the resin molded products 2 and 3, respectively. If the lead-out direction of the wiring from the coil is one direction without providing the terminal blocks 71a and 71c on the two yoke part sides of the core, the terminal block may be provided only on one yoke part side. . Also, the number of resin molded products is not limited to two, but the entire annular core is molded into one resin molded product, or three or more resin molded products are used as in the case where the annular core is composed of a plurality of divided cores. The present invention is also applicable to the reactor provided. In that case, terminal blocks may be provided for all resin molded products, or terminal blocks may be provided for any one or a plurality of selected resin molded products.

(2) The position of the terminal block is not limited to the yoke portion side of the core, and the terminal block can be arranged on the side of the coil in parallel with the axial direction of the coil. In this case, the connector holder may be provided integrally with the terminal block, or the connector holder may be provided integrally with the resin molded products 2 and 3.

(3) The shapes of the resin molded products 2 and 3 are not limited to the illustrated embodiment, and the resin molded products having openings on the upper surface of the covering portion as shown in FIGS. The invention is applicable. Therefore, the present invention can also be applied to a resin molded product that does not have an opening formed by a mold that supports the core on the lower surface of the molded product.

(4) In the above embodiment, since the connector is large with respect to the reactor, the connector is arranged at right angles to the axial direction of the bobbin. However, if the connector is small, it is parallel to the axial direction of the bobbin. A holder can also be provided.

(5) In the above-described embodiment, the entire connector is substantially within the plane projection range of the resin molded product 2, but a part of the connector protrudes from the plane projection range of the resin molded product 2, You may protrude from the surroundings.

(6) As the core, a combination of two U-shaped cores in a ring shape or a combination of two U-shaped cores and a plurality of I-shaped cores in a ring shape can be used. As the annular core, an E-shaped core provided with a central leg in parallel with the left and right leg portions, and a core in which a coil is wound around the central leg or the left and right leg portions can be used. What comprised the cyclic | annular core from one member may be sufficient.

(7) Although the I-shaped core is fitted and fixed inside the bobbin, the I-shaped core may be embedded in the molded product 2 by a molding method, similarly to the U-shaped core.

(8) In addition to the temperature sensor, a sensor that detects other physical quantities such as magnetism, electricity, position, vibration, and humidity can be used as the sensor. It is also possible to hold a connector connected to another electronic component other than the sensor.

(9) As the shape of the holder, a groove, a recess, a through hole or the like for inserting the entire connector can be used. It is also possible to form a holder by providing a hook or a recess on the connector side and a protrusion or hook engaged therewith. When the connector is fixed with a band or a wire, a hole through which the band passes can be used as a holder. The holder can also be provided on a resin molded product integrally provided with a terminal block.

(10) As the case, a metal case other than aluminum or a resin case excellent in thermal conductivity can be used. As for the shape of the case, in addition to a box shape having an open upper surface as shown in the figure, a dish shape having a shallow edge or a plate shape may be used. In addition, implementation of only the annular core, the resin molded product, and the coil assembly without using resin for the case or the gap between the cases is also an embodiment of the present invention.

(11) The connector in the present invention is not limited to the illustrated configuration. It is a member that connects the sensor lead wire and external wiring, and includes all shapes that need to be fixed to the reactor, for example, a fitting type, a sliding type, and a joining structure by welding or fastening. It can also be applied to a reactor in which a plurality of connectors are provided on one reactor. Instead of the connector, it is possible to attach a transmitter or a device for wirelessly transmitting the physical quantity data detected by the sensor to the holder.

DESCRIPTION OF SYMBOLS 1 ... Ring core 1a, 1b ... U-shaped core 1d ... Spacer 1e ... Exposed part 2, 3 ... Resin molded product 21, 31 ... Cover part 21a, 31a ... Opening part 22a, 22b ... Bobbin 24a, 24b, 34a, 34b ... Screw insertion holes 25, 35 ... Support plates 32a, 32b ... Holding member 4 ... Cases 41a, 41b, 43a, 43b ... Screws 51a, 51b ... Coil 6 ... Sensor 61 ... Lead wire 62 ... Connectors 63a, 63b ... Groove 64 ... Projections 71a, 71c ... Terminal blocks 72a, 72b, 72c ... Recesses 73a, 73b, 73c ... Bus bars 74a, 74b, 74c ... Screw insertion holes 75a, 75b ... Screw insertion holes 8 ... Holders 81 ... Walls 81a ... Locking portions 82 ... blocks 83a, 83b ... guide 84 ... hook 9 ... filler

Claims (6)

In a reactor including an annular core and a coil wound around the outer periphery of the leg of the annular core,
An electronic component provided in the reactor, and a connector connected to the electronic component,
Around the annular core, a resin molded product formed by molding the annular core is provided,
Separately from the resin molded product, a terminal block is provided by molding a bus bar connected to the lead portion of the coil end,
On the terminal block, a connector holder for pulling out the wiring of the electronic component provided in the reactor is integrally formed ,
A reactor , wherein the terminal block is provided on an upper surface of the resin molded product . In a reactor including an annular core and a coil wound around the outer periphery of the leg of the annular core,
An electronic component provided in the reactor, and a connector connected to the electronic component,
Around the annular core, a resin molded product formed by molding the annular core is provided,
Separately from the resin molded product, a plurality of terminal blocks are provided by molding a bus bar connected to the lead portion of the coil end,
The reactor is characterized in that a connector holder for pulling out wiring of an electronic component provided in the reactor is formed integrally with at least one of the plurality of terminal blocks. Reactor according to claim 1 or claim 2, characterized in that there is no opening in the upper surface of the resin molding. Wherein there is no exposed portion is provided to cover the bottom of the core to the lower surface of the resin molding, the terminal block on the upper surface of the resin molded article is provided claim 1, characterized in claims 3 The reactor of any one of Claims. An assembly having a resin molded product in which the annular core is embedded and a coil wound around the bobbin is housed in a case,
5. The gap according to claim 4 , wherein a gap is formed between the assembly and the case, the gap is filled with a filler and solidified, and the exposed portion of the core bottom is covered with the filler. Reactor. A guide that extends perpendicular to the axial direction of the coil is provided on the holder, and a connector is attached to the guide, and a hook is provided on the holder, and the hook is engaged with a connector mounted on the guide. The reactor according to any one of claims 1 to 5 , characterized in that:

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